Sheet Metal Optimisation Utilising the advanced capabilities of VR&D GENESIS, the design optimisation of sheet metal pressings can yield significant savings over traditional methods of product design. Using the processes shown below companies can:- Significantly reduce development cycle times Minimise component mass and material usage Save money                                                                 Typical material savings of 30% can be achieved whilst reducing development cycle times by over 50%.

Topology - Optimal Sheet Metal Design Example of Topology Optimisation Sheet Metal Manufacturing Constraint The example opposite shows the results of the unique sheet metal topology manufacturing constraint carried out on an automotive front subframe design. The design has evolved both top and bottom pressings. Traditionally topology has required a great deal of interpretation to get to a sheet metal design, with manufacturing constraints aimed at casting and extrusion manufacturing methods. This new feature addresses this issue, with the amount of interpretation required greatly reduced, meaning designs closer to the optimisation results. To view examples of GENESIS optimisation capabilities view our case studies section. For more information about GENESIS click here.      Beginning with the available package space model the optimal material sheet design can be developed for all loading requirements.  These could be static, buckling and vibration loadings depending on the product requirements.  Once the load cases are decided upon the topology study can be set up using the unique capabilities of GENESIS to minimise the mass under those load cases and constraints.  The topology results will show the optimal pressed form for either a single or two piece pressed solution, depending on the engineers requirement.  No limit is placed on the number of load cases being considered.  The images below show the bottom and top layers of the subframe design after topology was performed taking into consideration all the constraints.

Sizing/Shape Using GENESIS and Design Studio it is possible to set up a design optimisation study for sizing and shape.  The target here was to optimise thickness and section sizes of pressed parts.  The front member of the sub-frame shown below reveals a geometric shape change when specific load cases and constraints are considered.    The objective of the study below was to optimise the thickness of a sub-frame to maximise its frequency.  Each frame (1 - 13) represents an iteration by GENESIS in meeting the objectives and constraints until it reaches the optimum result (frame 13).  The results of the thickness optimisation allow standard gauges to be defined.  This means exact 'off the shelf' thicknesses can be used and the optimised design easily manufactured.

Topography Through an efficient set-up process the optimal addition of swaging to pressed metal forms can be calculated.  Typical applications where Topography can offer significant benefits are: Maximising panel natural frequencies to eliminate vibration problems Maximise buckling performance Maximise component global stiffness                                                                                                                                                     Back to Top