Topology Optimization (Report)
Uploaded by
Mahmoud KassabTopology Optimization (Report)
Uploaded by
Mahmoud KassabFaculty of Engineering – Cairo University
Mechanical Design and Production Engineering
Two Semesters System –4th Year
MDP403: Mechanical System Design – Spring 2021
Project #1
(Topology of an Aircraft Door Hinge Bracket)
Submitted to
Prof. Dr. Hesham A. Hegazi
Prepared by
Team #7
Name B.N
Anton Tamer Shafique Abdel-Sayed 12
Ayman Hisham Mahmoud Ahmed 13
Mahmoud Ahmed El-Sayed Kassab 28
Hager Ali Mahmoud Ali 35
Sunday, May 30, 2021
Table of Contents
Table of Contents ....................................................................................................................... I
Introduction ................................................................................................................................ 1
First Attempt .............................................................................................................................. 2
Second Attempt .......................................................................................................................... 3
Third Attempt............................................................................................................................. 4
Fourth Attempt ........................................................................................................................... 5
Topology Optimization .............................................................................................................. 6
Topology Attempt Results ..................................................................................................... 6
Topology Optimization Attempt ............................................................................................ 7
Decision Matrix ......................................................................................................................... 9
I
Introduction
Our objected part is an aircraft door hinge bracket that fixed to the body of the aircraft.
As in planes, the most important factor is weight so the selected material for the bracket is (AL
7075-T6) which is used for many components in planes for its low density and high strength.
For our application there are two load case scenarios:
1. First Scenario
❖ The door is opened, and the mass of the door
pulls the part down.
❖ Fixation: Fixed inside bolts holes.
❖ Load: Aligned to inner hole surface (2000N).
2. Second Scenario
❖ The door is closed and the hinge exerting
reaction force on the bracket.
❖ Fixation: Fixed inside bolts holes.
❖ Load: Normal to hole surface (inward to the
part) (2200N).
Material Properties (AL 7075-T6)
Property Value Units
Elastic Modulus 72000 𝑁/𝑚𝑚2
Poisson’s Ratio 0.33 𝑁/𝐴
Shear Modulus 26900 𝑁/𝑚𝑚2
Mass Density 2810 𝐾𝑔/𝑚3
Tensile Strength 570 𝑁/𝑚𝑚2
Yield Strength 505 𝑁/𝑚𝑚2
Page | 1
First Attempt
𝑀𝑎𝑠𝑠 = 8194.69 𝑔𝑟𝑎𝑚𝑠
First Scenario Second Scenario
𝑀𝑎𝑥. 𝐷𝑒𝑓𝑜𝑟𝑚𝑎𝑡𝑖𝑜𝑛 = 0.02496 𝑚𝑚 𝑀𝑎𝑥. 𝐷𝑒𝑓𝑜𝑟𝑚𝑎𝑡𝑖𝑜𝑛 = 0.0109 𝑚𝑚
𝑀𝑖𝑛. 𝐹𝑎𝑐𝑡𝑜𝑟 𝑜𝑓 𝑆𝑎𝑓𝑒𝑡𝑦 = 40 𝑀𝑖𝑛. 𝐹𝑎𝑐𝑡𝑜𝑟 𝑜𝑓 𝑆𝑎𝑓𝑒𝑡𝑦 = 53
So, based on the first attempt simulation, the maximum possible
deformation is 0.02496 𝑚𝑚 and the minimum factor of safety is 40
Page | 2
Second Attempt
𝑀𝑎𝑠𝑠 = 5044.74 𝑔𝑟𝑎𝑚𝑠
First Scenario Second Scenario
𝑀𝑎𝑥. 𝐷𝑒𝑓𝑜𝑟𝑚𝑎𝑡𝑖𝑜𝑛 = 0.02895 𝑚𝑚 𝑀𝑎𝑥. 𝐷𝑒𝑓𝑜𝑟𝑚𝑎𝑡𝑖𝑜𝑛 = 0.01280 𝑚𝑚
𝑀𝑖𝑛. 𝐹𝑎𝑐𝑡𝑜𝑟 𝑜𝑓 𝑆𝑎𝑓𝑒𝑡𝑦 = 42 𝑀𝑖𝑛. 𝐹𝑎𝑐𝑡𝑜𝑟 𝑜𝑓 𝑆𝑎𝑓𝑒𝑡𝑦 = 49
So, based on the second attempt simulation, the maximum possible
deformation is 0.02895 𝑚𝑚 and the minimum factor of safety is 42
Page | 3
Third Attempt
𝑀𝑎𝑠𝑠 = 1781.81 𝑔𝑟𝑎𝑚𝑠
First Scenario Second Scenario
𝑀𝑎𝑥. 𝐷𝑒𝑓𝑜𝑟𝑚𝑎𝑡𝑖𝑜𝑛 = 0.2412 𝑚𝑚 𝑀𝑎𝑥. 𝐷𝑒𝑓𝑜𝑟𝑚𝑎𝑡𝑖𝑜𝑛 = 0.6847 𝑚𝑚
𝑀𝑖𝑛. 𝐹𝑎𝑐𝑡𝑜𝑟 𝑜𝑓 𝑆𝑎𝑓𝑒𝑡𝑦 = 7.3 𝑀𝑖𝑛. 𝐹𝑎𝑐𝑡𝑜𝑟 𝑜𝑓 𝑆𝑎𝑓𝑒𝑡𝑦 = 6.3
So, based on the third attempt simulation, the maximum possible
deformation is 0.6847 𝑚𝑚 and the minimum factor of safety is 6.3
Page | 4
Fourth Attempt
𝑀𝑎𝑠𝑠 = 1363.51 𝑔𝑟𝑎𝑚𝑠
First Scenario Second Scenario
𝑀𝑎𝑥. 𝐷𝑒𝑓𝑜𝑟𝑚𝑎𝑡𝑖𝑜𝑛 = 0.3664 𝑚𝑚 𝑀𝑎𝑥. 𝐷𝑒𝑓𝑜𝑟𝑚𝑎𝑡𝑖𝑜𝑛 = 1.054 𝑚𝑚
𝑀𝑖𝑛. 𝐹𝑎𝑐𝑡𝑜𝑟 𝑜𝑓 𝑆𝑎𝑓𝑒𝑡𝑦 = 5.6 𝑀𝑖𝑛. 𝐹𝑎𝑐𝑡𝑜𝑟 𝑜𝑓 𝑆𝑎𝑓𝑒𝑡𝑦 = 3.7
So, based on the fourth attempt simulation, the maximum possible
deformation is 1.054 𝑚𝑚 and the minimum factor of safety is 3.7
Page | 5
Topology Optimization
For our application there are two load case scenarios:
❖ Fixation: Fixed inside bolts holes.
