Author : Anish Pramod Borkar and V.R.Naik

CAE driven design processes boosting all modern manufacturing units by providing cost effective and optimized design. The product design is stimulated by structural optimization tools like geometrical (topology) optimization, shape optimization and size optimization. Geometrical optimization is a mathematical approach that optimizes material layout within a given design space, for a given set of loads and boundary conditions such that the resulting layout meets a prescribed set of performance targets. Using geometrical optimization, engineers can find the best concept design that meets the design requirements. Geometrical optimization is used at the concept level of the design process to arrive at a conceptual design proposal that is then fine tuned for performance and manufacturability.  The main focus of the machine tool manufacturers has been shifted to conservation of natural resources and optimum energy utilization through weight reduction. Weight reduction can be achieved by the introduction of better material, better manufacturing processes and design optimization. In automobile and aircraft sector, topological optimization has become an integral tool of product design and development for the optimum weight evaluation. Enhanced structural performance and stability is achievable by geometry (topology) assisted design model which gives optimized results which are better and innovative in terms of product design. In other words, simulation saves time, reduces costs, and strengthens the competitiveness of companies, thus strengthened market position through enhanced structural design. Also Rapid Prototyping has been used over traditional manufacturing and forming for the pattern making process which helps reducing material wastage and time associated with tooling (for Forming) and it allows a complex shape to be produced directly and automatically from its 3D CAD model usually within hours. This paper deals with the structural optimization of guide bracket for horizontal band sawing machine by using topology based optimization technique using Optistruct. It is observed that weight of the guide bracket has been optimized up to 26% without changing its load bearing capacity under current operating load conditions. Also it saved cost of material up to 26% for the optimized model.

Keywords: Hyperworks, Optistruct, Structural Analysis, Geometrical Optimization, Rapid Prototyping

Article published in International Journal of Current Engineering and Technology, Vol.8, No.2 (March/April 2018)