scholarly journals Fastener products lightweight design and forming process simulation

2018 ◽  
Vol 185 ◽  
pp. 00030
Author(s):  
Jinn-Jong Sheu ◽  
Chien-Jen Ho ◽  
Cheng-Hsien Yu ◽  
Kuo-Ting Wu
Keyword(s):  
Topology Optimization ◽  
Lightweight Design ◽  
Integrated Design ◽  
Optimization Method ◽  
Design System ◽  
Forming Process ◽  
Multi Stage ◽  
Die Stress ◽  
Final Design ◽  
Evaluation Stage

In this research, an integrated design system was established to design the product of nuts with flange and generate the lightweight geometry of product. The multi-stage forming process was evaluated using the CAE simulations. The topology optimization method was used to achieve the lightweight design, that included keeping necessary geometrical features and remove the excess volumes. The topological discrete model had been remodelled into a meaningful geometry which is able to satisfy the requirement of proof load of fastener specification. The final design of the lightweight geometry was adopted to test the capability of carrying proof load required using CAE simulations with the boundary conditions of the related ASTM standard. In the evaluation stage, the finite element method was used to do the topology optimization, the proof load evaluation, the forging process and the die stress analysis. The simulation results showed the lightweight design was able to reduce the weight of product and maintain enough mechanical strength. The proposed process and die designs were able to obtain the lightweight product without defects.

scholarly journals An efficient approach to reliability-based topology optimization for the structural lightweight design of planar continuum structures

2021 ◽  
Vol 37 ◽  
pp. 270-281
Author(s):  
Fangfang Yin ◽  
Kaifang Dang ◽  
Weimin Yang ◽  
Yumei Ding ◽  
Pengcheng Xie
Keyword(s):  
Topology Optimization ◽  
Lightweight Design ◽  
Integrated Design ◽  
Optimization Methods ◽  
Filter Function ◽  
Continuum Structures ◽  
Performance Indexes ◽  
Reliability Method ◽  
Economic Indexes ◽  
The Impact

Abstract In order to solve the application restrictions of deterministic-based topology optimization methods arising from the omission of uncertainty factors in practice, and to realize the calculation cost control of reliability-based topology optimization. In consideration of the current reliability-based topology optimization methods of continuum structures mainly based on performance indexes model with a power filter function. An efficient probabilistic reliability-based topology optimization model that regards mass and displacement as an objective function and constraint is established based on the first-order reliability method and a modified economic indexes model with a composite exponential filter function in this study. The topology optimization results obtained by different models are discussed in relation to optimal structure and convergence efficiency. Through numerical examples, it can be seen that the optimal layouts obtained by reliability-based models have an increased amount of material and more support structures, which reveals the necessity of considering uncertainty in lightweight design. In addition, the reliability-based modified model not only can obtain lighter optimal structures compared with traditional economic indexes models in most circumstances, but also has a significant advantage in convergence efficiency, with an average increase of 44.59% and 64.76% compared with the other two reliability-based models. Furthermore, the impact of the reliability index on the results is explored, which verifies the validity of the established model. This study provides a theoretical reference for lightweight or innovative feature-integrated design in engineering applications.

scholarly journals Lightweight Design of Front Suspension Upright of Electric Formula Car Based on Topology Optimization Method

2020 ◽  
Vol 11 (1) ◽  
pp. 15 ◽  
Author(s):  
Jixiong Li ◽  
Jianliang Tan ◽  
Jianbin Dong
Keyword(s):  
Topology Optimization ◽  
Optimization Design ◽  
Lightweight Design ◽  
Geometric Model ◽  
Load Condition ◽  
Optimization Method ◽  
Structure Design ◽  
Front Suspension ◽  
Emergency Braking ◽  
Topology Optimization Method

In order to obtain a lightweight front upright of an electric formula car’s suspension, the topology optimization method is used in the front upright structure design. The mathematical model of the lightweight optimization design is constructed, and the geometric model of the initial design of the front upright is subjected to the ultimate load condition. The structural optimization of a front upright resulted in the mass reduction of the upright by 60.43%. The optimized model was simulated and verified regarding the strength, stiffness, and safety factor under three different conditions, namely turning braking, emergency braking, and sharp turning. In the experiment, the uprights were machined and assembled and integrated into the racing suspension. The experimental results showed that the optimized front uprights met the requirements of performance.

scholarly journals A topology optimization method of robot lightweight design based on the finite element model of assembly and its applications

