New applications of topology optimization in automotive industry

Topology optimization is used for obtaining the best layout of vehicle structural components to achieve predetermined performance goals. In this research, the structural topology optimization based on density formulation is employed. The topology design problem is formulated as a general optimization problem and is solved by mathematical programming methods so that the objective and the constraint functions can be any structural performance measure. Design variables for this formulation parameterize the material of each element. NASTRAN-based finite element codes are employed for the response analyses. Traditionally, the topology optimization is used in body and chassis structures for determining optimal structural layouts. In this research, new applications including weight reduction, manufacturing process selection, weld and bead pattern designs for three-dimensional automotive examples are presented and discussed.