Design optimization application in accordance with product and process requirements

Abstract

Structural optimization techniques are a well-known approach for improving product performances. Often, optimization procedures do not include manufacturing constraints arising from corporate technologies. This aspect becomes a disadvantage in the design review phase when the final product release is a trade-off between optimization results and manufacturing constraints. This paper describes a specific new approach, which considers product/process guidelines an input/output data in the optimization phase. The study case is represented by a high performance aeronautic seat structure having as mission profiles the SAE-AS Standard, in order to demonstrate occupant protection when a seat/occupant/restraint system is subjected to statically applied ultimate loads and to dynamic impact test conditions. The authors' aim, in accordance with standards' requirements, is to achieve a final design based on an optimized structural solution for the chosen process technologies, taking into account the low volume production and typical attitude of the aeronautical industry. The presented study case offers the proper reference in order to extend this methodology to more complex structural applications.

Topology optimization with manufacturing constraints: A unified projection-based approach

“…The approach of this work consists in defining the constraints of an optimization problem, by employing projection techniques [13,14] tailored to meet the requirements of the manufacturing processes, thus, simplifying the process of interpreting topology optimization solutions. The current tendency to develop a product cycle leads to procedures in which design, simulation, and optimization with manufacturing constraints can be simultaneously executed in computer-aided engineering (CAE) phase design [15], instead of the traditional procedures, in which the design and optimization are developed separately, in computer-aided design (CAD) and CAE phases, respectively. Final shapes with high resolution incorporating manufacturing constraints can be obtained by adopting highly discretized FEM models [16], reducing time and product development cost.…”