Integrated Topology, Shape and Size optimization - Application in Automotive Design and Manufacturing.

CAE (Computer Aided Engineering) optimization plays a pivotal role in various industries to gain a competitive edge. CAE optimization is essential in several industries, such as automotive, aerospace and consumer electronics, etc., concentrating on enhancing component structural design. The process helps in addressing complex design challenges, including weight reduction, material usage efficiency and operational effectiveness. This paper presents applications for an integrated form shape, size and topology optimization approach of structural systems by using CAE tools. For the present study, CAD (Computer Aided Design) was prepared using CATIA V5 followed by meshing in Altair Hyper-works software. Hyper-mesh (Optistruct) was used as a solver tool. Modal analysis was performed to extract the natural frequencies of vibration and respective mode shapes. According to the results of the frequency response function study performed on the automobile air conditioning condenser, based on low-stress areas, brackets and side plates were optimized, aiming to minimize weight, improve structural strength and optimize material quantity while maintaining the component's usefulness and safety. Therefore, the sheet metal bracket was optimized for topology and shape, and the side plate was optimized for size. Thereafter, the condenser assembly resulted in a 2.9% reduction in mass.