Papers by Keyword: Topology Optimization

Abstract: While the use of composite materials increases the specific stiffness of structural parts, their manufacture using automated fiber placement processes such as Tailored Fiber Placement (TFP) allows for the addition of functionalization. An example of such a part is the hydrofoil, which can gain hydrodynamic performance if its shape adapts to the different loads encountered in the three modes of navigation. One method that can meet these requirements is passive functionalization. In this context, the development of digital design support tools is essential. Among them, topology optimization is a well-established method. This work focuses on the development of a strategy for optimizing the topology or the fiber density distribution of the part and the orientation of the fibers for composite materials with an objective function of path generating type allowing passive functionalization. A method for generating fiber trajectories for the TFP process is also presented. The topology optimization results of a cantilever type test case and a shell plate are shown and discussed.

Abstract: Integrating topology optimization (TO) with lattice infilling for additive manufacturing provides an effective route to lightweight, high-performance structures for aerospace applications. Reducing structural mass can deliver environmental and economic benefits by lowering fuel consumption and associated emissions. This study evaluates a computational workflow for weight reduction of an aircraft bearing bracket by combining topology optimization with stress guided lattice infilling. First, compliance minimizing TO is performed under additive manufacturing constraints to obtain an efficient global load-path layout. Next, lattice infill is introduced using both Triply Periodic Minimal Surface (TPMS) unit cells (gyroid) and strut-based unit cells (diamond). To avoid manual trial-and-error in selecting unit cell size, and thickness, an implicit modeling approach with Python-driven iteration is used to systematically explore lattice parameters and identify feasible configurations. The proposed method uses the TO-derived stress field to tailor lattice parameters spatially, enabling graded cellular architectures aligned with local load demands. Compared with the baseline bracket, TO alone achieved a 44.42% mass reduction, while the stress-guided lattice designs achieved 70% (gyroid) and 68.6% (diamond) weight savings. Finite element analysis is used to compare the baseline, TO, and lattice-infilled brackets in terms of mass, maximum deflection, and von Mises stress, demonstrating that stress-guided lattice infill can improve structural efficiency beyond TO alone while maintaining AM oriented manufacturability through self-supporting cellular features. A key contribution is an automated, stress-guided ramp mapping for graded lattice-parameter control, which is broadly applicable to other components, loading scenarios, and lattice families.

Abstract: Mechanical vibrations are abundant in human-made environments and can be harnessed using piezoelectric transduction. Among the piezo materials, piezoelectric polymers exhibit flexibility and mechanical compliance, improving resilience to shock and deformation—suited for low-frequency high strain environments. In this paper, distinct designs of piezoelectric active area were topology optimized using ANSYS. Three designs of bimorph cantilevered energy harvesters were developed to obtain the optimum material layouts of piezoelectric PVDF, maximize the voltage output, decrease the resonant frequency, and reduce the amount of material needed. Two additional designs with varying volume retainment were also simulated to investigate the effects of optimization parameters. The best topology optimized design, #2, had a resonant frequency of 16.9 Hz and a piezo voltage of 1.08E-3 V/mm³ normalized to the amount of remaining PVDF after optimization. Although the frequency is still higher than the target ambient energy sources, this study showed that topology optimization in conjunction with design can be used to define structures leading to the energy harvesting application frequency.

Abstract: Generative design (GD) and topology optimization (TO) are two advanced methods that make it possible to design lightweight and high-performance structures for industrial and mechanical needs. This study offers an approach that combines generative design and topology optimization to reach the best possible balance of material efficiency and manufacturability in complex components. By utilizing GD's capacity to provide several design options within predetermined parameters and TO's material distribution methodology, the suggested approach minimizes weight while maximizing structural integrity. To validate the methodology, a case study involving optimization of performance, weight, and manufacturability of a motorcycle triple clamp is discussed in the paper. The study uses ANSYS for TO to create a preliminary efficient design, it then uses Fusion 360's Generative Design tools to develop the design and investigate various manufacturable configurations (additive and subtractive manufacturing). The final design is confirmed by finite element analysis (FEA), which evaluates each alternative's mechanical performance, manufacturability, with significant weight reduction—up to 35%—while preserving manufacturing viability and structural integrity.

Abstract: Parametric and generative design represent key elements of contemporary design, offering faster and more efficient ways of creating compared to traditional approaches. This article explores the use of generative design and parametric design in the field of industrial design, focusing on the application of generative design tools in Fusion 360 software for designing functional objects. Generative design, through algorithms and rules, enables the exploration of various design variants to find the optimal solution. It focuses on creating organic shapes and optimizing them based on specific criteria, drawing inspiration from natural elements. Parametric design, on the other hand, concentrates on directly defining and manipulating model parameters, allowing for quick design adjustments. The article also provides a detailed view of the generative study design process in Fusion 360 software, including a description of settings and design options. Furthermore, it highlights the benefits of its use through practical examples of generative design applications and the design possibilities offered by this approach. In the practical part of this article, the creation of a real component through generative design in Creo PTC software was demonstrated. This process shows how modern tools allow not only the creation of complex and functional shapes but also the direct application of optimization algorithms to improve designs in a real-world environment.

