Design of Wind Deflector Ribs using Topology Optimization and Validation through FE Analysis and Testing 2008-01-2665

This paper presents the use of CAE tools at the up-stream stage of design of ribs in a wind deflector, and experimental validation of the design. Wind deflector is an add-on device used on top of truck cabins for reducing drag. Based on the field conditions that the wind deflector is subjected to, design requirements were formulated. One of the requirements was to provide stiffening ribs in the deflector. Topology optimization analysis was performed to arrive at the optimum layout of the stiffening ribs. The layout was finalized after comparing the results from two commercially available FEA tools - namely, ANSYS and Altair Optistruct. Finite element static analysis and random vibration dynamic analysis were performed in order to validate the strength of the deflector. A prototype of the wind deflector was made and tested under laboratory condition for dynamic loads. The analysis and testing results demonstrated that the design was robust.