Exploring better product design with Topology Optimization and Manufacturing Simulations

In the design synthesis process, it has become a prime focus of all modern enterprises to optimal design an initial layout of the component that fulfill aesthetics, quality, and manufacturing constraints. Topology optimization is used to design an optimal initial layout of the component and computer simulations in CAE environment have also become vital tools to shorter product development time by reducing experimentation with prototypes. In this research, an integrated approach is implemented to design a multi pocket beam type component in CAE environment using topology optimization. CATIA is used for part modeling, machining constraints and to check machineability via virtual machining module. ANSYS is used to simulate the post machining distortions by using element deactivation technique firstly by developing an initial residual stress field through Sequential Coupled Field analysis. Material removal simulations are done by different sequences to determine the optimal machining process route. Comparison of simulated results with actual experimentation validates that optimization enabled design with computer simulations are very convenient for better product designs.

1 INTRODUCTION

To remain competitive, manufacturing enterprises have been compelled to reduce product development timewhile keeping aesthetics, quality, and intended product functionality to the desired level. These reservations put great pressure to the designer for optimaldesign of products within shortest possible time. Besides this, manufacturing and machining constraints are also incorporated early in the product development cycle to avoid and reduce unnecessary experimentations, computational and analysis efforts. Presently, initial layout design for optimummaterial distribution of a component is one of the most important concerns, because repeated changes in the initial layout design repeats the ongoing development efforts which result in extra time and cost. In present design practice, designer recommends the initial layout of the components based on his background experience and already some established designs.