Challenge: 

The optimization of a slide for a high-speed milling machine to be cross-accelerated with 2g raised the question if the traditional box ribbing used for this purpose was actually the best solution. A time-consuming manual study undertaken in 1997 had already shown a significant improvement in which deformation could be reduced by 50% and the weight of the component by 15%. Due to an improved castability of the mold, manufacturing costs were also reduced by 15%. This layout was used as a reference during the evaluation done with the optimization software Tosca Structure to determine an even better design.

Solution: Topology Optimization with Tosca Structure

The available design space was defined in the optimization model, taking into account that connecting surfaces to the surrounding components should be maintained unchanged. During the optimization process certain areas not contributing to the stiffness were successively removed from the structure. At the same time the requirements necessary to insure the manufacturability of the proposed design were fulfilled. The design suggestion could be imported to the CAD system and converted to a castable design with very few modifications.

Benefit: 

This example achieved an additional 30% reduction in deformation compared to the earlier manual solution. In comparison to the original ribbing pattern which represents the prevalent design on the market, this design shows advantage of 65%. Comparing the automatic Tosca Structure topology optimization process with a manual topology optimization, only 22% engineering time and 32% computing time was required. A significant reduction in costs and time was achieved. Heidenreich & Harbeck AG has been able to position itself as a premium partner to its customers and to guard against economic fluctuations through the expansion of its engineering services by the use of topology optimization. 

"Through the use of standard automatic optimization processes in the design phase, we have been able to satisfy complex part requirements in a short time saving material and manufacturing costs at the same time. SIMULIA Tosca Structure has not only given our company a distinctive competitive edge, but has also allowed a significant saving in time."

[Erns Du Maire, Chairman of the Board, Heidenreich & Harbeck AG]