The Pitfalls of Reverse Engineering Topology Optimised Load-Carrying Structural Parts into Parametric Models

Abstract

In this paper, we will show the topological optimization of a load-carrying structural parts and the errors that can occur when the topological solution in the form of a triangulated mesh of the surface of the optimized part is reconstructed into a parametric CAD form. Such a reconstruction always introduces geometric errors in the resulting optimal structure of the structural element. A numerical example will be used to show how quickly stress concentrations are reproduced on surfaces where they should not be. The numerical results are also supported by experiment. In the conclusion, it is suggested how, with a specific topological model, the obtained stress concentrations at the edges of the structure can be reduced.