Topology optimization and finite element analysis of a conventionally manufactured mechanical part

In today's industry, the criteria of energy efficiency, manufacturing cost, precision, ergonomics and lightness come to the fore in machine devices and systems. For each of these criteria, separate engineering applications are needed in machine part manufacturing. Within the scope of this study, a bracket part manufactured in the automotive industry was selected and mass reduction was realized by performing a topology optimization study. In this study, design criteria were reduced by proposing additive manufacturing to avoid constraints in the manufacturing of the designed part. In the optimization study, input parameters; lattice cell type, maximum and minimum cell thickness in lattice cells and unit cell size were selected. For the lattice cell type, 6 types of cells were selected as schwarz, diamond, gyroid, lidinoid, splitp and neovious. For minimum cell thickness; 0,4 mm, 0,5 mm, 0,6 mm, for maximum cell thickness; 4 mm, 4,5 mm, 5 mm and for unit cell volume; 27 mm3, 64 mm3 and 125 mm3 were selected. Taguchi method was used for the optimization of the planned finite element analyses (FEA) and the number of FEAs was determined as 18. As a result of the FEA, it was concluded that more than 32% mass reduction can be realized based on the von-Mises stress on the selected part.