Applying topology optimization to 3D machine parts under static and fatigue loading

Topology optimization of 3D parts under the effect of static and fatigue loading is studied in this thesis. Element removal method (ERM) is used to apply topology optimization (TO). Basic idea of ERM is removal of less effective elements from the design domain. The idea is applied for static and fatigue design of 2D and 3D parts to create algorithm of ERM. TO is a powerful method to obtain initial design geometry especially for aerospace and automotive industries where tradeoff between weight and strength of the parts are critical. Main drawbacks of the method such as longer process times and requirement of complicated software are eliminated with the present study. The use of ERM yielded minimized optimization times. A graphical user interface is developed for the algorithm considering ease of use of third parties. Different cases are selected to validate the algorithm which includes optimization of 3D parts subjected to static loading and optimization of 2D and 3D parts subjected to fatigue loading. In static cases, solution times, stress and deformation results of ERM and ANSYS are compared. In the fatigue cases, safety factor results of some optimized models are determined by using ERM and ANSYS then the results are compared. Some parts, which are already used in industrial applications, are optimized and their results are compared with original models. In experimental studies, fatigue tests are performed. A test stand is designed and constructed for the tests. Satisfactory agreements are observed for these verifications.