Topology Optimization Of Mechanical Structure And Its Application In Heavy Trucks Balance-axle Brackets To Improve Design

Structural topology optimization can be used to optimize the material arrangements in design domain to achieve a better performance. It is significant for product design especially in the concept design phase. Presently, topology optimization techniques for continuum structures are mainly concentrating on plane or simple three-dimensional structure. With simple initial structure, regular optimal design domain and single optimization constraint .Therefore, it is important to study on topology optimization and apply it in the design of 3D complex structureBased on knowing about structural topology optimization, learning HyperWorks software, the principle of variable density method was discussed in this paper.The balance-axle brackets are important loading components in the rear suspension system of heavy trucks, by the tracking of product quality some local cracks had been founded in balance-axle brackets of a certain type of truck, and the result of finite element analysis showed that, its stress in some local area was higher. Topology optimization was used for the improve design of balance-axle brackets structure in this paper, in order to obtain an optimum topological structure and shape with rational material distribution.Based on the platform of HyperWorks, finite element model was found in HyperMesh, an original design-domain, the objective function and constrains were defined in Optistruct, and obtained iterative solutions. By changing the initial design regional and constraints, the structure was optimized in three different conditions, the results of the optimization was compared to selects the best design plan. According to the cloud gained in topology optimization, a new 3D model of balance-axle brackets was set up and analyzed with FEM. The result of finite element analysis for the improved balance-axle brackets showed that, its maximum stress significantly reduced, the stress distribution was more uniform, but its weight reduced greatly. Such a successful application of topology optimization has proved that, topological optimization is an effective method in structure design, especially for the components with complicated shape and loading condition like in autos.