Magna Steyr uses topology and shape optimization to improve fatigue life of components.
It seems that they are using their own software FEMFAT in conjunction with other commercial software to reach the desired results. FEMFAT is a software specialized in fatigue analyses.
A FreeFem++ toolbox is developed by G. Allaire, B. Boutin, C. Dousset and O. Pantz of Ecole Polytechnique in France. FreeFem++ is itself a free software for solving partial differential equations by the finite element method. With the toolbox 2D topology optimization and shape optimization can be conducted, a 3D version is being developed.
A screenshot from a intermediate step of Shape optimization.
The toolbox seems like a script written for FreeFem++, and does not have a graphical interface to set up the design space etc. It is thus not quite user-friendly. You have to alter the script which requires quite an effort. However one should remember that the toolbox is also free. Once the optimization is started, it works smoothly and gives decent results. If developed properly the toolbox can be a very useful software for many.
Airbus researches use of topology optimization on aircraft wing ribs (link). It is stated that usage of topology optimization results in around 1000 kg of weight savings per aircraft. (link for photo)
J.S. Rao et al. (link) from India studied topology optimization for commercial aircraft wing and obtained some interesting results.
The resulting structure has a strong dendritic form, or as the authors suggest a feather like structure, a very interesting point where bio-mimicry is suggested by an optimization process. This particular topology was obtained without any manufacturing constraints and manufacturing such a structure would itself be a very interesting feat of engineering.
Brembo GP 4RX Brake Caliper
Brembo, the worldwide brake technology giant uses topology optimization for GP4 RR and GP4 RX calipers. The calipers are intended for Moto2 racing and are machined from billet. It is stated that thanks to topology optimization these calipers are much lighter than comparable components now on the market, and feature a mass/stiffness ratio second to none in its class.
MCE-5 VCRi deploys topology optimization for its extraordinary piston rack. MCE‑5 VCRi is aadvanced internal combution engine, with variable displacement, advertised to produce very imprssive 420 Nm and 160 kW (220 hp) from a 1.5 L 2-stage turbo engine. The piston racks have the characteristic unusual shape of all topology optimized structures.
Piston racks were stated to be lightened from 1400 to 900 grams
The manufacturing processes used to produce the racks are also impressive, Near-Netshape forging and electrochemical machining are used to produce parts at ± 2 microns accuracy in close to 1 minute.
BLOODHOUND, the successor of Thrust SSC which was the first supersonic car in the world, uses topology optimization to design its structure. In their website, it is stated that stiffness is the main design criteria for the body so it seems they naturally chose topology optimization to find the optimum structure. The design space was denoted by a shell structure and two load cases were used (bending and torsion)
[youtube=http://www.youtube.com/watch?v=pvsA0JU33cg&feature=player_embedded]
TopOpt is developed by Technical University of Denmark. The 2D version was online by 1999 and since then the online tool has been used for more than 180.000 times. Its 3D version was online by 2004 and is used for more than 7000 times by now (2011). The applets are free to use and their purpose is to promote Topology Optimization to masses. And we also for the first time had the opportunity to use a topology optimization software with their applets! As you can guess the applets have rather limited capabilities as they are not designed as commercial tools. The number of elements that can be used is limited and geometry has to be defined by very basic box tools. The 3D applet uses voxels so meshing is not necessary.
2D optimization result
3D result from TopOpt
Top opt is ideal for introduction to Topology Optimization, it has tools like defining voids, filled regions, three loadcases and it is quite accurate too. So if you are new to Topology Optimization, go on and check their web site. All you have to do is place some forces and supports, and watch the structure take shape.
Trinitas is developed by Linköping University for mainly research. It provides many forms of Finite Element Analysis and is quite useful. As far as we are aware its commercial usage price is very low. We tried the 30 day limited version and our impression is as follows.
It has an integrated CAD suite, despite rather primitive, sufficient for many topology optimization needs. It has a pre-processing section which again is primitive however sufficient. Its meshing capabilities are sufficient with respect to its price. It has 2D structured and un-structured meshing capabilities and 3D structured meshing capabilities. Defining loads, contact conditions and other boundary conditions is easy. However the software crashes when, for instance prescribed displacements are used in topology optimization. It is possible to exclude volumes, however this seems to slow down the optimization process significantly. We used various models to test the topology optimization process and it is satisfactory.
The result of a 2D optimization at rather low resolution gave a very neat result
One drawback is that the software cannot use more than one core of CPU, this slows down the process tremendously. Also when using too many elements Trinitas crashes. It also cannot import models from common formats, so we have to rely on its own capabilities. It does not have advanced features like die draw direction to account for manufacturing methods to be used.
A 3D application
Despite many drawbacks Trinitas does not have any rivals at its price point. If you cannot afford high-end software, Trinitas is the way to go. At their homepage you can see it has many useful features, including Shape optimization, that is used very closely with topology optimization or Transient Heat Transfer analysis.
