Manufacturability-Oriented Ground Beam-Joint Topology Optimization for Multi-Piece Frame Structure Design

Topology optimization is a useful design tool, but it often yields layouts difficult to manufacture without considerable post structural modification. As a result, its structural performance can be significantly deteriorated. To minimize the undesirable postprocessing, we aim to develop a manufacturability-oriented compliance-minimizing topology optimization using a ground beam model incorporating additional zero-length elastic joint elements. In the present formulation, design variables control the stiffness of zero-length elastic joints, not the stiffness of beams. Because joint stiffness values at the converged state can be utilized to select candidate assembly locations, the technique is extremely useful to design multi-piece frame structures. An optimal layout is also extracted based on the stiffness values. Because structural properties of ground beams can take only on discretely available values or remain unchanged for optimization process, no post structural modification is required in an actual manufacturing step.