Topology Optimisation as Method for Improving the Design Process of Tipping Semi-trailer

When designing a new better product, besides all the engineering knowledge, time and money, more modern techniques as possible should be presented at any stage of the development process. Hence, “brainstorming” as the earliest stage in the process can be more accurate and productive for the development team with data of initial material distribution in the form of a typical “topology optimization - TO” result based upon the predetermined technological, geometrical, economical and homologation constraints. Design objectives such as lowering mass or displacements are tangible variables when using the TO approach and are suitably desired by the development team. This paper presents a simulation study based on the finite element method used in the development process for designing a chassis for a typical tipping semi-trailer vehicle. The expected load cases are described and calculated for a specific direction of movement. The tipping sequence described as longitudinal bending, the tipping on uneven ground is longitudinal torsion or the short turning is lateral bending of the potential new chassis. Based on the envelope simulation results from the multiple scenarios with the pre-defined constraints a topology geometry model has been created. For that, a two-stage process of optimizing is presented. First optimizing the 2D initial area, then a 3D solution for minimum structural compliance of the extruded initial 2D design. As a main tool for pre-processing and post-processing, Siemens Simcenter is used. The solving is performed with Nastran's topology optimization SOL200 solver.