Topology Optimization Method of Stamping Structures Based on the Directional Density Field

Area of Science:

• Mechanical Engineering
• Computational Mechanics
• Materials Science

Background:

• Stamping processes create thin-walled structures with uniform thickness and no cavities.
• Current density-based topology optimization methods struggle with geometric constraints for stamping structures.
• Achieving uniform wall thickness and controlling features like enclosed cavities is challenging.

Purpose of the Study:

• To propose a novel topology optimization method for stamping structures.
• To address the limitations of existing methods in achieving desired geometric features.
• To enable control over wall thickness and rib drawing angles in stamped components.

Main Methods:

• Development of a directional density field for material addition/removal along the stamping direction.
• Utilizing Heaviside projection with tunable truncation thresholds for geometric control.
• Employing calibrated filter radius for drawing angle control of stamping ribs.

Main Results:

• The proposed method successfully performs topology optimization for stamping structures.
• Tunable uniform wall thickness and drawing angle control of ribs were achieved.
• The method effectively avoids internal voids and undercuts in the optimized structures.

Conclusions:

• The directional density field approach is effective for stamping structure optimization.
• Tuning truncation thresholds is crucial for uniform wall thickness and drawing angle control.
• Varying threshold increments via surface offset and polynomial fitting is necessary for optimal results.