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Endress, Felix; Rieser, Jasper; Zimmermann, Markus

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Abstract:

Optimization-driven design offers advantages over traditional experience-based mechanical design. As an example, topology optimization can be a powerful tool to generate body shapes for Additive Manufacturing (AM). This is helpful, when (1) load paths are non-intuitive due to complex design domains or boundary conditions, or (2) the design process is to be automated to minimize effort associated with experience-based design. However, practically relevant boundary conditions are often difficult to put into a formal mathematical language to, for example, either feed it into a topology optimization algorithm, or provide precise quantitative criteria for CAE-supported manual design. This paper presents a survey of three industry use cases and identifies three types of requirements: the first can be directly cast into parts of an optimization problem statement (∼ 40%), the second is considered indirectly by adapting the optimization problem without explicit reference to the requirement (∼ 20%), and the third is only assessed after the design is finalized (∼ 40%). For categories 2 and 3 we propose directions of improvement to support formulating complex design tasks as unambiguous design problems.

Keywords:

Requirements, Optimisation, Design for Additive Manufacturing (DfAM), Product Development, Topology Optimisation