Topology Optimization- Problem Formulation and Pragmatic Outcomes by integration of TOSCA and CAE tools

Structural optimization tools have grasped enormous applications in engineering design and development activities because of increasing demands of lightweight and rigid products. In this milieu, researchers have exploited the potentials of nonparametric structural optimization tools like topology optimization by coupling and integrating with other compatible softwares. The first part of this paper deals with the mathematical physical fundamentals of the problem formulation of topology optimization. In the second part application of topology optimization is described by adopting an integrated design approach. The objective is to find the optimal design proposal of a thing walled aerospace component, for which a predecessor design subsists. ANSYS is used to develop the FE model of initial design space of component. TOSCA is used for topology optimization, data reduction and smoothing of optimization results for CAD compatible output. The optimized model is then imported in CATIA to incorporate necessary refinements for manufacturing, machining and geometric restrictions. To validate this new design proposal, optimized model is then imported in ANSYS and analyzed again under the stipulated loads and boundary conditions. At the end, a comparison is made between the predecessor design and the new optimized design proposal. Comparison validates the new design proposal assisted by optimization and simulations is more reliable and reduced weight with enhanced structural performance.