I designed the block in SolidWorks, and after running a static analysis and collecting the relevant data, I proceeded to perform topology optimization.
However, I’m facing an issue during the optimization step: although I have defined the parameters correctly (load, constraints, preserved regions, etc.), when I run the simulation, the resulting optimized geometry includes holes through the block in physically unrealistic or structurally critical regions. These holes should not appear, as they compromise the engine block's functionality and integrity.
As for the parameters I used:I applied 15.1 MPa pressure on the cylinder surfaces (representing combustion pressure).I also applied 20 MPa pressure on the contact surfaces with the cylinder heads (representing bolt/clamping force.In the Goals and Constraints section, I selected "Best Stiffness to Weight Ratio" with a mass constraint of 20%.For Preserved Regions, I selected:the contact surfaces with the cylinderheads,the contact surface with the oil pan,and the internal surfaces at the front and rear ends of the block, since these were the areas where the largest undesired holes were appearing.
Under Thickness Control, I set a minimum thickness of 10 mm. For Symmetry Control, I selected Half Symmetry using the Right Plane. Finally, for the mesh, I chose a medium mesh density (roughly in the middle of the scale).
Based on the parameters I mentioned above, I’m not sure which of them might be incorrect or misconfigured. I've tried several adjustments — for example, changing the minimum thickness by a few millimeters, as well as modifying the mass constraint percentage — but the resulting topology is always very similar and still contains undesired holes in critical areas.Is there anything in my setup that stands out as a possible cause of this behavior?I would really appreciate any insight on what I might need to change or refine in order to get a more realistic and functional result.
Could anyone help me identify what I might be doing wrong? Is there a recommended way to restrict or guide the optimization to avoid such problematic results? Any advice on which parameters I should review or adjust to prevent material removal in critical areas?
