Shift Fork Design Optimisation
This project focuses on optimizing the design of a shift fork for automotive transmissions to reduce its weight while maintaining structural integrity and operational efficiency. Through an iterative process using finite element analysis (FEA) in Abaqus, areas of low stress were identified, enabling significant material reduction without compromising performance. The final design achieved a 70% weight reduction and improved material efficiency by adopting 7068 Aluminum Alloy, offering high strength-to-weight ratio and cost-effectiveness. Dynamic and static analyses validated the reliability of the optimized design, ensuring it meets all operational criteria and eliminates resonance risks in automotive environments.