Revolutionary superposition layout method for topology optimization of nonconcurrent multiload models: Connecting‐rod case study

2020 ◽  
Author(s):  
Mohamed G. Alkalla ◽  
Mahmoud Helal ◽  
Ahmed Fouly
Keyword(s):  
Topology Optimization ◽  
Connecting Rod

Optimization design of titanium alloy connecting rod based on structural topology optimization

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Bin Zheng ◽  
Yi Cai ◽  
Kelun Tang
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Topology Optimization ◽  
Optimization Design ◽  
Equivalent Stress ◽  
Connecting Rod ◽  
Element Analysis ◽  
Content Type ◽  
The Finite Element Analysis ◽  
Maximum Equivalent Stress

Purpose The purpose of this paper is to realize the lightweight of connecting rod and meet the requirements of low energy consumption and vibration. Based on the structural design of the original connecting rod, the finite element analysis was conducted to reduce the weight and increase the natural frequencies, so as to reduce materials consumption and improve the energy efficiency of internal combustion engine. Design/methodology/approach The finite element analysis, structural optimization design and topology optimization of the connecting rod are applied. Efficient hybrid method is deployed: static and modal analysis; and structure re-design of the connecting rod based on topology optimization. Findings After the optimization of the connecting rod, the weight is reduced from 1.7907 to 1.4875 kg, with a reduction of 16.93%. The maximum equivalent stress of the optimized connecting rod is 183.97 MPa and that of the original structure is 217.18 MPa, with the reduction of 15.62%. The first, second and third natural frequencies of the optimized connecting rod are increased by 8.89%, 8.85% and 11.09%, respectively. Through the finite element analysis and based on the lightweight, the maximum equivalent stress is reduced and the low-order natural frequency is increased. Originality/value This paper presents an optimization method on the connecting rod structure. Based on the statics and modal analysis of the connecting rod and combined with the topology optimization, the size of the connecting rod is improved, and the static and dynamic characteristics of the optimized connecting rod are improved.

Additively Manufactured Continuous Fibre-Reinforced Thermoplastics for Mechanisms Subjected to Predominant Inertial Load: A Case Study

2020 ◽  
Author(s):  
Luca Luzi ◽  
Giacomo Quercioli ◽  
Riccardo Pucci ◽  
Guido Bocchieri ◽  
Rocco Vertechy ◽  
...  
Keyword(s):  
Aluminum Alloy ◽  
Topology Optimization ◽  
High Performance ◽  
Permanent Magnet Synchronous Motor ◽  
Three Dimensional ◽  
Direct Drive ◽  
Continuous Fibre ◽  
Mechanical Components ◽  
Reinforced Thermoplastics

Abstract In the last decade, the adoption of additive manufacturing technologies (AMT) (3D printing) has increased significantly in many fields of engineering, initially only for rapid prototyping and more recently also for the production of finished parts. With respect to the long-established material subtractive technologies (MST), AMT is capable to overcome several limitations related to the shape realization of high-performance mechanical components such as those conceived via topology optimization and generative design approaches. In the field of structures and mechanisms, a major advantage of AMT over MST is that, for the same loading and constraining conditions (including kinematic and overall encumbrance), it enables the realization of mechanical components with similar stiffness but smaller volume (thus smaller weight, density being equal). Recently, the potentialities of AMT have also been increased by the introduction of the fuse filament deposition modeling (FDM) of continuous fibre-reinforced thermoplastics (CFRT), which combines the ease of processing of plastic AMT with the strength and specific modulus of the printed components that are comparable to those attainable via metallic AMT. In this context, the present paper investigates the potentialities of FDM-CFRT for the realization of mechanisms subjected to predominant inertial loads such as those found in automated packaging machinery. As a case study a Stephenson six-bar linkage powered in direct drive by a permanent magnet synchronous motor is considered. Starting from an existing mechanism realized in aluminum alloy with traditional MST, a newer version to be realized with FDM-CFRT has been conceived by keeping the kinematics fixed and by redesigning the links via three-dimensional topology optimization. To provide a fair comparison with the more traditional design/manufacturing approach, size optimization of the original mechanism made in aluminum alloy has also been performed. Comparison of the two versions of the mechanism highlights the superior performances of the one manufactured via FDM-CFRT in terms of weight, motor torque requirements and motion precision.

Aplication of the Force Cone Method in topology optimization: a case study on truss design.

2015 ◽  
Author(s):  
Arthur Pandolfo da Veiga ◽  
Gustavo Marques Hobold ◽  
Rogério de Castro Lambert
Keyword(s):  
Topology Optimization ◽  
Truss Design

Lattice Structure Design for Additive Manufacturing: Unit Cell Topology Optimization

2019 ◽  
Author(s):  
Bradley Hanks ◽  
Mary Frecker
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
Lattice Structure ◽  
Optimization Method ◽  
Structure Design ◽  
Unit Cell ◽  
Lattice Structures ◽  
Design For Additive Manufacturing ◽  
Structure Topology

Abstract Additive manufacturing is a developing technology that enhances design freedom at multiple length scales, from the macroscale, or bulk geometry, to the mesoscale, such as lattice structures, and even down to tailored microstructure. At the mesoscale, lattice structures are often used to replace solid sections of material and are typically patterned after generic topologies. The mechanical properties and performance of generic unit cell topologies are being explored by many researchers but there is a lack of development of custom lattice structures, optimized for their application, with considerations for design for additive manufacturing. This work proposes a ground structure topology optimization method for systematic unit cell optimization. Two case studies are presented to demonstrate the approach. Case Study 1 results in a range of unit cell designs that transition from maximum thermal conductivity to minimization of compliance. Case Study 2 shows the opportunity for constitutive matching of the bulk lattice properties to a target constitutive matrix. Future work will include validation of unit cell modeling, testing of optimized solutions, and further development of the approach through expansion to 3D and refinement of objective, penalty, and constraint functions.

