The benefits of topology optimisation

saecon topology cadfem medical

Topology optimisation is a process of optimising the material mass of a component, reducing its weight (and thus its cost) while maintaining the same stiffness.

Rising energy and raw material costs have a major economic impact on the production of mechanical components. In order to keep costs down, manufacturers in recent times have increasingly focused on the production of optimised components, thus avoiding costly over-dimensioning.

This translates not only into savings for the customer, but also into an advantage in terms of sustainability. In fact, taking an industrial pick and place machine as an example, through optimisations such as mass reduction it is possible to decrease the energy consumption required for handling, resulting in environmental benefits.

Through the FEA method, and in particular the Topology Optimisation procedure, we are able to realise components for a specific use, with an attractive design, but at the same time optimised and durable, without wasting material.

What is topology optimisation and what is it used for?

Analysing the meaning of the term, topology optimisation is a procedure in which, starting from a known volume of material, it allows excess material to be removed and optimised structures to be created according to a predefined objective.

Starting from a given 3D volume, the algorithm is able to generate different scenarios through an iterative process, removing unnecessary material.

Saecon topology optimization

Optimised component (source ANSYS)

The aim of this procedure is not only to reduce the mass of the components, but also to meet certain objectives in terms of:

  • Stiffness
  • Eigenfrequencies
  • Thermal dispersion
  • Moments of inertia
  • Fatigue strength

Depending on requirements, further customised targets can also be defined by means of ad-hoc mathematical functions. Following the mathematical calculation, the optimised design is extracted, which will be used as a guideline for the construction of a traditional 3D model.

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Example of mass reduction of a component (source ANSYS)

Topology optimisation not only for additive manufacturing (AM)

3D printing might appear to be the best solution to build a topology optimised component. However, through appropriate measures, the potential of the method can also be exploited for components manufactured with traditional technologies, such as:

– CNC

– EDM

– Laser

– Mould

– Plastic injection

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Optimised profile manufactured by extrusion process (source ANSYS)

How topology optimisation is implemented: the workflow in SAECON

To apply the methodology of topology optimisation, we can start either from an existing component or from a concept drawing provided by the customer. Using the most advanced optimisation tools, we can provide design support or perform a redesign at any stage of manufacturing.

THE STEPS FOLLOWED AT SAECON:

  1. Customer objective and needs

In this preliminary phase, SAECON investigates with the customer what his needs are and what component is being studied. Based on this information, the applicability of the method is assessed, and the next steps are planned.

  1. Defining the scope of application

In order to make the correct assessments, it is necessary to define the loads and constraints to which the component will be subjected, and finally the desired manufacturing process.

  1. Evaluation of the scope for improvement

Exploiting fast topology optimisation tools, the approximate improvement margin is assessed on the basis of the above information, and a qualitative estimation is then provided.

  1. Topology optimisation work

The actual topology optimisation work takes place in this phase. By taking into account the load combinations to which a component will be subjected, defining its material, manufacturing method and required objectives, the iterative engineer-software process is initiated in order to extrapolate the final model.

  1. Design validation

Once the optimised design is obtained, further dedicated simulations are carried out in order to validate the optimisation. For example, static, transient, modal analyses or more specific evaluations such as component lifetime analyses can be carried out.

  1. Delivery of the optimised 3D model

In the final meeting with the customer, the results obtained are presented and the manufacturing methods are discussed.

saecon stairs topology optimization

Optimisation of a staircase (source: ANSYS)

What are the benefits of topology optimisation?

By carrying out a topology optimisation process on existing components, some customers have reduced masses by more than 50% on series production components of 20’000 parts. This resulted in significant savings in terms of raw materials, transport and energy.

The advantages of this topology optimisation methodology have positive feedback in the 3 phases of a product’s life cycle:

Design

The design phase is much faster, resulting in components that are optimised for the field of application while still maintaining the safety factors required by standards. The support of software also allows to perform an objective optimisation. As a result of that, optimised designs are not influenced by a specific designer, but only by the applied loads. The component is already optimised with the aim of being produced according to certain manufacturing methods.

Production

Reduced material requirements result in considerable savings, especially for large series production, in terms of manufacturing costs, raw materials, energy and transport.

Use

Due to its reduced mass, the optimised component will achieve higher performance, as well as having lower energy requirements.

Example of a suspension developed with the aid of topology optimisation tools. Note the shapes that can be produced using traditional technologies (source ANSYS)

Why is topology optimisation useful?

To summarise, when might topology optimisation be useful?

  • To reduce the production cost of a machine while maintaining the safety constraints imposed by regulations.
  • To improve the design of a component: for example, designs obtained with topology optimisation can be bio-inspired, i.e. very similar to natural forms such as shells, trees, etc. They are therefore not only extremely functional, but also aesthetically impactful and sophisticated.
  • When redesigning a machine or element.
  • To achieve a lower environmental impact in terms of raw material and energy consumption.
  • To improve the performance of a component or assembly of components.

 

To which sectors can it be applied?

We can state that there are no limits of application. Topology optimisation can be very useful in all sectors: automotive, industrial, robotics, aerospace and medical.

Author: Josef Bellea

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