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Mayer, Johannes; Denk, Martin; Wartzack, Sandro

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Abstract:

Topology Optimization (TO) is an established method for the development of high strength and lightweight structural components. However, its results have to be geometrically revised to obtain a computational model that meets product development requirements. Design has to be in accordance with manufacturing constraints. Geometry reconstruction therefore still is a typically manual and tedious task, but increasingly supported by computational and automated approaches. In this paper, the inclusion of a casting constraint in an automated Medial Axis based reconstruction method is presented. Since the Medial Axis provides cross-section values by the computation of maximally inscribed spheres, this information is used for geometry reconstruction and even further for the purposeful adaption of the cross-section to match Heuver's circle method. Thereby, the directed solidification of molten material is considered. With a predefined feeder position, the demonstrator of a suspension control arm is used to show the application of the method. Resulting CAD-models are also structurally evaluated for their stiffness characteristics.

Keywords:

Topology Optimization, Medial Axis Transform, Computational design methods, Computer Aided Design (CAD), Lightweight design