A personalized mandibular implant with supporting and porous structures designed with topology optimization – a case study of canine

2019 ◽  
Vol 25 (2) ◽  
pp. 417-426 ◽  
Author(s):  
Kangjie Cheng ◽  
Yunfeng Liu ◽  
Chunyan Yao ◽  
Wenquan Zhao ◽  
Xu Xu
Keyword(s):  
Topology Optimization ◽  
Optimal Design ◽  
Three Dimensional ◽  
Fem Analysis ◽  
Von Mises Stress ◽  
Content Type ◽  
Optimized Model ◽  
Supporting Structures ◽  
External Shape

Purpose The purpose of this study is to obtain a titanium mandibular implant that possesses a personalized external shape for appearance recovery, a supporting structure for physiological loading and numerous micro-pores for accelerating osseointegration. Design/methodology/approach A three-dimensional intact mandibular model of a beagle dog was created from cone-beam computerized tomography scans. A segment of the lower jaw bone was resected and replaced by a personalized implant with comprehensive structures including a customized external shape, supporting structures and micro-pores, which were designed by topology optimization. Then with FEM analysis, the stress, displacement distribution and compliance of the designed implant were compared with the non-optimized model. The weight of the optimized implant that was fabricated by SLM with titanium alloy powder was measured and contrasted with the predicted non-optimized model for evaluating the viability of the design. Findings The FEM results showed the peaks of von Mises stress and displacement on the optimized implant were much lower than those of the implant without optimization. With topology optimization, the compliance of the implant decreased significantly by 53.3 per cent, and a weight reduction of 37.2 per cent could be noticed. Originality/value A design strategy for personalized implant, with comprehensive structures and SLM as the fabrication method, has been developed and validated by taking a canine mandible as the case study. With comprehensive structures, the implant presented good biomechanical behaviors thanks to the most appropriate supporting structures obtained by optimal design. The topological optimal design combined with SLM printing proved to be an effective method for the design and fabrication of personalized implant with complex structures.

An Integrated Approach for the Sustainable Development of an Automotive Component Using CAD/CAE, DFE and DFMA Concept

2015 ◽  
Vol 766-767 ◽  
pp. 1009-1014 ◽  
Author(s):  
P. Suresh ◽  
S. Ramabalan ◽  
U. Natarajan
Keyword(s):  
Environmental Impact ◽  
Computer Aided Design ◽  
Cost Effective ◽  
Integrated Approach ◽  
Connecting Rod ◽  
Automotive Component ◽  
Minimal Impact ◽  
Computer Aided ◽  
Sustainable Product

In order to render cost effective and environmentally friendly products, sustainability is gaining importance in contemporary manufacturing organizations. The rapidly changing marketplace also means that organizations are in search of integrated approaches for creating sustainable product. In this context, this paper reports a case study carried out in an automotive component of single cylinder four stroke petrol engines. The candidate product is connecting rod. The existing handle of connecting rod has been modeled using computer-aided design (CAD). Then, the sustainability analysis has been carried out on the existing component for determining the environmental impact. This is followed by the engineering analysis of the component using computer aided engineering (CAE). Then the redesign of the handle performed by using design for manufacture and assembly (DFMA) principles. The sustainability factors have been measured in terms of carbon footprint, air acidification, energy consumption, and water impacts. It has been found that the redesigned product possesses minimal environmental impact. It could be knew from the results of the case study that the implementation of DFE (design for environment) and DFMA concept could initiate new developments in sustainable product design with minimal impact on the environment. This integrated approach is considered to be valuable for its implementation in similar product development situations to achieve business benefits such as reduced cost and time which would in turn improve the profitability.

Design for Fixturability (DFF) Methodology for Commodity Parts: A Case Study With Connecting Rod Designs

2002 ◽  
Vol 2 (1) ◽  
pp. 21-27 ◽  
Author(s):  
Khurshid A. Qureshi ◽  
Kazuhiro Saitou
Keyword(s):  
Mass Production ◽  
Parametric Representation ◽  
Design Stage ◽  
Design Parameters ◽  
Concept Design ◽  
Connecting Rod ◽  
Automotive Engine ◽  
Part Families ◽  
Manufacturing Facilities

This paper presents a methodology called ‘Design for Fixturability’ (DFF). This methodology enables designers to perform manufacturability analysis of their product designs upfront into the design process. The DFF approach provides a mapping between parametric representation of a part design and fixturing capability of a facility and presents a methodology to evaluate the design with respect to the fixturing capabilities. The methodology is applicable to the mass-production commodity parts and part families, which typically require dedicated manufacturing facilities. A prototype DFF system for connecting rods of an automotive engine is developed. The system enables the designers to design the connecting rods by considering the fixturing (datums) capabilities of existing manufacturing facilities during the concept design stage, when design parameters are still not frozen. The DFF system analyzes the design with respect to fixturing capabilities of facilities and generates suggestions for the designer, to modify his design if required.

scholarly journals Optimization of Brake Calipers Using Topology Optimization for Additive Manufacturing

2021 ◽  
Vol 11 (4) ◽  
pp. 1437
Author(s):  
Evangelos Tyflopoulos ◽  
Mathias Lien ◽  
Martin Steinert
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
Optimization Procedure ◽  
Optimization Approach ◽  
Design Flexibility ◽  
Current State ◽  
3D Printed ◽  
Removal Processes ◽  
Material Layout

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.

Sign in / Sign up

Export Citation Format

Share Document