Multi-component topology optimization of structures under design-dependent pressure loads
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The need to manufacture a mechanical product in a multi-component fashion is apparent. This need can arise from manufacturability limitations, tolerance/precision specifications, or assembly requirements. This work proposes a topology optimization framework for multi-component design [1-2] of structures subjected to design-dependent pressure loads. The interface region between two connected subcomponents is modeled as a rigid body element 2 (RBE2) in finite element analysis to enforce a weld-like connection. Design-dependent pressure loads within topology optimization are implemented via the boundary identification and load evolution (BILE) model [3]. The BILE model deals with the pressure load such that the magnitudes of resulting equivalent forces applied on ``load nodes" are nearly constant with respect to the design variable, as the loading surfaces evolve. This is possible because the topological boundary identification steps that determine the placement of equivalent forces are sandwiched between a predetermined number of load-evolution steps, thereby ensuring that pressure adaptability to the topology's boundary is maintained. This eliminates the dependence of the force vector on the pseudo-density design variable, thereby simplifying sensitivity computation. The effectiveness of the proposed methodology is shown by its application to internally and externally pressure-loaded structures in 2D and 3D. In the future, the material properties of the heat-affected zones (HAZ) near the interface bonds will be treated as inferior to the solid material strength-wise.
