University: Indian Institute of technology (IITI), Indore, Madhya Pradesh, India
Abstract:
This study focuses on optimizing a table tablet stand to improve structural stability, reduce mass, and minimize stress concentration. A tablet of mass 750 g was used as the load for analysis. The project began with force calculations and a Free Body Diagram (FBD) to determine the forces acting on the stand. An initial simulation was conducted to evaluate stress distribution and mass of the original design. Topology optimization was then performed to refine the cross-section by removing unnecessary material, followed by parametric design optimization (PDO) to identify optimal geometric variables for reducing stress and mass. The results of both optimizations were merged into an intermediate design, which was further refined by adding fillets to reduce stress concentration. The final design achieved significant mass reduction while maintaining structural integrity, demonstrating an effective balance between material efficiency and durability, results in a decrease in the cost of production.
Methodology:
To analyze the forces acting on the stand, Free Body Diagrams (FBD) of tablet and stand were created. The tablet, weighing 750 g (7.5 N). Let two Normal Reactions N1 and N2 acting on the stand for achieving equilibrium.
Observations:
INITIAL STAGE:
Designed the original stand and performed the simulations.
Initial Max von mises stress is 0.6301 MPa and mass is 309.37 gm
INTERMEDIATE STAGE
In this stage i have simulated the Parametric Design Optimization(PDO) and topology optimization for a cross section of the stand after PDO.
FINAL STAGE
In the final stage, I meticulously worked to reduce the mass as much as possible by carefully analyzing the simulations. I strategically removed material from areas where the stresses were minimal and had no significant impact on failure, ensuring an optimal balance between strength and efficiency. This precise approach not only streamlined the design but also enhanced its overall performance.
- Mass: 217.24 grams.
- Maximum Stress: 0.136 MPa .
Stress Concentration: Reduced significantly due to fillets.
Novelty:
By combining Parametric Design Optimization (PDO) with Topology Optimization, we achieved groundbreaking results in both performance and design. Here's a detailed breakdown of the process and outcomes:
- Iterative Process: Followed a structured approach moving from the initial design to intermediate stages, culminating in the final optimized version.
- Remarkable Mass Reduction: Successfully reduced the mass from 309g to 217g, with even greater reductions still possible.
- Exceptional Stress Reduction: The final design achieved a 6-fold reduction in maximum stresses, ensuring superior durability and reliability.
- Aesthetic Appeal: Delivered a visually striking design that balances form and function seamlessly.
- Strategic Material Removal: Focused on eliminating material from low-stress regions that do not contribute to structural failure, maximizing efficiency without compromising integrity.
Conclusion and Key Takeaways:
- The final optimized design successfully reduced mass while maintaining structural integrity and minimizing stress concentration. By combining topology optimization with parametric design optimization, a highly efficient intermediate design was achieved and further refined through stress concentration reduction techniques like adding fillets and removal of mass from lower stress area. The best design is justified as it meets all performance criteria—lightweight construction, durability under load, and ergonomic considerations—making it suitable for practical use.
- The importance of iterative simulations in achieving optimal designs.
- The effectiveness of combining multiple optimization techniques
- Lowering the stress concentration factor by applying fillets at sharp corners.
Link to the 3DDrive( For screen recording of simulation ):
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