Abstract
Topology optimisation is a process that is becoming increasingly reliable and necessary in the pursuit of highly efficient components comprising of low mass with a high structural performance. These components are typically mass-produced on a large-scale in automotive sectors for instance, where components are usually metallic and pressed. The ability to maximise a component’s structural characteristics has yielded many variations of computational topological solvers over the years. Over time many different methodologies have been used to generate suitable manufacturable solutions. Despite this, a gap between the generation of topology optimisation solutions and the creation of ready-to-manufacture solutions still exists today. This review paper outlines existing methods for computational topology optimisation and addresses any refinement methods used to generate a manufacturable solution, particularly focussing on methodologies used in automotive sheet metal forming. These methods are scrutinised in regards to the level of manual user input needed to create a Computer Aided Design (CAD) model representation of the manufacturable solution. Suggestions are also made to highlight further work to improve these techniques for large-scale industry-standard product development.
Similar content being viewed by others
References
Altair University (ed) (2015) Practical aspects of structural optimisation: a 1753 study guide, 2nd edn. Altair University
European-aluminium.eu (2017) Aluminium Automotive Manual. [online] Available at: https://www.european-aluminium.eu/resource-hub/aluminiumautomotive-manual/
Auricchio F et al (2010) Isogeometric collocation methods. Math Models Methods Appl Sci 20(11):2075–2107
Auricchio F et al (2012) Isogeometric collocation for elastostatics and explicit dynamics. Comput Methods Appl Mech Eng 249(252):2–14
Callister WD Jr (2005) Fundamentals of materials science and engineer-1761ing, 2nd edn. Wiley, Hoboken, p 199 ISBN 978-0-471-47014-4
Cam Machine (2017) Automotive CNC Machines for the Automobile Industry. [online] Available at: http://www.cam-machine.com/automotive-cnc-machinesfor-the-automobile-industry/
Chacón JM, Bellido JC, Donoso A (2014) Integration of topology optimized designs into CAD/CAM via an IGES translator. Struct Multidiscip Optim 50(6):1115–1125
Challis VJ (2009) A discrete level-set topology optimization code written in matlab. Struct Multidiscip Optim 41(3):453–464
Chen X (2012) Solving topology optimization problems based on RAMP method combined with guide-weight method. Journal of Mechanical Engineering 48(01):135
Christensen J (2015) Topology optimisation of structures exposed to large (non-linear) deformations. PhD. Coventry University, Coventry
Christensen J, Bastien C (2015) Nonlinear optimization of vehicle safety structures, 1st edn. Elsevier, London
Deadcoderscoiety.org (2017) Bezier Curves, B-Splines, NURBS. Presentation
Deloitte University Press (2017) 3D opportunity in the automotive industry. [online] Available at: https://www.dupress.deloitte.com/content/dam/dup-us-en/articles/additivemanufacturing-3d-opportunity-in-automotive/DUP_707-3D-Opportunity-Auto-Industry_MASTER.pdf
Designer.mech.yzu.edu.tw (2017) A Review and generalization of 2-D structural topology optimization using material D - optimal design lab, YZU. https://www.Designer.mech.yzu.edu.tw . N.p. Web
Devarasiddappa D (2017) Automotive applications of welding technology – a study. IJMER Available at: http://www.ijmer.com/papers/Vol4_Issue9/Version-4/C0409_04-1319.pdf
En.wikipedia.org (2017) Non-uniform rational B-spline. [online] Available at: https://www.en.wikipedia.org/wiki/Nonuniform_rational_B-spline
GKN (2017) Process - GKN sinter metals. https://www.Gkngroup.com. N.p. Web. 17 Aug. 2017
Groover MP (2011) Principles of modern manufacturing, 1st edn. J. Wiley & Sons, Hoboken
Huang X, Xie YM (2008) Topology optimization of nonlinear structures under displacement loading. Eng Struct 30(7):2057–2068
Hughes TJR, Cottrell JA, Bazilevs Y (2005) Isogeometric analysis: CAD, finite elements, NURBS, exact geometry and mesh refinement. Comput Methods Appl Mech Eng 194(39–41):4135–4195
Hvejsel CF, Lund E (2011) Material interpolation schemes for unified topology and multi-material optimization. Struct Multidiscip Optim 43(6):811–825
Kalpakjian S, Schmid SR (2008) Sheet-metal forming processes, 1st edn. Pearson Education, London
Kanarachos S, Griffin J, Fitzpatrick ME (2017) Efficient truss optimization using the contrast-based fruit fly optimization algorithm. Comput Struct 182:137–148
Kang P, Youn S-K (2016) Isogeometric topology optimization of shell structures using trimmed NURBS surfaces. Finite Elem Anal Des 120:18–40
Koguchi A, Kikuchi N (2006) A surface reconstruction algorithm for topology optimization. Eng Comput 22(1):1–10
Kumaravel M et al (2012) Human face image segmentation using level set methodology. Int J Comput Appl 44(12):16–22
