Topology optimization Applied on Injection Molding Part Design

Topology optimization Applied on Injection Molding Part Design

Minghui Dai, Kai Chen, Christine Roucoules

Valeo Lighting Hubei Technical Center Co. Ltd, Wuhan,China, 430014

Valeo Lighting Systems, Bobigny, France, 93012

*Contact email address: minghui.dai@valeo.com

Abstract—Carbon neutrality is one of the main challenges, where Valeo has been investing heavily since 2010. A new effort is focussing on emission reduction related to its operating activities. One challenge is to design lighter parts and use recycled material.   Currently, topology optimization is one of most popular lightweight design methods and widely applied in generative design especially for additive manufacturing. New optimization method allows accounting for injection constraints such as uniform thickness or demoulding axis direction to find the most effective design as function of the load path. This paper is presenting the application of optimization combined to a structural simulation and vibration on a structural part of the headlamp, the housing. Different methods of optimization were applied with the target of minimizing the weight and maintaining the mechanical properties.   First, the results of optimization under static loading are presented. Then the results of the modal optimization are analyzed. The output results from different methods are discussed. The validation of the optimized shape was validated inside a real headlamp in 3D simulation to verify its robustness under different loading. Although the quality of the optimization CAD can be very rough and incompatible with injection constraints, some conditions can help to identify design shape leading to significant reduction of weight. The optimized CAD   can be used as a reference to guide design of   injection parts in the direction of weight structure.

    Keywords-Topology optimization; lightweight; injection; design