Topology optimization approach in a process of designing of composite shell structures

Nowadays, engineers and designer are forced to conduct their work quickly and efficiently. That led to introduction and development of many computer-based tools, which aid the process of designing. One of those methods is a topology optimization, which can be used in many branches of industry, such as an automotive or aerospace industry, where many shells and monocoque structures are used, for which this method is very useful. It is an iteration approach that allows obtaining optimal results of material's placement and continuity in a construction, as well as its properties and thickness, in accordance with introduced loads, boundary conditions and needed shape. That allows the designer to obtain needed stiffness and strength of the design, with minimum weight and usage of resources. There are many ways to conduct the topology optimization and one the simplest is considering the material as isotropic and homogenous, which greatly simplifies the calculations and reduces needed time. Nevertheless, the composite structure, especially laminates, should be considered as orthotropic and heterogeneous. The process of topology optimization is shown in the case of preparing the concept solution for lightweight, shell-based support system for an electrical UrbanConcept class vehicle for Shell Eco-Marathon. The description of the outer shape, loads acting on the structure and boundary conditions connected with other subsystems were described, as well as the preparation of the computer model and the process of topology optimization using Altair HyperWorks software. Additionally, the results were presented and a final solution obtained basing on them.