Fakultät für Maschinenbau und Sicherheitstechnik

Topology optimization method for the adaptation of mechanical structures

Adaptation of structures is done when an object is used commonly in a product family with variants having different requirement levels. An example of this process is when a series vehicle is the basis for the design of a motorsport vehicle where stiffness and rigidity behavior have to be adapted to a new specific use. To do so, reinforcements are added using specific struts and framework structures.

To find the topology of these reinforcing structures, the known topology optimization methods do not deliver satisfying results because the added material is spread on the surface of the basis structure, which makes their manufacturing difficult and costly.

In this thesis, an analysis of the adaptation task from the structural point of view is made and compared to the classical structural design and optimization task from scratch. All adaptation cases are classified depending on the type of basis structure and the investigated load case. Furthermore, some benchmark problem statements to assess the performance of adaptation methods are proposed.

A new method is presented that allows to generate reinforcing structures that are producible, without significant loss in performance compared to the results obtained with the so far available methods. In order to give the user more control over the optimization outcome, several features are implemented as input parameter such as the distance between basis and added structures or the properties of the connections between them.

To validate the method, an extensive parameter study applied on several adaptation cases and on 2D and 3D models is conducted. Finally some further adaptation cases are investigated, such as when members of the basis structure are removed and sequential steps adaptations.

Shaker Verlag, ISBN:   978-3-8440-8306-4

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