Modelling and Simulation Approach for Fiber-Reinforced Polymer Components in Passenger Car Engine Mounting Brackets

<div class="section abstract"><div class="htmlview paragraph">The functionality of the Powertrain mount is to securely anchor the engine and gearbox within a vehicle, and effectively absorb vibrations, while simultaneously shielding the vehicle's body from powertrain movements and road irregularities. The mounts are supported by engine mount brackets, which serve as connectors between the engine mount and the vehicle's body-in-white (BIW), providing a structural link that secures the engine and gearbox assembly. Conventionally made with materials such as aluminum, sheet metal, or cast iron, a recent surge has been seen toward using a viable substitute in Fiber Reinforced Polymer (FRP). This transition is driven by the potential to reduce weight and cost, while also improving Noise, Vibration, and Harshness (NVH) characteristics. This study aimed to evaluate the relative strengths of existing brackets compared to those made of FRP, with a focus on their modal response and crash resistance. Due to the absence of a standardized method for modelling orthotropic materials in powertrain mounting brackets, a systematic approach to address this gap is proposed in this paper. By conducting a comprehensive literature review, FRP was examined and contrasted with other conventional materials currently utilized. Subsequently, a series of stress-strain and eigenmode finite element method (FEM) analysis was performed to assess the performance of various materials and material models. Moreover, an analysis to determine the maximum injection pressure and maximum clamp force was conducted, serving as an integral part of validating manufacturability.</div><div class="htmlview paragraph">To validate the results, physical components were produced based on simulation outcomes and recommendations, followed by testing to confirm the correlation. A case study is presented as an illustrative demonstration of this methodology.</div></div>