Topology optimisation in practice is the development and optimisation of a component based on a given installation space, taking into account a given load profile.
This development process is also called generative design. The example shown here of the topology optimisation of a swing arm used as a mounting for a device was created with the kind permission of the German Aerospace Center (DLR).
Customer requirements for the design of the swing arm
A rotating camera is to be attached to a swing arm to be developed on a solar-powered aircraft that will be in operation in the stratosphere for a long period of time. In addition to the mechanical requirements due to the rotation of the device, influencing factors such as the large temperature differences and UV radiation must also be taken into account for the design of the swing arm. Furthermore, a suitable material and a suitable manufacturing process must be selected for the production of the component.
Our customer's requirement is to minimise the weight of the bracket and maximise the rigidity. The shape should not change as much as possible despite rotation around two axes. The bracket (swing arm) on which the unit is mounted should only allow small movements. Despite the low weight, the stiffness of the component should be designed in such a way that handling and assembly are easy.
Results of the topology optimisation
After the topology optimisation carried out by us on the basis of several simulations, the weight of the swing arm can be reduced by 66% from the desired target weight without any disadvantages in practical handling due to an excessively filigree component structure. The stiffness can also be increased by a factor of 4.