Abstract: Uprights are one of the most critical structural elements in vehicles suspension systems. A standard upright serves as a physical mounting for the wheel hub and brake components as well as links the axle to the control arms. Uprights are relatively bulky by design to withstand the significant loads they observe during vehicle braking, maneuvering, and driving on rough terrain. In automotive design, specifically, race car design, utilizing lightweight components and reducing fuel consumption are imperative. This weight reduction-based paradigm is being adopted by the car industry at large, particularly due to the shift towards automotive electrification. Consequently, this work investigates the potential for using topological optimization to reduce the bulkiness and weight of uprights without compromising their structural integrity and reliability. An upright designed for a racing car is selected in this study. Topological optimization is performed on the upright using the finite element software ANSYS. Results show that a considerably enhanced upright is obtained after 48 topological optimization iterations while maintaining a factor of safety of 2.5. The optimized upright exhibited less stress concentrations and 39% lesser weight than the original upright.

Abstract: Manufacture of intricate components, products without the need for tooling, shorter lead times and material grading are the most beneficial applications of Additive Manufacturing (AM). The goal of this study is to develop a design optimization framework for developing an aircraft component using additive manufacturing utilizing topology and lattice optimization techniques. Solid works were used to create a 3D model of an aircraft bracket made of Titanium alloy. To minimize mass and maximize frequency and stiffness, the optimization was performed using Altair Inspire 2022.1 software. Component optimization was performed using the finite element method, which entails reducing material while maintaining the proper function of the modelled component. The optimal performance of the designed aerospace component using topology with lattice infill is achieved with minimization of mass from 2.24810 kg to 0.16235 kg and the volume from 5.07579x10⁵ mm³ to 4.70922x10² mm³, frequency is increased from 0.02 kHz to 13.9537 kHz, stiffness is maximized from 1,485,884.1 N/m to 4,558,924.0939 N/m with a factor of safety of 1.73. Therefore, the mechanical properties of the optimized model can full fill its overall performance.

Abstract: Commercial tyres that are specifically designed for higher speed and on-highway tarred road conditions are currently being used on lightweight underground mining utility vehicles. This is due to there being no alternative tyres that are readily available to better suite the application and environment. This research calls attention to the side effects of using commercial tyres in mining environments. As a result, a model-based systems engineering approach is used to design a more appropriate tyre for this environment. Airless tires have been a focus area for many top tyre manufacturing companies however the criteria and focus of existing papers has predominantly been on commercial tyres that follow a completely different set of design rules and requirements. In this research a topologically optimised tyre that better conforms with the design parameters of the vehicle, is proposed and analysed. A computational aided design (CAD) model of a commercial pneumatic tyre and a foam filled tyre was created. Data from a typical mining vehicle of this class was captured and used to calculate the mechanics as inputs to the finite element model (FEM) including driveshaft effects. This model is then statically analyses and optimised over various iterations of topologies. The iteration stopping criteria is reduced stresses on drivetrain components and being able to accommodate a greater payload. This research provides a proof of concept on the feasibly of replacing standard commercial pneumatic or foam filled tyres with purpose designed airless tyres to better serve the mining market whilst retaining original equipment manufacturer vehicle design parameters. From the results it was found that these tyres can meet the loading requirements as specified given the resultant deflections, reduced stresses and reduced polar second moment area on the driveshaft component (s).

Abstract: Most design-to-manufacturing frameworks combining topology optimization (TO) and additive manufacturing (AM) integrate mesh smoothing methods as post-processing techniques to remove discrete irregularities of optimized topologies. Notably, a design framework is proposed incorporating all the CAD development stages within the design phase providing smooth and ready-to-print topologies. The Laplacian-based smoothing algorithms have demonstrated a high capacity in removing surface noise. This study focuses on investigating the smoothing capacity of both HC Laplacian and Taubin methods using mesh quality metrics to assess on their performance in terms of geometric preservation and volume shrinkage. Taubin method was found to produce high-quality smooth meshes with less volume shrinkage compared to HC Laplacian. The Taubin model exhibited an increase of 15.06% in mesh volume whereas the HC Laplacian model had a volume shrinkage of 28.14%. Additionally, finite element analyses of the three-point bending test using ANSYS is set to measure the flexural stiffness of an optimized MBB beam under both HC Laplacian and Taubin smoothing methods. Overall, the flexural stiffness of Taubin is nearly two times the original model with a surplus of 46.91% whereas HC Laplacian exhibited a flexural stiffness that is less with 72.07% than the original model.

Abstract: Numerical simulation is nowadays increasingly used to avoid the costs and time associated with the development and optimization of metal forming processes. However, the accuracy of the numerical results is still an issue. Material behavior and characteristics are required by simulation software, and these are usually obtained by performing a considerable number of classical mechanical tests. To improve this procedure, heterogeneous tests have been used instead. More and richer information can be obtained with a single test due to the heterogeneous displacement and strain fields that are induced. This work aims at designing a heterogeneous mechanical test using a topology-based optimization methodology. Highly heterogeneous displacement fields are induced on the sheet specimen by applying an extended version of the theory of compliant mechanisms. To account for large deformations, a geometrically nonlinear finite element analysis is proposed together with a consistent topology optimization approach. The material behavior is considered linear elastic. The performance of the obtained solutions is evaluated considering the heterogeneity of stress states using a mechanical indicator. Validation of the developed methodology is performed and an optimal mechanical test is obtained presenting a high diversity of stress states.