International Research Journal of Engineering and Technology (IRJET)
e-ISSN: 2395-0056
Volume: 13 Issue: 06 | Jun 2026
p-ISSN: 2395-0072
www.irjet.net
STRUCTURAL OPTIMIZATION OF ENGINE MOUNT FOR MARUTI SUZUKI WAGON R: WEIGHT REDUCTION AND VIBRATION ATTENUATION STUDY Karan Kankate1, Omkar Dhaybar2, Atharva Patil3, Abhishek Abhale4, Prof. M.P. Shah5 1,2,3,4UG Student, Department of Mechanical Engineering, AISSMS College of Engineering, SPPU, Pune, Maharashtra,
India
5Assistant Professor, Department of Mechanical Engineering, AISSMS College of Engineering, SPPU, Pune,
Maharashtra, India ---------------------------------------------------------------------***---------------------------------------------------------------------
Abstract - Engine mounts are critical vibration-isolating components that support the powertrain, limit engine motion,
reduce the transmission of vibrations to the vehicle body, and improve ride comfort. This study presents the structural optimization of the front engine mount bracket of a Maruti Suzuki Wagon R (1.2 L K-series engine) using finite element analysis (FEA). The existing bracket geometry was modelled in CAD software and analysed in ANSYS Workbench under representative static loading conditions, including engine torque reaction, acceleration, and road-induced impact loads. Static structural and modal analyses were conducted to evaluate stress distribution, deformation, and natural frequencies. Topology optimization was then performed with a target volume reduction of 30% to identify regions where material could be safely removed while maintaining structural integrity. The optimized design achieved a significant reduction in component mass while keeping the maximum von Mises stress below the material yield strength with an adequate factor of safety. In addition, the optimized bracket exhibited an increase in natural frequency, reducing the likelihood of resonance with the engine operating frequency range and thereby improving vibration isolation characteristics. The results demonstrate that topology optimization is an effective approach for reducing engine mount bracket weight while maintaining strength and enhancing structural and dynamic performance, making it suitable for lightweight automotive applications. Key Words: engine mount, Wagon R, structural optimization, topology optimization, SIMP, finite element analysis, NVH, vibration isolation, weight reduction, ANSYS
1. INTRODUCTION Engine mounts, also known as powertrain mounts or motor mounts, are critical components that support the engine while isolating vibrations from the vehicle chassis. They must provide sufficient stiffness to control engine movement during acceleration and road-induced loads while remaining compliant enough to reduce Noise, Vibration, and Harshness (NVH), thereby improving ride comfort and vehicle durability. The front engine mount bracket is a primary load-bearing component that transfers engine loads to the vehicle structure. Conventional brackets are generally designed with conservative material distribution to ensure strength, often resulting in unnecessary weight. With the increasing demand for lightweight and fuel-efficient vehicles, structural optimization has become an effective approach for reducing component mass without compromising performance. This study focuses on the structural optimization of the front engine mount bracket of the Maruti Suzuki Wagon R (1.2 L K-series engine) using Finite Element Analysis (FEA) and topology optimization in ANSYS Workbench. Static structural and modal analyses are performed to evaluate the baseline design under representative loading conditions. The optimized design is then re-analysed and compared with the original bracket in terms of stress distribution, deformation, mass reduction, and natural frequency.
2. LITERATURE REVIEW Brach [1] established the analytical foundations of engine mount design by demonstrating that appropriate mount placement and stiffness selection can minimize vibration transmission across the powertrain. Shangguan [2] further reviewed modern engine mounting systems and highlighted the importance of optimizing mount stiffness and damping characteristics to improve Noise, Vibration, and Harshness (NVH) performance under varying operating conditions.
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