This summer the McMaster EcoCAR Propulsion Integration (PSI) Team has been working hard on several different projects. One key component that we have been working on is a light weighted engine mount. The PSI team determined it would be beneficial to design an engine mount that is significantly lighter the current mount in our 2019 Chevrolet Blazer. This process started by identifying features of the current design that could be improved upon. Once the team had a general idea created in CAD, we then ran several Finite Elemental Analyses (FEAs) to determine weak areas in the design as well as what material will yield the best results.

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After running many FEAs, the team decided that using Aluminum 7075 T6 was the best option for material. This was determined through analysing the yield stress experienced by the part as well as the overall goal of creating a light part. The team also considered using Aluminum 6061 however, this material was closer to failure in our simulations and the team decided to go with the material with the higher yield strength.  

The design itself is created to use the least amount of material while still being able to withstand the loads experienced by the engine mount. Some key features of the design include ribs that strengthen bolt loading points and support the top of the part. The design includes inserts for standoffs that will allow for the engine mount to fit perfectly into the engine bay. These standoffs will be press fitted into the engine mount.  

Currently the team is working with different manufacturers to produce this part. We are excited to post updates once the part is fully made and installed into the car.

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