Lighter And Less Expensive Designs Thanks To Topology Optimization

2023 Author : Hannah Pearcy | [email protected] . Last modified: 2023-05-24 11:12

The conflict of objectives is old: the engineer develops reliable mechanical constructions and has to use more or high-performance material in order to achieve the strength, stability and rigidity goals. The businessman, on the other hand, looks at a construction through cost glasses and pursues opposite goals. In order to survive the tough cost competition, the construction has to be lighter and cheaper. Above all, the material costs have to be minimized, since these z. B. in automobile and mechanical engineering amount to about 70% of the manufacturing costs and are the greatest lever for cost reduction.

The technical-economic conflict can be resolved with topology optimization. The optimization method is based on a simple idea: In the area of tension between the load introduction (= Actio) and the load suspension (= Reactio) there is "hard-working" and "rotten" material. To meet the technical requirements, more of the "hard-working" material has to be used, since this highly stressed material makes an enormous contribution to load transmission. In order to achieve the economic goals, one has to eliminate the “rotten” material, since this less stressed material does (almost) nothing for the load transmission and has to be paid dearly. In this way, waxing (more material) and shrinking (less material) creates a design that is in line with the force, and the technical-economic optimum is approached.

In the book "80/20 Topology Optimization" Alexander Brunner describes numerous approaches, methods, exercises, examples and over 80 practical tips for making mechanically based constructive decisions. The advantage: According to the 80/20 principle, the construction is freed of material ballast and material costs in the 3 to 7-digit euro range are saved. The book can be purchased at ISBN: 978-3-9818764-4-4 from specialist retailers.

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Link: Topology optimization can also be deepened in Alexander Brunner's seminar.