❖ Topology Constraints:
• Mass Constraint: Minimum Reduction of Total
Mass = 87 %
• Factor of Safety Constraint: Minimum Factor
of Safety = 3
• Displacement Constraint: Maximum
Displacement = 1 mm
❖ Topology Preserved Regions (5mm):
• Six Holes for Bolts.
• Loading Location.
Topology Attempt Results
Page | 6
Topology Optimization Attempt
𝑀𝑎𝑠𝑠 = 745 𝑔𝑟𝑎𝑚𝑠
First Scenario Second Scenario
𝑀𝑎𝑥. 𝐷𝑒𝑓𝑜𝑟𝑚𝑎𝑡𝑖𝑜𝑛 = 1.2 𝑚𝑚 𝑀𝑎𝑥. 𝐷𝑒𝑓𝑜𝑟𝑚𝑎𝑡𝑖𝑜𝑛 = 1.07 𝑚𝑚
𝑀𝑖𝑛. 𝐹𝑎𝑐𝑡𝑜𝑟 𝑜𝑓 𝑆𝑎𝑓𝑒𝑡𝑦 = 2.95 𝑀𝑖𝑛. 𝐹𝑎𝑐𝑡𝑜𝑟 𝑜𝑓 𝑆𝑎𝑓𝑒𝑡𝑦 = 3
So, based on the topology optimization attempt simulation, the maximum possible
deformation is 1.2 𝑚𝑚 and the minimum factor of safety is 2.95
Page | 7
Meshed Topologized Part Created Part
𝑀𝑎𝑠𝑠 = 745 𝑔𝑟𝑎𝑚𝑠 𝑀𝑎𝑠𝑠 = 850 𝑔𝑟𝑎𝑚𝑠
First Scenario Second Scenario
𝑀𝑎𝑥. 𝐷𝑒𝑓𝑜𝑟𝑚𝑎𝑡𝑖𝑜𝑛 = 0.83 𝑚𝑚 𝑀𝑎𝑥. 𝐷𝑒𝑓𝑜𝑟𝑚𝑎𝑡𝑖𝑜𝑛 = 0.27 𝑚𝑚
𝑀𝑖𝑛. 𝐹𝑎𝑐𝑡𝑜𝑟 𝑜𝑓 𝑆𝑎𝑓𝑒𝑡𝑦 = 3.8 𝑀𝑖𝑛. 𝐹𝑎𝑐𝑡𝑜𝑟 𝑜𝑓 𝑆𝑎𝑓𝑒𝑡𝑦 = 7.1
So, based on Created Part designed suggested by topology optimization simulation, the maximum
possible deformation is 0.83 𝑚𝑚 and the minimum factor of safety is 3.8
Page | 8
Decision Matrix
Decision Parameters:
❖ Part Mass (60%); Because it is the most important factor for our application.
❖ Deformation (1%); According to our application, deformation is a critical parameter.
But the relative change to its values is significant as shown in decision matrix.
❖ Design Factor (39%); To avoid the over design.
Mass (gm) ↓ Deformation (mm) ↓ Factor of Safety ↓ Total
W. F 60% 1% 39% 100%
First 8194.69 0.025 40 1
Design =1 =1 =1
8194.69 0.025 40 0.39
Attempt 0.6 0.01
Second 5044.74 0.029 42 0.79
= 0.615 = 1.16 = 1.05
Design 8194.69 0.025 40
Attempt 0.369 0.0116 0.41
Third 1781.81 0.684 6.3 0.465
= 0.217 = 27.36 = 0.1575
Design 8194.69 0.025 40
Attempt 0.13 0.2736 0.0614
Fourth 1363.51 1.05 3.7 0.556
= 0.1663 = 42 = 0.0925
Design 8194.69 0.025 40
Attempt 0.1 0.42 0.036
Topology 850 0.83 3.8 0.431
= 0.104 = 33.2 = 0.095
Design 8194.69 0.025 40
Attempt 0.062 0.332 0.037
• The lowest value goes to Topology Design Attempt (Loss Matrix), So, the topology
attempt is most feasible.
• Considering That Third Design Attempt is too close to Topology Design Attempt, so
both considered to be feasible. However, the last decision could be made based on
available manufacturing techniques and manufacturing cost.
Page | 9
