Track: Sustainable Manufacturing

Abstract

Topology optimization plays a key role in the production of strong, lightweight functional parts. It uses mathematical algorithms to create optimized geometries under given constraints while at the same time improving performance. The conventional design process is time consuming and requires high technical expertise. The raisons d’etre for using algorithms is to reduce part development time and to keep the computational cost low. Further reduction in cost through weight savings can be realized though monolithic (one piece) design. In this method, weight reduction is achieved through the elimination of bolts, nuts and other joining material. Combining topology optimization with monolithic design also blends the benefit of weight reduction with the simplification of the assembly process. To reach optimum weight, an effective part development process requires a methodology which takes into account the objective function and all the constraints. The methodology can be used from the early stages, throughout the design process. This provides a step-by-step approach to the design process and keeps iterations to a minimum, thereby reducing the product development time. This research therefore focuses on the trends in the development of a methodology for the topology optimization of monolithic vehicle components. It also highlights the challenges and opportunities, placing emphasis on the vehicle aftermarket industry components.