Formulation and Execution of Structural Topology Optimization for Practical Design Solutions

Topology optimization has gained prime significance due to increasing demands of lightweight components. In this paper, a general mathematical formulation of topology optimization is presented with some imperative manufacturing constraints for maximizing the stiffness of a structure with mixed boundary conditions. A methodology is implemented to determine the optimal configuration of operative structural components by executing TOSCA in batch-process mode with ANSYS software. CAD viable design is attained by smoothing the topological optimized surfaces. The geometry at the maximum stressed areas is also optimized. Analysis of the customized reduced weight configuration reveals that it comprises the harmonized stress distribution and improved structural performance.