2020 ◽  
Vol 103 (3) ◽  
pp. 003685042093648
Author(s):  
Liansen Sha ◽  
Andi Lin ◽  
Xinqiao Zhao ◽  
Shaolong Kuang
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Topology Optimization ◽  
Lightweight Design ◽  
Element Model ◽  
Optimization Method ◽  
Maximum Displacement ◽  
Element Analysis ◽  
Upper Limb Exoskeleton ◽  
Topology Optimization Method

Topology optimization is a widely used lightweight design method for structural design of the collaborative robot. In this article, a topology optimization method for the robot lightweight design is proposed based on finite element analysis of the assembly so as to get the minimized weight and to avoid the stress analysis distortion phenomenon that compared the conventional topology optimization method by adding equivalent confining forces at the analyzed part’s boundary. For this method, the stress and deformation of the robot’s parts are calculated based on the finite element analysis of the assembly model. Then, the structure of the parts is redesigned with the goal of minimized mass and the constraint of maximum displacement of the robot’s end by topology optimization. The proposed method has the advantages of a better lightweight effect compared with the conventional one, which is demonstrated by a simple two-linkage robot lightweight design. Finally, the method is applied on a 5 degree of freedom upper-limb exoskeleton robot for lightweight design. Results show that there is a 10.4% reduction of the mass compared with the conventional method.

Application of Topological Optimization on Aluminum Alloy Automobile Wheel Designing

2012 ◽  
Vol 562-564 ◽  
pp. 705-708
Author(s):  
Zhi Jun Zhang ◽  
Hong Lei Jia ◽  
Ji Yu Sun ◽  
Ming Ming Wang
Keyword(s):  
Topology Optimization ◽  
Lightweight Design ◽  
Optimization Method ◽  
Variable Density ◽  
Topological Optimization ◽  
Optimal Topology ◽  
Element Analysis ◽  
Material Interpolation ◽  
Strength And Stiffness

Topology optimization method based on variable density and the minimum compliance objective function was used on designing the wheel spokes. SIMP material interpolation model was established to compensate these deficiencies of variable density method. Considering manufacturing process and stress distribution, five bolt wheels was chose to topology optimization. The percentage of material removal of the optimal topology 40% was reasonable. Finite element analysis was used to test the strength and stiffness of the structure of the wheel, the result meets the requirements after wheel topology optimization, and reduces the quality of wheels to 7.76kg, achieve the goals of lightweight design.

scholarly journals Advanced Optimization Design of Cross Beams Structure

2014 ◽  
Vol 8 (1) ◽  
pp. 117-123
Author(s):  
Ke Zhang ◽  
Xuan Mu ◽  
Dehong Zhao ◽  
Yuhou Wu
Keyword(s):  
Topology Optimization ◽  
Optimization Design ◽  
Simulation Analysis ◽  
Lightweight Design ◽  
Optimization Method ◽  
Production Costs ◽  
Structure Quality ◽  
Machining Center ◽  
Traditional Structure ◽  
Inherent Frequency

Solid Isotropic Microstructure with Penalization(SIMP) in topology optimization was deeply analyzed, and thus SIMP topology optimization criteria algorithm was deduced. Simulation analysis to the results was also conducted by Ansys, so as the structural lightweight design to machine crossbeams of the HTM series gantry. By verifying, the structure was 3.8% lower than the traditional structure quality, stiffness increased by 16.07%, and the overall inherent frequency was improved. By applying topology optimization method to the design process of the machining center HTM series, ma-terial utilization is improved and production costs were reduced.

Lightweight Design of PLATE ShearS Bed Based on Topology Optimization and Test Methods

2013 ◽  
Vol 568 ◽  
pp. 143-149
Author(s):  
Yong Wang ◽  
Kun Li ◽  
Bao Ping Cui ◽  
Zu Fang Zhang
Keyword(s):  
Topology Optimization ◽  
Lightweight Design ◽  
Optimization Method ◽  
Maximum Principal Stress ◽  
Test Methods ◽  
Total Displacement ◽  
Design Requirements ◽  
Improvement Scheme ◽  
Different Thickness ◽  
Topology Optimization Method

In order to meet the lightweight design requirements of one swing-type plate shears, the topology optimization method is applied to improve the structure of bed. According to the analysis of the actual working conditions, the reasonable load and boundary conditions are determined. The conceptual model of bed structure is established by using topology optimization method. Lightweight improvement scheme is proposed based on the topology optimization results, and the rationality of scheme is verified by test and analysis. Different parts of the bed are thickened or thinned, and the influences of different thickness of the stiffener on the maximum principal stress, total displacement, displacement in Y direction and weight of bed structure model are analyzed. A reasonable lightweight scheme of shear machine bed is proposed. The weight of the bed is reduced and the lightweight purpose is finally achieved in the case of meeting the requirements of shearing accuracy.

