Audi

Posted on March 18, 2011 by io

A presentation by Audi (link) shows how extensively topology optimization is used by them, and shares some of the knowhow with us. It is a very useful resource.

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Mahindra Engine FEAD Brackets and Covers

Posted on March 18, 2011 by io

Components to be optimized

The components shown above were optimized (link) by Mahindra. Rather than weight gains or performance improvements, the decrease in design cycle is highlighted in the conclusions. 50% less time is required to design the components.

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Prosthetic Knee Joint

Posted on March 18, 2011 by io

An injection moldable prosthetic knee-joint (link) was topology optimized. The material to be used is Derlin. Three load cases were applied as ISO-10328 specifications require. The prosthesis is composed of three main parts. All of them were optimized, to get 15% weight loss with 70% decrease in compilance. Probably if the same compilance was sought, higher weight reduction could be obtained.

Three optimized parts

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MAN Diesel

Posted on March 17, 2011 by io

MAN Diesel (link) uses topology optimization for large diesel engines used for propulsion of ships and stationary power plants. In one example they optimize the Cylinder Frame which connects cylinder liner to engine frame. The engine itself is huge, the Cylinder Frame for one cylinder is alone 13.8 tonnes. The weight gain from the optimization was %15 which reduces production costs significantly.

 

Cylinder Frame before and after optimization

 

 

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BMW Mini

Posted on March 17, 2011 by io

BMW utilizes a topology optimized cross beam named R56 in the Mini (link). The structure was optimized and produced by Meridian Lightweight Technologies Inc.

While the weight savings are not reported, the final structure is said to be 4.49kg, which is rather light for such a big one, and keep in mind that it is magnesium. It is stated that previous structures used excessive ribbing to ensure stiffness, some of which were not needed. Using topology optimization ribs are placed wherever needed. Using advanced design technologies like topology optimization, saves time and money for the producer. The company is estimated to save £268,800 for a years worth design proposals, and thousands of qualified man-hours.

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Lotus-Usa

Posted on March 16, 2011 by io

Topology optimization for different materials

 

Lotus-Usa is reported to use topology optimization to develop a low weight body in white structure (link). To be honest we cannot see how the results are incorporated to the design, as the structure seems to lack any cross members.

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Rinspeed eXasis

Posted on March 15, 2011 by io

Rinspeed eXasis is a mostly transparent concept car developed to demonstrate advanced polymer technologies by Bayer MaterialScience AG. The car is reported to be drivable as it is. Topology Optimization was incorporated while designing the car, which is apparent from the visible structure of the car. The car weighs only 750 kg.

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Continental

Posted on March 15, 2011 by io

Continental,  hydraulic brake systems supplier, employed topology optimization to design 2FNR-Al aluminum brake caliper’s housing. The structure provides the same amount of stiffness, while losing 440 grams from its initial weight of 4,185 grams (%10). (link 1, link 2)World's 500 millionth floating caliper with special coating

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Introductory article

Posted on March 15, 2011 by io

A nice introduction to topology optimization for non-engineers by nDsgn. (link)

Modular usage of topology optimization to form a bike.

 

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Hegerguss

Posted on March 13, 2011 by io

Hegerguss, a foundry specialized in spheroidal graphite cast irons, uses topology optimization to design structures.

Das optimierte Modell, digitalModell der Vorstufe

The component shown above is reported to be %57 lighter than the conventional counterpart. The company also uses casting simulations to ensure the best performance from their castings, and save more time.

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