Messing with boundaries - quantifying the potential loss by pre-set parameters in topology optimization

Tyflopoulos, Evangelos; Steinert, Martin

doi:10.1016/j.procir.2019.04.307

Cited by 11 publications

(7 citation statements)

References 4 publications

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“…On the one hand, ABAQUS with the TOSCA optimization module is one of the most traditional TO tools with a plethora of choices for both the optimization algorithms, the objective functions, the optimization constraints, as well as the load cases and the boundary conditions. In other words, for all possible designer choices [36]. On the other hand, the ANSYS discovery in this version (2020) is limited to simple load cases, basic constraints, and a sensitivitybased optimization algorithm that does not take the displacement of the structures into consideration, making it not ideal for multiple load cases and combined optimization goals.…”

Section: Topology Optimization For Manufacturingmentioning

confidence: 99%

Optimization of Brake Calipers Using Topology Optimization for Additive Manufacturing

2021

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The weight optimization of a structure can be conducted by using fewer and downsized components, applying lighter materials in production, and removing unwanted material. Topology optimization (TO) is one of the most implemented material removal processes. In addition, when it is oriented towards additive manufacturing (AM), it increases design flexibility. The traditional optimization approach is the compliance optimization, where the material layout of a structure is optimized by minimizing its overall compliance. However, TO, in its current state of the art, is mainly used for design inspiration and not for manufacturing due to design complexities and lack of accuracy of its design solutions. The authors, in this research paper, explore the benefits and the limitations of the TO using as a case study the housings of a front and a rear brake caliper. The calipers were optimized for weight reduction by implementing the aforementioned optimization procedure. Their housings were topologically optimized, partially redesigned, prepared for 3D printing, validated, and 3D printed in titanium using selective laser melting (SLM). The weight of the optimized calipers reduced by 41.6% compared to commercial calipers. Designers interested in either TO or in automotive engineering can exploit the findings in this paper.

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Section: Topology Optimization For Manufacturingmentioning

confidence: 99%

Optimization of Brake Calipers Using Topology Optimization for Additive Manufacturing

2021

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“…Different exercises can be conducted in a CAD environment, where students can practice using tools for TO, FEM, and CAD through the design of the initial design concepts and the redesign of the optimized design solutions. In addition, postgraduate students can explore the impact of the designers' input on the optimized results, as by Tyflopoulos and Steinert [34].…”

Section: Examples Of Active Learning Tools In Topology Optimizationmentioning

confidence: 99%

Topology-Optimization-Based Learning: A Powerful Teaching and Learning Framework under the Prism of the CDIO Approach

2021

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Topology optimization (TO) has been a useful engineering tool over the last decades. The benefits of this optimization method are several, such as the material and cost savings, the design inspiration, and the robustness of the final products. In addition, there are educational benefits. TO is a combination of mathematics, design, statics, and the finite element method (FEM); thus, it can provide an integrative multi-disciplinary knowledge foundation to undergraduate students in engineering. This paper is focused on the educational contributions from TO and identifies effective teaching methods, tools, and exercises that can be used for teaching. The result of this research is the development of an educational framework about TO based on the CDIO (Conceive, Design, Implement, and Operate) Syllabus for CAD engineering studies at universities. TO could be easily adapted for CAD designers in every academic year as an individual course or a module of related engineering courses. Lecturers interested in the introduction of TO to their courses, as well as engineers and students interested in TO in general, could use the findings of this paper.

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“…The maximum identified mass reduction was 34.7%, and it could be achieved at the second optimization level with the TO. Finally, a new round of parametric size optimization was held at process (6). The final designs of the processes in this workflow are illustrated in Figure 12.…”

Section: Parametric Optimization Of a Hollow Platementioning

confidence: 99%

“…However, it is possible to prefer CMP to AM. In this case, the designer adds the corresponding geometric restrictions due to manufacturing constraints, such as design for extrusion or size minimums [6]. The choice between these two different TO orientations depends on the optimized design, the cost, and the production time.…”

Section: Introductionmentioning

confidence: 99%

Topology and Parametric Optimization-Based Design Processes for Lightweight Structures

Tyflopoulos

Steinert

2020

Applied Sciences

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Topology and Parametric Optimization are two of the most implemented material optimization approaches. However, it is not clear in the literature which optimization procedure, or possible combination of them, can lead to the best results based on material reduction and optimization time. In this paper, a quantitative comparison of different topology and parametric optimization design processes is conducted using three benchmark examples: A Hollow Plate, an L-Bracket, and a Messerschmitt–Bölkow–Blohm Beam (MBB-Beam). Ten different design processes that were developed in each case study resulted in 30 simulations in total. The design processes were clustered in three main design workflows: The Topology Optimization, the Parametric Optimization, and the Simultaneous Parametric and Topology Optimization. Their results were compared with respect to mass, stress, and time. The Simultaneous Parametric and Topology Optimization approach gave the lightest design solutions without compromising their initial strength but also increased the optimization time. The findings of this paper will help the designers in the pursuit of lightweight structures and will create the basis for the identification of the ideal material optimization procedure.

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Messing with boundaries - quantifying the potential loss by pre-set parameters in topology optimization

Cited by 11 publications

References 4 publications

Optimization of Brake Calipers Using Topology Optimization for Additive Manufacturing

Optimization of Brake Calipers Using Topology Optimization for Additive Manufacturing

Topology-Optimization-Based Learning: A Powerful Teaching and Learning Framework under the Prism of the CDIO Approach

Topology and Parametric Optimization-Based Design Processes for Lightweight Structures

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