Methodological Recommendations on Topological Optimization of Power Structures Using Numerical Modeling Tools

Abstract

Methodological recommendations are proposed for the development of the process of topological optimization of load carrying structures adapted for the use of additive technologies. The stage of postprocessing of the polygonal geometry of the part generated as a result of optimization is considered in detail. The validation stage is included in the process of topological optimization by comparing the calculated and experimental data to assess the operability (strength) of the optimized structure. For the option of manufacturing load carrying structures by 3D printing, it is planned to conduct studies of the mechanical properties of the material obtained on a 3D printer, taking into account the printing settings and the orientation of the material layers relative to the applied load during testing. An example of approbation of the proposed methodological recommendations is given on the example of a load carrying hook included in the design of a wheeled transport anti-ram device. The optimization was performed in the SolidThinking Inspire software environment (Altair Engineering, USA). The results of the calculated and experimental determination of the destructive load are presented for the initial and optimized hook design. For the experiment, the hooks were made of ABS plastic using FDM technology. Finite element models of hooks were developed in the ANSYS Workbench software package (ANSYS, USA). Assignment of material properties, boundary conditions and applied load is performed in the LS-PrePost application, calculation in the LS-DYNA solver (ANSYS, USA). The calculated and experimental efficiency estimates were 44.4 and 57.8 %, i.e. their difference is within 13.4 %. The zones and the nature of the destruction identified by calculation and experimentally completely coincide. The results obtained confirm the correctness of the proposed methodological recommendations, the selected modeling approaches and the determination of the properties of the material of the structure manufactured by 3D printing.

Keywords

• computer-aided design
• modeling
• topological optimization
• methodology
• power structure
• weight reduction
• stiffness increase
• strength
• abs plastic
• 3d printing
• fdm technology