Optimization

Component optimization involves the targeted improvement of design, materials and manufacturing processes. The goal is to increase performance, service life and cost-effectiveness. This makes products more efficient, robust and reliable in use.

Procedure


1. Analysis of operating conditions and measurement of actual operating loads

  • Recording of actual operating conditions
  • Conducting or organizing operational load measurements in the field 
  • Collaboration with specialized external measurement partners
  • Use of modern measurement technology (e.g., acceleration, force and displacement sensors)
  • Recording of actual load profiles under operating conditions
     

Result: A representative load profile as the basis for optimization


2. Processing and definition of load groups

Processing of measurement data (filtering, classification, statistical analysis) and derivation of relevant load groups considering: 

  • Amplitudes
  • Frequencies
  • Superpositions
     

Result: Validated and application oriented load set
 

3. FEA Simulation and component analysis

Development of detailed finite element models (FEA) taking into account the nonlinear material properties of elastomers

Analysis of: 

  • Stress and strain distributions
  • Local hotspots
  •  Dynamic behavior 
     

Result: Identification of critical areas and optimization potential

 

4. Design Optimization

Taking advantage of all opportunities to improve performance, for example,

  • Geometric adjustments (shaping, transition radii, wall thicknesses)
  • Material selection and tuning (elastomer blends)
  • Optimization of stiffness and damping properties
  • Reduction of local strains
  • Minimization of stress peaks
  • Improvement of vibration behavior
     

Result: Robust, durable component design

 

5. Damage analysis / service life assessment

  • Application of modern damage models for elastomers
  • Evaluation of: 
    • Fatigue
    • Crack initiation and propagation
  • Conducting service life assessments under variable loads
     

Result: Prediction of component service life under real-world conditions

 

6. Derivation of test load sets

  • Omission of load components not relevant to damage to reduce test time
  • Transformation of real operating data into accelerated test profiles
     

Result: Efficient test execution with high statistical significance

 

7. Dynamic (residual) life tests

  • Conducting component tests under realistic load sets
  • Simulation of failure behavior during operation
  • Validation of: 
    • Simulation results
    • Service life predictions
    • Optimization measures
       

Result: Verified component performance

 

8. Benchmarking and verification of improvements

Comparison: Initial design vs. optimized design

Verification:     

  • Prevention or reduction of local damage
  • Extension of service life
  • Reduction of critical strains
  • Maintenance of functional tolerances and increased load-bearing capacity
     

Result: Transparently verifiable performance improvement
 

Added Value

  • Real-world operational data from field measurements rather than assumptions
  • Higher prediction accuracy through validated load sets
  • Extended component service life
  • Reduction in failures and warranty costs
  • Optimization of test time and costs
  • Well-founded design instead of trial and error

GMT - Partner for Sustainable Solutions

We combine field measurements, simulation, materials expertise and testing technology into an integrated development process. Through close collaboration with specialized partners, we ensure that optimizations are based on real-world operating conditions.