Sheet metal plate design: A structured approach to product optimization in the presence of technological constraints

Geometrical optimization of structural components is a topic of high interest for engineers involved with design activities mainly related to mass reduction. The study described in these pages focuses on the optimization of plates subjected to bending for which stiffness is obtained by a pattern of ribs. Although stiffening by means of ribs is a well-known and old technique, the design of ribs for maximum stiffness is often based on practice and experience. Classical optimization methods such as topological, topographical and parametric optimization fail to give an efficient design with a reasonable programming effort, especially when dealing with many and complex constraints. These constraints are both technical and technological. A most promising technique to obtain optimal rib patterns was to define a set of feasible rib trajectories and then to select the subset with the most efficient combinations. The result is not unique and a method to select the optimal patterns is required. In fact, the stiffening effect increases with increasing rib length, but at a greater cost. A trade-off must be found between structural performance and cost: The tools to guide this selection process is the main objective of the paper, with particular attention in evaluating the stiffening due to the presence of beads on the plate with a close link with the production system and possible technological constraints which can occur during manufacturing processes, such as minimum rib distance or the presence of discontinuities or the presence of holes or other elements on the plate. A special tool with enforced rib cross section is considered, and optimal rib deployment has to be found. Numerical examples attached show the methodology and obtainable results. © 2011 Springer-Verlag London Limited.