Topology optimization in industrial desing and an application

This study examines a lifting/handling apparatus commonly used in industrial settings. The model was first subjected to structural analysis, followed by topology optimization to reduce its mass. The aim of the study is to minimize material usage while maintaining structural strength and safety criteria. All parts of the apparatus whose dimensions were measured were solid modeled in SolidWorks 2025 software. The model was transferred to ANSYS Workbench 2021 R2 software for analysis. As a result of the specified boundary conditions and loads, the analysis results were calculated as maximum stress 118.59 MPa, total deformation 4.33 mm, and safety factor 2.99. After this stage, a target was set to reduce mass. Designs suggested by the software were examined in line with this target, and the appropriate design was selected. Missing or broken surfaces were corrected. Static analyses were reapplied to the new design to verify whether it met the working conditions. The analysis results after optimization showed a maximum stress of 116.81 MPa, total deformation of 4.52 mm, and a safety factor of 3.03. The analysis results of the model obtained from topology optimization were compared with those of the initial model. When the analysis results are examined, it is seen that although there is a limited increase in total deformation, there is also a limited decrease in the maximum stress value. Considering the safety factor in the analysis results, it is seen that the load-bearing capacity of the model is not negatively affected. When the analysis results of this study are compared with the results of similar optimization studies in the literature, it is seen that the model remains within structurally acceptable limits according to the safety factor. As a result, this study has achieved a new design that is lighter and maintains structural performance through topology optimization.