New applications of topology optimisation in automotive industry

Abstract

Topology optimisation is used for obtaining the best layout of vehicle structural components to achieve predetermined performance goals. In this research, the structural topology optimisation based on density formulation is employed. The topology design problem is formulated as a general optimisation problem and is solved by mathematical programming methods so that the objective and the constraint functions can be any structural performance measure. Design variables for this formulation parameterise the material of each element. NASTRAN-based finite element codes are employed for the response analyses. Traditionally, the topology optimisation is used in body and chassis structures for determining optimal structural layouts. In this research, new applications including weight reduction, manufacturing process selection, weld and bead pattern designs for three-dimensional automotive examples are presented and discussed.