Simulation based topology optimization assessment with manufacturing constraints

In Automotive and Aerospace industries, Topology Optimization (TO) is being used for the last few decades to produce lightweight structures. On the other hand, TO produces very complex geometrical features (i.e. irregular shape and hidden cavities along the thickness) that is sometimes difficult to be manufactured even with Additive Manufacturing (AM) and Casting techniques. In this paper suitable design and manufacturing constraint (MC) are applied during TO process that act as an Optimization Tool (OT) and improves geometrical features of the mechanical structures for easy manufacturing. Three mechanical structures with different geometries and boundary conditions have been considered for analysis purpose. Topology Optimization based on linear static analysis has been performed using OptiStruct (HyperWorks) solver. Finally, results of analysis conclude that the proposed OT produces lightweight structures with very simple geometries that can easily be manufactured with the help of AM or Casting techniques.