Misalignment topology optimization with manufacturing constraints

This work aims at introducing misalignment response in the design of mechanical transmission components using topology optimization. Misalignment considerations can be of high importance for various industrial applications as in gearbox or differential, where aligned axes are to be ensured during the usage of the part. Nevertheless, to the authors’ knowledge, no work so far implements such response in a topology optimization framework. In this contribution, misalignment between two spatial vectors is evaluated in various ways using trigonometry and vector functions. The misalignment is formulated through the spatial displacements of the constituent nodes of the objective vectors. The authors choose a formulation among other and implement the later in a 2D topology framework for further investigation on test cases. Issues such as material disconnection, non-discrete solutions or lack of engineering meaning are tackled along this work by the introduction of constraints and parametric studies. A performance test is achieved on a simplified gearbox transmission system to assess the performance between designs with or without misalignment considerations.Manufacturing constraints are introduced to improve the manufacturability of the optimized solution. Subsequently a 3D test case further highlights the usefulness of this contribution.