{"id":8302,"date":"2020-11-03T17:08:06","date_gmt":"2020-11-03T15:08:06","guid":{"rendered":"https:\/\/fractory.com\/?p=8302"},"modified":"2024-01-26T15:21:19","modified_gmt":"2024-01-26T13:21:19","slug":"topology-optimisation","status":"publish","type":"post","link":"https:\/\/fractory.com\/topology-optimisation\/","title":{"rendered":"Topology Optimisation"},"content":{"rendered":"

In recent years, many computer-aided methods have been developed to find the most optimum design for a problem. These intelligent techniques have allowed engineers to create designs that were beyond what we could come up with manually<\/a>. One of these methods is topology optimisation.<\/p>\n

Topology optimisation (TO) is a computer-based design method used for creating efficient designs today. Fields such as aerospace, civil engineering, bio-chemical and mechanical engineering use this method proactively to create innovative design solutions that will outperform manual designs.<\/p>\n

What Is Topology Optimisation?<\/h2>\n
\"Metal
The starting point<\/figcaption><\/figure>\n

Topology optimisation is a mathematical method used at the concept level of design development. The aim of this method is to spread the amount of material present more effectively over the model. It takes into account the boundaries set by the designer, applied load, and space limitations to create a design.<\/p>\n

In simple terms, topology optimisation takes a 3D model and creates a design space. It then removes or displaces material within it to make the design more efficient. While carrying out the material distribution, the objective function does not take aesthetics or the ease of manufacturing into account.\u00a0<\/p>\n

\"Topology
Part after topology optimisation – the placement of holes was determined along with a load<\/figcaption><\/figure>\n

At the very least, the method needs us to provide the magnitude of loading and the constraints within which it should operate. Using this information, the optimisation algorithm creates a possible load path using the minimum amount of material.\u00a0<\/p>\n

Once a design is finalised, we use additive (and sometimes subtractive) manufacturing methods to produce the part. As the name suggests, in additive manufacturing (here on out referred to as AM), the material is added (e.g. 3D printing) bit by bit until the final model is complete.\u00a0<\/p>\n

AM is capable of creating complex shapes and structures that may be extremely difficult to create using other methods. This is why we prefer it for creating complex products that emerge after optimisation.<\/p>\n

\"Optimised
Part after final touches for manufacturing<\/figcaption><\/figure>\n

Sometimes, however, the design suggested by topology optimisation is too complex even for AM. In such situations, we make small changes to the design to improve its manufacturability.<\/p>\n

How Does It Work<\/strong>?<\/h2>\n

Topology optimisation is carried out on an already existing model. We can choose to optimise an entire component or elements of it. This area of focus is known as the design space.\u00a0<\/p>\n

Topology optimisation uses finite element analysis (FEA) to create a simple mesh of the design space. The mesh is analysed for stress distribution and strain energy. This informs the system about the amount of loading the different sections are handling.<\/p>\n

While some sections will have optimal material distribution, there will be some that could use trimming. Sections with low strain energy and stress level are marked using the finite element method. Once all the inefficient sections within the design space are identified, the objective function gradually removes the material.<\/p>\n

During this trimming process, the system will also check how much the overall structure is affected by the removal process. If the removal process compromises its integrity, the process stops and the material in that region is retained.<\/p>\n

Before running the TO algorithm, we set the amount of material we intend to remove as a percentage of the total material. For example, we may set the target material reduction percentage at 50%.<\/p>\n

The system removes the excess material in stages. At every stage, it checks the structure for stress levels by reiterating the element distribution until it reaches the target percentage.<\/p>\n

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