Topology Optimization of Multi-component Structures via Decomposition-based Assembly Synthesis

∗ corresponding author ABSTRACT A method is presented for synthesizing multi-component structural assemblies with maximum structural performance and manufacturability. The problem is posed as a relaxation of decomposition-based assembly synthesis [1,2,3], where both topology and decomposition of a structure are regarded as variables over a ground structure with non-overlapping beams. A multi-objective genetic algorithm [4,5] with graph-based crossover [6,7,8], coupled with FEM analyses, is used to obtain Pareto optimal solutions to this problem, exhibiting trade-offs among structural stiffness, total weight, component manufacturability (size and simplicity), and the number of joints. Case studies with a cantilever and a simplified automotive floor frame are presented, and representative designs in the Pareto front are examined for the trade-offs among the multiple criteria.