Mehrdad Zoroufi - Assistant Professor Department of Mechanical Engineering, Iran University of Science and Technology, Tehran, Iran
Ali Fatemi - Professor, Department of Mechanical, Industrial and Manufacturing Engineering, The University of Toledo, Toledo, Ohio, USA

A procedure was developed to improve forged automotive components for weight reduction and cost saving with durability parameters as key performance indicators. Guidelines were developed and limitations were identified for the improvement procedure. By considering geometry variations, alternative materials and manufacturing process parameters as design variables, an example part was improved. Although the improvement results show limited changes for the particular example component, the approach that was followed is meant to be applicable to other forged components. It is emphasized that geometrical optimization of manufactured components could only be realistic and practical if other important parameters like material, manufacturability, and cost are taken into account.

Automotive Components, Weight Reduction, Cost, Manufacturing Process, Fatigue