Nested Topology Optimization Methodology for Designing Two-Wheel Chassis

Manios, Stefanos E.; Lagaros, Nikos D.; Nassiopoulos, Elias

doi:10.3389/fbuil.2019.00034

Cited by 8 publications

(5 citation statements)

References 24 publications

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“…by other investigators [29,33] and the current study, the initial topology optimization results still required manual process to eliminate holes, shape, irregular and complex edges, for example, see Figure 10. The topology optimization results were manually reconstructed to smoothen the shape and complex edges and to fill the missing pores to improve its manufacturability to the final design before the fabrication commencing.…”

Section: Bell Crank Prototype Fabricationmentioning

confidence: 84%

“…The optimization algorithms are based on published work [18,19,29]. Topology optimization for a continuum structure can be regarded as a material distribution problem, where the target is to find an optimized material distribution within the design domain, for the minimum compliance (or maximum global stiffness) according to Equation (3).…”

Section: Optimization Problem Statementmentioning

confidence: 99%

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Reverse Engineering and Topology Optimization for Weight-Reduction of a Bell-Crank

Pang

Fard

2020

Applied Sciences

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This paper describes a new design method that was developed to achieve an optimal design method for weight reduction of a bell crank, sourced from a Louis Christen Road Racing F1 Sidecar. The method involved reverse engineering to produce a 3D model of the mechanical part. The 3D bell crank model was converted to a finite element (FE) model to characterize the eigenvalues of vibration and responses to excitation using the Lanczos iteration method in Abaqus software. The bell crank part was also tested using a laser vibrometer to capture its natural frequencies and corresponding vibration mode shapes. The test results were used to validate the FE model, which was then analysed through a topology optimization process. The objective function was the weight and the optimization constraints were the stiffness and the strain energy of the structure. The optimized design was converted back to a 3D model and then fabricated to produce a physical prototype for design verification and validation by means of FE analysis and laboratory experiments and then compared with the original part. Results indicated that weight reduction was achieved while also increasing the natural frequency by 2%, reducing the maximum principal strain and maximum von Mises stress by 4% and 16.5%, respectively, for the optimized design when compared with the original design. The results showed that the proposed method is applicable and effective in topology optimization to obtain a lightweight (~3% weight saving) and structurally strong design.

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Section: Bell Crank Prototype Fabricationmentioning

confidence: 84%

Section: Optimization Problem Statementmentioning

confidence: 99%

Reverse Engineering and Topology Optimization for Weight-Reduction of a Bell-Crank

Pang

Fard

2020

Applied Sciences

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“…Others simultaneously optimize the three-dimensional shape of a surface and the two-dimensional material topology within it, such as for the design of shell structures [26,27]. There are also methods where explicitly defined shapes are combined with completely free-form topology optimization, such as for shape optimization of a pre-stressing tendon embedded within a topology optimized concrete beam [28], for shape and positioning optimization of a battery pack within a structural frame [29] or for finding the optimal shapes and locations of boundary conditions in topology optimization [5]. Previous studies have also used numerical optimization methods to synthesize multi-body dynamic systems [30,31], or individual components with loading conditions based on analysis of the system [32].…”

Section: (C) Literature Surveymentioning

confidence: 99%

Computational synthesis of wheeled vehicles via multi-layer topology optimization

James,

Kelley,

Kang

et al. 2023

Proc. R. Soc. A.

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In current engineering practice, computer-aided design (CAD) tools play a key role in the design and fabrication of most mechanical systems, including the design of most vehicles. This software tends to rely heavily on human designers to provide the basic design concept, with the software being used to computationally render an existing design, or to perform modifications to a design to achieve incremental improvements in performance. However, an emerging class of computational methods, known as topology optimization methods, offers the potential for true black box computational design. Under this general framework, practitioners provide the algorithm with the constitutive properties of the design materials, and the mechanical function being designed for (e.g. maximum stiffness under a given loading condition), and the algorithm autonomously generates a description of the corresponding structure. With some exceptions, existing topology optimization methods are limited to generating static, single-body designs. In this study, we present a novel method that builds upon the current state of the art by combining multiple collocated planar design domains to achieve automated computational synthesis of multi-body wheeled vehicles. This capability represents an important step on the path toward automated computational design of increasingly complex, innovative and impactful mechanical systems.

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“…In literature, 1–5 Topology Optimization (TO) is used to improve the stiffness-to-weight ratio of various structural components. Cavazzuti et al.…”

Section: Introductionmentioning

confidence: 99%

“…In literature, [1][2][3][4][5] Topology Optimization (TO) is used to improve the stiffness-to-weight ratio of various structural components. Cavazzuti et al 6 report the benefits of including linearized crash load cases in TO to obtain light components with enhanced crash performance.…”

Section: Introductionmentioning

confidence: 99%

Steering column support topology optimization including lattice structure for metal additive manufacturing

Mantovani

Campo

Giacalone

2020

Proceedings of the Institution of Mechanical Engineers, Part C:

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Structural engineering in the automotive industry has moved towards weight reduction and passive safety whilst maintaining a good structural performance. The development of Additive Manufacturing (AM) technologies has boosted design freedom, leading to a wide range of geometries and integrating functionally-graded lattice structures. This paper presents three AM-oriented numerical optimization methods, aimed at optimizing components made of: i) bulk material, ii) a combination of bulk material and graded lattice structures; iii) an integration of solid, lattice and thin-walled structures. The optimization methods were validated by considering the steering column support of a mid-rear engine sports car, involving complex loading conditions and shape. The results of the three methods are compared, and the advantages and disadvantages of the solutions are discussed. The integration between solid, lattice thin-walled structures produced the best results, with a mass reduction of 49.7% with respect to the existing component.

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Nested Topology Optimization Methodology for Designing Two-Wheel Chassis

Cited by 8 publications

References 24 publications

Reverse Engineering and Topology Optimization for Weight-Reduction of a Bell-Crank

Reverse Engineering and Topology Optimization for Weight-Reduction of a Bell-Crank

Computational synthesis of wheeled vehicles via multi-layer topology optimization

Steering column support topology optimization including lattice structure for metal additive manufacturing

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