Abstract
A light-weight design method of integrated structural topology and size co-optimization for the force-performance-structure of complex structural parts is presented in this paper. Firstly, the supporting function of a complex structural part is built to map the force transmission, where the force exerted areas and constraints are considered as connecting structure and the structural configuration, to determine the part performance as well as the force routines. Then the connecting structure design model, aiming to optimize the static and dynamic performances on connection configuration, is developed, and the optimum design of the characteristic parameters is carried out by means of the collaborative optimization method, namely, the integrated structural topology optimization and size optimization. In this design model, the objective is to maximize the connecting stiffness. Based on the relationship between the force and the structural configuration of a part, the optimal force transmission routine that can meet the performance requirements is obtained using the structural topology optimization technology. Accordingly, the light-weight design of conceptual configuration for complex parts under multi-objective and multi-condition can be realized. Finally, based on the proposed collaborative optimization design method, the optimal performance and optimal structure of the complex parts with light weight are realized, and the reasonable structural unit configuration and size characteristic parameters are obtained. A bed structure of gantry-type machining center is designed by using the proposed light-weight structure design method in this paper, as an illustrative example. The bed after the design optimization is lighter 8% than original one, and the rail deformation is reduced by 5%. Moreover, the lightweight design of the bed is achieved with enhanced performance to show the effectiveness of the proposed method.
Highlights
Parts as supporting structure with heavy and complex structure in machine, are known as rack parts or complex parts, such as base, box [1]
Many scholars have applied the finite element analysis method and structural topology optimization technology to design the structures of mechanical products such as machine tools, automobiles and airplanes for reducing the weight and improving the performance of products [10]
The structural light-weight design optimization of static and dynamic performance of the part is realized through the co-operative optimization by integrating structural topology optimization and size optimization
Summary
Parts as supporting structure with heavy and complex structure in machine, are known as rack parts or complex parts, such as base, box [1]. The shape and size of the parts structure directly affects the static and dynamic performance of the machine [2]. Many scholars have applied the finite element analysis method and structural topology optimization technology to design the structures of mechanical products such as machine tools, automobiles and airplanes for reducing the weight and improving the performance of products [10]. The structural light-weight design optimization of static and dynamic performance of the part is realized through the co-operative optimization by integrating structural topology optimization and size optimization. For a complex part design, the goal of the structure optimization design is to achieve a light weight structure configuration with optimal static and dynamic performance [21]. K is the system stiffness matrix, λj(x) is the jth order eigenvalue, NOMR is the correction coefficient to correct the strain energy and eigenvalue contribution degree, Vi(x) is the total volume after optimization, V0 is the initial volume, Δ is the optimization volume ratio constraint, generally taken 0 − 1, xk is the design variable of material density, varying between 0 and 1
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