Evaluation of Topology Optimization and Generative Design Tools as Support for Conceptual Design

Abstract

Nowadays, a large number of different tools that support early phases of design are available to engineers. In the past decade a specialized set of CAD-based tools were developed, that support the ideation process by generating different design alternatives according to the criteria given by the designer. Two types of tools are discussed in this paper: topology optimization and generative design tools. To investigate to what extent these tools are suitable for use in early design phases and what are the main differences between them, a study was conducted on an industrial case.

Guidelines for Topology Optimization as Concept Design Tool and Their Application for the Mechanical Design of the Inner Frame to Support an Ancient Bronze Statue

“…To improve the performance of TO, passing through a natural process of scientific progress, several approaches have been established, such as the homogenization method [2,3], the SIMP method [4,5], the level set method [6,7], the MMC/MMV method [8,9], and some evolutionary and heuristic methods [10][11][12]. For the last few decades, TO has been implemented effectively as a conceptual design tool to achieve the desired mechanical performance with feasible manufacturing [1,13,14]. The desired mechanical performance is achieved with the help of a specific objective function (e.g., compliance minimization, maximization of fundamental frequency, mass reduction, etc.)…”

“…Conceptual design is a fundamental milestone at the initial phase of any product development process, helping the early assessment of optimal design solution with regard to other crucial factors such as manufacturing, time-to-market, performance, testing and cost [1,13,14]. Therefore, the designers always come up with several design solutions in the concept design phase and after a meticulous evaluation, select the best one.…”

“…In addition, the latest technological advancements in the field of computer, programming, artificial intelligence, CAD tools (i.e., integrated in many commercial software) and numerical solvers have further enhanced the design process with regard to fast computations and complex simulations [53][54][55]. For the last few decades, topology optimization (TO) has been extensively studied together with generative design (GD) as superior conceptual design methodologies [1,13,14,42,56]. Despite this, TO is usually seen as a specific structural optimization tool instead of a way to define concepts.…”

Generative Design of a Mechanical Pedal

“…Furthermore, the development of Additive Manufacturing (AM) technologies, 3D printing in particular, tremendously helped the utilisation of generative design, because manufacturing is no longer limited to the traditional manufacturing process but rather engineers have the possibility to design parts that were not possible to manufacture in the past [4]. Several research studies on generative design were made when it first emerged, and most of them were theoretical without real-world applications, then the concept became more feasible and was applied in several applications [5]. Vlah et al implemented the generative design and topology optimization on a race car rocker, with several results of different masses and geometries were generated [5], Gavacova et al made a study on the automotive hood and employed the generative design theory in their work taken into consideration a set of constraints [6], further work in the automotive industry utilizing the generative engineering design was made particularly, in the surface-based components, Gulanová et al conducted a development study in the automotive surface-based components putting into consideration several criteria such as economic, safety, and Aesthetical criteria [7].…”

“…Several research studies on generative design were made when it first emerged, and most of them were theoretical without real-world applications, then the concept became more feasible and was applied in several applications [5]. Vlah et al implemented the generative design and topology optimization on a race car rocker, with several results of different masses and geometries were generated [5], Gavacova et al made a study on the automotive hood and employed the generative design theory in their work taken into consideration a set of constraints [6], further work in the automotive industry utilizing the generative engineering design was made particularly, in the surface-based components, Gulanová et al conducted a development study in the automotive surface-based components putting into consideration several criteria such as economic, safety, and Aesthetical criteria [7]. In terms of mass reduction, as generative engineering design is oriented on reducing the mass while not compromising the functionality or the effectiveness of the component, a GD study was conducted on an E-bike for reducing its mass while keeping up with the safety requirements, the results show a mass reduction of the frame by 23.913% [8], another study aiming to reduce the weight while maintaining or preventing strength reduction on a connecting rod of a V8 engine was made with results of 8.13% of mass reduction without a reduction in the strength [9].…”