Available at: https://digitalcommons.calpoly.edu/theses/2712
Date of Award
6-2023
Degree Name
MS in Mechanical Engineering
Department/Program
Mechanical Engineering
College
College of Engineering
Advisor
Peter Schuster
Advisor Department
Mechanical Engineering
Advisor College
College of Engineering
Abstract
Topology Optimization is a lightweighting method based on finite element analysis that produces a part with optimum material distribution in the design space. Results from topology optimization often have organic shapes and curves that are difficult if not impossible to machine with traditional subtractive manufacturing methods. This paper analyzes the implementation of the Solidworks® Topology Optimization add-in into the mechanical design process and discusses required postprocessing to ensure manufacturability of the optimized part though a case study on two example parts. Results of traditional optimization, topology optimization and “selective” optimization (optimization using the results from topology optimization to selectively remove material to ensure manufacturability) were compared in terms of weight reduction and time required for optimization. In addition, simplified lightweighted parts were experimentally tested to validate the results of Solidworks® FEA and Topology Optimization to ensure physical part performance and increase confidence in future model results. Overall, it was determined that due to the large amount of time to setup and run, topology optimization may not be the most effective lightweighting method if time is a significant design constraint. However, for some specific applications where part weight is of major importance or where additive manufacturing may be a possible manufacturing process, the benefits of topology optimization’s material removal capability outweigh the required solution time.