On configuration-based optimal design of load-carrying lightweight parts

Abstract

This paper discusses some aspects of FEA-based design procedures driven by topology optimization methods. Within this scope the problem of ensuring the robustness and reliability of optimized load-carrying lightweight parts is addressed. To achieve this goal the engagement of the so called design configuration with subsequent topology optimization is proposed. Adequate configuration tools can be used to define a shell/lattice structure and subsequent topology optimization makes sure to remove the stress concentrations and lower the stress levels to a minimum. The numerical and experimental results of the presented example illustrate the importance of proper cell type and orientation selection, as well the importance of optimization, especially, if the underlying part is planned to be produced by 3D printing.