Lee S-K et al (2012) Die shape design of tube drawing process using FE analysis and optimization method. Int J Adv Manuf Technol 66(1–4):381–392
Lee S-W, Yoon M, Cho S (2017) Isogeometric topological shape optimization using dual evolution with boundary integral equation and level sets. Comput Aided Des 82:88–99
Lin C-Y, Chao L-S (2000) Automated image interpretation for integrated topology and shape optimization. Struct Multidiscip Optim 20(2):125–137
Liu J, Ma Y-S (2015) 3D level-set topology optimization: a machining feature-based approach. Struct Multidiscip Optim 52(3):563–582
Lovadina C, Reali A, Sangalli G (2017) What is isogeometric analysis?. [PowerPoint presentation] Available at: https://www.sintef.no/globalassets/upload/ikt/9011/geometri/terrific/wmf/part1/2-lovadina.pdf
Lund E (2009) Buckling topology optimization of laminated multi-material composite shell structures. Compos Struct 91(2):158–167
Mandhyan A, Srivastava G, Krishnamoorthi S (2016) A novel method for prediction of truss geometry from topology optimization. Eng Comput 33(1):95–106
math.stackexchange.com (2017) What is the general formula for NURBS curves?. [online] https://www.Math.stackexchange.com. Available at: https://www.math.stackexchange.com/questions/417030/what-is-the-general-formulafor-nurbs-curves
Metal-AM (2017) Metal additive manufacturing processes. Metal Additive Manufacturing Available at: http://wwwmetal-amcom/introduction-to-metaladditive-manufacturing-and-3d-printing/metal-additive-manufacturingprocesses/NpWeb 1 June 2017
Nana A, Cuillière J-C, Francois V (2016) Towards adaptive topology optimization. Adv Eng Softw 100:290–307
Nptel.ac.in (2017) Formability. [PowerPoint presentation] Available at: https://www.nptel.ac.in/courses/112106153/Module2010/Lecture203/Module_10_Lecture_3_Formability.pdf Web. 2017
Omar MA (2013) The automotive body manufacturing systems and processes, 1st edn. Wiley, Hoboken
Osher S, Fedkiw RP (2001) Level set methods: an overview and some recent results. J Comput Phys 169(2):463–502
Osher S, Sethian JA (1988) Fronts propagating with curvature-dependent speed: algorithms based on hamilton-jacobi formulations. J Comput Phys 79(1):12–49
Paul S K (2017) Forming Limit Diagram. Available at: https://www.researchgate.net/figure/236156408_fig1_Figure-1-A-schematic-plotof-forming-limit-diagram N.p. Web. 12 Apr 2017
Rhino3d.com (2017) Rhinoceros - NURBS. [online] Available at: https://www.rhino3d.com/nurbs
Rozvany G (2009) A critical review of established methods of structural topology optimization. Struct Multidiscip Optim 37(3):217–237
Sethian JA (1994) Level set techniques for tracking interfaces; fast algorithms, multiple regions, grid generation, and shape/character recognition. Available at: https://math.berkeley.edu/~sethian/2006/Papers/sethian.trento.1994.pdf 5–6. 12 Web. Apr. 2017
Sigmund O (2001) A 99 line topology optimization code written in matlab. Struct Multidiscip Optim 21(2):120–127
Sigmund O, Maute K (2013) Topology optimization approaches. Struct Multidiscip Optim 6(48):1031–1055
SSAB (2017) Automotive steels for safe and lightweight cars. Available at: https://www.ssab.com/products/industries/automotive N.p., Web Apr 2017
Stergiou S, Siganos D (1996) Neural networks. Doc.ic.ac.uk. Available at: https://www.doc.ic.ac.uk/~nd/surprise_96/journal/vol4/cs11/report.html N.p. Web Apr 2017
Tanskanen P (2002) The evolutionary structural optimization method: theoretical aspects. Comput Methods Appl Mech Eng 191(47–48):5485–5498
Thomasnet (2017) About CNC Machining. Available at: https://www.thomasnet.com/about/cnc-machining-45330503.html N.p.Web. 1 June 2017
USNCCM (2017) New trends in topology optimization. Available at: https://www.14.usnccm.org/MS605 N.p. Web. 1 June 2017
van Dijk NP et al (2013) Level-set methods for structural topology optimization: a review. Struct Multidiscip Optim 48(3):437–472
Wikiversity.org (2017) Introduction to elasticity/constitutive relations. Available at: https://en.wikiversity.org/wiki/Introduction_to_Elasticity/Constitutive_relations N.p. Web. 12 Apr 2017
Yi G, Kim N (2016) Identifying boundaries of topology optimization results using basic parametric features. Struct Multidiscip Optim 55(5):1641–1654
Zegard T, Paulino GH (2015) Bridging topology optimization and additive manufacturing. Struct Multidiscip Optim 53(1):175–192
Zeid I, Sivasubramanian R (2010) Cad/cam, 1st edn. Tata McGraw Hill Education Private Ltd., New Delhi
Zhang S et al (2016) A geometry projection method for the topology optimization of plate structures. Struct Multidiscip Optim 54(5):1173–1190
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Sehmi, M., Christensen, J., Bastien, C. et al. Review of topology optimisation refinement processes for sheet metal manufacturing in the automotive industry. Struct Multidisc Optim 58, 305–330 (2018). https://doi.org/10.1007/s00158-017-1876-0
Received:
Revised:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00158-017-1876-0