Requirement

Goal of topology optimization is to find the best use of material for a body such that an objective criterion i.e. global stiffness, natural frequency, etc. meets the load/ application requirements with minimal material thereby improving load to weight ratio. It is prudent to add here that DFM (Design For Manufacturing) decides the overall material savings and therefore Optimisation is an iterative process to be taken up with close coordination with manufacturer and their capabilities and infrastructure .

Case study

A topology optimization was carried out to one of the products of our esteemed customer by considering various loads such as Axial forces and thrust, over hung components, bearing reaction forces, torque loads. Exclusion regions were discussed based on their requirements and topology optimisation was carried out using applicable material allowable limits, and verified using Campbell diagram regarding the optimal geometry.

Results

Geometric model has been optimized and the overall weight reduction by 25% was achieved without affecting the strength and manufacturability through 2-3 iterations.

Benefits

• Design optimisation leading to cost benefit due to reduced material consumption
• CAE driven process is faster without material consumption and multiple iterations is possible with minimal incremental cost
• Cost Effective CAD solution