Optimum design and analysis in glass packaging production with topology optimization

The packaging industry has made significant progress and developed in recent years by using very different materials and designed in very different ways. Due to the chemical and physical properties of glass packaging, it is necessary to be extremely careful and experienced in the design phase. In the design of a material that is not as hard and flexible as glass, special designs are required, especially against impact and physical strength. The customer expects a glass packaging design that will exhibit the product that he will put in the glass packaging in the best way, while being physically and chemically safe. In order to minimize the raw material and energy costs, which are the biggest costs in the production of glass packaging, the design of the glass packaging should be made with an optimum glass weight. In addition, the fact that the molds used in glass packaging production are extremely expensive and the lead times are long increase the cost of trial production of newly designed glass packaging. The design of glass packaging, which is extremely complex in terms of engineering and mathematics, can be made in the classical method in line with some assumptions. The finite element method, on the other hand, divides a large system into smaller components called finite elements, contrary to classical assumptions. The problem is solved with the limit and load values applied to each separated component. By comparing the finite element analysis results of the product designed with the classical method and the physical tests of the product, the closeness of the results obtained in the finite element method to the physical tests can be learned. Afterwards, by making topology optimization with the result data obtained from the finite element analysis of the traditional design, it is possible to make the final design at or very close to the optimum value of the lightening and shape revision to be made in the traditional design. In other words, topology optimization is a new approach that optimizes the material distribution in the specified region under the desired limits and loads, thus helping to optimize the design. In this way, it is foreseen that it will be faster and easier to transform the existing design into the most optimal design instead of making many alternative drawings. In this thesis, as an example, the accuracy of the finite element analysis results obtained by performing the finite element analysis of a design whose physical controls were completed by design and production with the traditional method was checked. Afterwards, the traditional design was optimized with topology optimization and finite element analysis was performed again and the resistance of the new design at the desired boundary conditions was examined. In the optimized design, the product weight was reduced by 8% and the cost by 8.49%. In addition, the contribution of topology optimization and optimum design to more environmentally friendly and sustainable production is explained.