Glossary: What is topology optimization analysis?

- Clever Design Methods for Lightweight and Strong Manufacturing -

In recent years, the need to create lighter and stronger parts has been increasing in all areas of the manufacturing industry. In many fields, such as automobiles, aircraft, and industrial machinery, the need is to reduce weight while ensuring strength and using materials without waste. One of the answers is "topology optimization analysis.

In this article, we will introduce topology optimization from its overview to specific application examples in an easy-to-understand manner so that even those who are not very familiar with analysis can understand it.

What is Topology Optimization?

Topology optimization is an analysis method in which a computer automatically considers "where to leave material and where to remove it? In other words, topology optimization is an analysis method in which a computer automatically considers "where to leave the material and where to cut it off. In other words,

In other words, it is a method to find the optimum “shape” to satisfy the required strength with the minimum amount of material.

In other words, it is a method to find the optimum “shape” to satisfy the required strength with the minimum amount of material.

In general design, the designer decides the shape, but topology optimization is the opposite. Topology optimization is the opposite approach, where only the conditions are given and the shape is left to the computer to figure out.

For example...this is how it looks like

Consider the following structure.

There is a square sheet of metal, right end is fixed

A pulling force is applied from the left end

Under these conditions, starting from a state where all the material is packed (i.e., a lump of metal), the computer decides, “Where should I cut to make it lighter while maintaining its strength?” The computer then determines "where to cut to make it lighter while maintaining its strength.

Then, like a skeleton in nature, a “branch-like” structure appears along the flow of force.

This is the optimal structure derived by topology optimization.

Specific Application Examples

Weight reduction of automotive parts

For example, suspension arm parts. This part is subjected to a heavy load during driving, but we do not want to use extra materials to make the car body lighter.

With topology optimization, the computer analyzes the load-bearing parts and automatically determines **“Material is absolutely necessary here” or “There is no problem even if material is removed here ”**.

The result is a design that is 30% lighter than before, yet still meets the required strength.

Optimization of mold cooling piping

Topology optimization may also be used to improve cooling efficiency in injection molds. By optimizing the route of cooling piping inside the mold,

Shortening the molding cycle

Improving product dimensional accuracy

Elimination of heat spots

While piping routes were conventionally designed based on human experience and intuition, topology optimization can automatically derive the **“optimal flow path for efficient heat release ”**.

◆Reducing the weight of medical implants

Topology optimization is also applied to medical implants such as artificial joints and bone replacement materials. In order to reduce the burden on the human body, they must be designed to be as light and strong as possible.

Topology optimization automatically produces a lightweight structure with a reticular interior, similar to the structure of bone. Such a shape is compatible with 3D printers and helps to realize a “human-friendly and strong” shape.

■Analysis Procedure (Easy-to-understand explanation)

The following is the general flow of topology optimization.

Prepare the initial model Prepare a state filled with material (e.g., block shape)

Set conditions Specify fixed sections, direction and magnitude of loads, amount of material to be used, etc.

1. 

2. Optimization process by computer: Optimal structure that retains strength is derived by gradually cutting the material.

3. Confirmation of results and shape modification Re-analysis by reducing the shape to one that can actually be machined

   

■ Cautions and Prospects

Topology optimization is a very powerful tool, but there are some caveats.

important point	Contents
Complicated shape	The resulting shape may be organic and complex and difficult to process
	Actual manufacturing processes and costs need to be taken into account and adjusted.
High computational cost	Large structures can be time and computationally resource intensive

Recently, however, with the evolution of 3D printers and the spread of generative design, it is gradually becoming more realistic to **“make the optimized form as is ”**. In the future, topology optimization will become even more widespread, and “maximum performance with minimum material” design will become the standard.

Conclusion

Topology optimization is an analysis technology that realizes the “ultimate waste-free design,” which has been difficult to achieve by human hands.

The computer determines where and how much material to leave

Currently being used in a wide range of fields including automobiles, aircraft, medicine, and molds

Methods becoming increasingly important with the evolution of manufacturing technology

Topology optimization will become one of the indispensable design approaches in the future for manufacturing sites aiming at weight reduction and cost reduction.