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1、2011 International Conference on Electronic & Mechanical Engineering and Information Technology Research on Conceptual Design of Heavy-duty Truck Frame based on Topology optimization Baozhong Qu1 2, Lingjin Qu * Electrical Engineering l.Henan Polytechnic Institute , Nanyang, China 2.WuHan Polytechni
2、c University, WuHan,China qubz_ AbstractTopology optimization is a design method based on mathematical programming, to seek an optimum distribution of material, greatly shortened product conceptual design cycle. With the help of variable-density method, topology optimization was carried out for heav
3、y-duty truck frame based on Hyper Works platform. The way not only satisfied with the design requirements, but also provides reference for the new product design. It provides an important technical message for conceptual design Keywords-topology optimization; variable-density method; Heavy-duty truc
4、k frame, conceptual design I. PREFACE Topology optimization takes mathematical programming as the theory basis. After taking full account of various design restraint premise, carry out the calculation by the optimized mathematical theory and the tools of computer and software in order to get the opt
5、imal distribution and shape by optimizing the material under a given space. The major characteristic of Topology Optimization is that the reasonable structure form analysis can be determined according to the known boundary and load conditions before the structural topology shape settled. Therefore,
6、designers can fully understand product structural and functional characteristics so that the general and detail design can be performed pertinently. As a result, Topology Optimization is fully applied to new concept design and redesign of a product. Heavy-duty Truck works in tough environment and be
7、ars the load with complex forms and great changes. As the main load component, truck frame is the key of Heavy-duty Truck design. It can directly affect the performance of safety, economy and power. This article takes a new product of certain vehicle manufacturing firm as background in order to intr
8、oducing Topology Optimization Technique to Heavy-duty Truck frame concept design. On the one hand, the design result can provide a reference to product detail design. On the other hand, it can verify the existing mature Heavy-duty Truck frame structure. II. THEORETICAL BASIS OF TOPOLOGY OPTIMIZATION
9、 A. Mathematical basis of Variable-density method The main idea of Topology Optimization is to answering the question which is the optimal material distribution of structure in the given design area. For continuous structure topology optimization, there are some mature methods as follows: Uniform me
10、thod, Variable-density method, Evolutionary structural optimization method, etc. This article takes variable-density method as mathematical basis. The basic idea is that turn continuous structure into finite element model first, and then introduces one hypothetical density variable materials which d
11、ensity is between 0, 1 and considers the density of every unit as design variable. Consequently, the Topology Optimization turns to optimizing the material distribution. In density iso-surface distribution drawing made by variable-density method calculation, the big stress unit is high density, and
12、the small stress unit is low. The general material density distribution is uniform and density continuous variation never exists. Therefore, it is needed that designer adjust the calculated topology structure according to density iso-surface drawing to meet the requirement of actual projects. Usuall
13、y, the density method takes minimum structure deformation as the target and considers the volume constraint (quality constraint) and the balance of structure. Therefore, the mathematical model of Topology Optimization is as follow: Solution for: X = (XY ? X2, XN ) min : C = FTD Make: f=V-Vi To Satis
14、fy: 0 min Xe max In F KD C js Structure Deformation; F is Load Vector; K is stiffness matrix; D is Displacement Vector; V V v is the volume with which material is filled; is the volume of design area; Vl is the volume of material which unit density is less than ; f is the percentage of surplus 978-l
15、-61284-088-8/ll/$26. 00 2011 IEEE 73 12-14 August, 2011 material; Xmin is the lower control of unit relative density; Xmax is the upper control of unit relative density. Under various working conditions, take weighted summation of each sub working conditions deformation. The target function turns to
16、: turns to: min : C = WiCi In upper format, Wi the weighting factor of No.i sub working deformation C the deformation of No.i sub working deformation B. Process of Topology Optimization For carrying out Topology Optimization on structure according to HyperWorks platform, first make a 3D model and a finite element model. Then define optimization variable, target function, constraint function, optimization parameter according to actual working conditi
