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Automated Derivation of CAD Designs from Topology Optimization Results

Gomes Alves, Christian and Barthel, Yannick and Halsner, Matthias (2022) Automated Derivation of CAD Designs from Topology Optimization Results. In: World Congress on Railway Research (WCRR) 2022. World Congress on Railway Research 2022, 2022-06-06 - 2022-06-10, Birmingham, UK.

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Abstract

Topology optimizations are gaining track in many development processes, especially in designing large structural components such as railway car bodies. This paper proposes an automatic process to derive design proposals from SIMP topology optimization results in early product development stages. The topologies are interpreted as truss-like structures in order to be modelled using beam elements in FE or CAD applications. In a first step, a wireframe is extracted by using a voxelization approach with subsequent skeletonization and junction identification using flood-fill algorithms. The wireframe can already be used as a basis for a parametric CAD design since it follows the topology optimization result closely. In order to extrude beam sections along the wireframe axes, cross sections are extracted from the topology optimization result. This is done by first matching the geometric outline of a topology branch to basic shapes such as rectangles. These shapes are refined by identifying the load case of each branch which is achieved by evaluating the stress distributions in a branch of the topology optimization. The consolidated result is a model consisting of beam elements which can further be processed in an FE or CAD application. The process enables a faster design exploration in the early product development process with the goal of achieving lightweight designs.

Item URL in elib:https://elib.dlr.de/148477/
Document Type:Conference or Workshop Item (Speech)
Title:Automated Derivation of CAD Designs from Topology Optimization Results
Authors:
AuthorsInstitution or Email of AuthorsAuthor's ORCID iDORCID Put Code
Gomes Alves, ChristianUNSPECIFIEDhttps://orcid.org/0000-0002-0897-6951138359022
Barthel, YannickDLR e.V.UNSPECIFIEDUNSPECIFIED
Halsner, MatthiasDLR e.V.UNSPECIFIEDUNSPECIFIED
Date:June 2022
Journal or Publication Title:World Congress on Railway Research (WCRR) 2022
Refereed publication:Yes
Open Access:Yes
Gold Open Access:No
In SCOPUS:No
In ISI Web of Science:No
Status:Published
Keywords:Topologieoptimierung, Automatisierung, Wagenkasten automation; topology optimization; virtual product development process
Event Title:World Congress on Railway Research 2022
Event Location:Birmingham, UK
Event Type:international Conference
Event Start Date:6 June 2022
Event End Date:10 June 2022
HGF - Research field:Aeronautics, Space and Transport
HGF - Program:Transport
HGF - Program Themes:Rail Transport
DLR - Research area:Transport
DLR - Program:V SC Schienenverkehr
DLR - Research theme (Project):V - NGT BIT (old)
Location: Stuttgart
Institutes and Institutions:Institute of Vehicle Concepts > Vehicle Architectures and Lightweight Design Concepts
Deposited By: Gomes Alves, Christian
Deposited On:04 Aug 2022 13:19
Last Modified:24 Apr 2024 20:46

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