scholarly journals Topology optimization of transmission gearbox under multiple working loads

2018 ◽  
Vol 10 (11) ◽  
pp. 168781401881345 ◽  
Author(s):  
Mingxuan Liang ◽  
Jianhong Hu ◽  
Shuqing Li ◽  
Zhigao Chen
Keyword(s):  
Finite Element ◽  
Topology Optimization ◽  
Finite Element Model ◽  
Lightweight Design ◽  
Dynamic Performance ◽  
Reference Value ◽  
Element Model ◽  
Optimization Method ◽  
Dynamic Excitation ◽  
Topology Optimization Method

This article is concerned with topology optimization of transmission gearbox under multiple working loads by taking dynamic performance as research object. First, the dynamic excitation model and finite element model are established, the vibration responses of the key points on gearbox are obtained by applying dynamic excitation on finite element model based on modal dynamic method, and the simulation responses are compared with testing results to validate finite element model. Finally, the gearbox structure is optimized by utilizing topology optimization method, and the lightweight model of transmission gearbox structure is redesigned. The dynamic performance indexes such as natural frequency are improved obviously, which indicates that the topology optimization method is very effective in optimizing dynamic performance of complex gearbox structure. The research has an important theoretical significance and reference value for lightweight design of transmission gearbox structure.

A New Design of a Hydraulic Steel Radial Gate with Two Oblique Arms by Topology Optimization

2013 ◽  
Vol 712-715 ◽  
pp. 2906-2912
Author(s):  
Kun Cai ◽  
Hong Yang He ◽  
Xin Huan Li ◽  
Yan Li
Keyword(s):  
Topology Optimization ◽  
Optimization Method ◽  
Size Optimization ◽  
Traditional Design ◽  
Final Design ◽  
Current Design ◽  
Main Components ◽  
Supporting Frame ◽  
Radial Gate ◽  
Topology Optimization Method

A hydraulic steel radial gate (SRG) with two oblique arms is designed by using topology optimization and size optimization. Topology and size optimization are carried out by using CAD software, e.g., Hyperworks. In the current design, the SRG is initially considered to have three main components, i.e., the arms, the supporting frame of arms and a panel for water retaining. To give a better design of these components, e.g., arms and its supporting frame, topology optimization is adopted. By topology optimization method, the shape of arm and the supporting frame are obtained. As construction of the new SRG is reconstructed by the components obtained, the stiffness, strength and stability of the new SRG is checked and some sizes of components in SRG are readjusted by using size optimization. The final design of the SRG is around 24% lighter than the traditional design whilst the safety of the new design is much better.

Aero-Mechanical Optimization Method With Direct CAD Access: Application to Counter Rotating Fan Design

2006 ◽  
Author(s):  
S. Pierret ◽  
H. Kato ◽  
R. Filomeno Coelho ◽  
A. Merchant
Keyword(s):  
Three Dimensional ◽  
Integrated Design ◽  
Optimization Method ◽  
Optimization Techniques ◽  
Operating Conditions ◽  
Design System ◽  
Cad System ◽  
Design Variables ◽  
Automatic Optimization ◽  
Turbomachinery Blades

The detailed design of three-dimensional turbomachinery blades is a very challenging problem requiring multi-disciplinary analysis (MDA), efficient numerical optimization techniques and efficient shape parameterization techniques. Moreover, CAD systems have become an integral and critical part of the complete design process in various fields, and in particular in the field of turbomachine design. The connection of an automated design system to drive CAD geometry directly in the native CAD software is therefore mandatory in order to obtain an integrated design system that can be used in an industrial design chain. This paper presents and discusses an effort to incorporate these technologies into a single and integrated design system for the automatic optimization of turbomachinery blades. First, a brief summary of the algorithms and software used in this design system is presented. Then, the performance of this design system is first demonstrated on the automatic optimization of a counter-rotating fan stage. The fan is redesigned for several aerodynamic operating conditions as well as for multi-disciplinary objectives with constraints involving a CFD solver and structural mechanics FEM solver. The fan geometry is parameterized using 70 design variables and an optimum solution is found in 300 optimization cycles. The peak efficiency is increased by 1.5%, while the static stresses and dynamic vibration modes satisfy the constraints imposed during the optimization. Finally, a second application demonstrates the design optimization of a CAD model of the counter-rotating fan performed with direct integration to the CAD system using the CAPRI middleware. In this case the tip section of the first rotor is parameterized using 7 design variables. The efficiency is increased by 0.5% and the CAD integration in the optimization cycle is demonstrated.

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