Advanced mesh based design optimization for early-stage virtual prototyping

A mesh modification approach based on the use of morphing technology has been developed which allows to address the challenge of fast re-analysis of modified structures without the need of changing the CAD model. Furthermore, the method offers interesting perspectives for early stage design optimization using existing FE models from predecessor designs as starting point to derive the meshes for various new concepts. A design space can then be evaluated in a reduced time before the basic design decisions have to be taken and the detailed CAD models developed. In particular, by parametrizing the mesh modifications, an automated design exploration can be performed for various attributes, ranging from durability, structural dynamics to acoustics and crash models. The paper discusses the basic methodology used and illustrates it with various examples from the aerospace and automotive design practice. The discussed research was conducted in the context of the Flemish Aeronautics research project "Mesh Morphing".