Shape Optimization of Stamped Structural Components with Flanges

Much of the current research in shape optimization has been directed toward the design of rather simple, two-dimensional problems. That work has generally been based upon patch-type mesh generation schemes which closely tie the boundary description to the mesh generation. Extension to more realistic, non-planar stamped parts has not been accomplished. The authors of this paper, however, have previously developed a general approach based upon a parameterized boundary description that uses a design element concept which was easily extended to folded parts. Although relatively general stamped parts could be designed, this previous work provided no convenient means of including stiffening flanges in the shape optimization model, although such flanges are often present on stamped parts. A new capability has been developed to add a continuous flange along the edge of a shape optimization model, sueh that the flange height is a design variable which can be controlled by the optimization program. An interactive graphics-oriented geometric modeling capability will also be described for the efficient creation of design models. Two design examples will be presented which demonstrate the automated flange design capability.