Topology Optimization for Giga-Casting Design in Automotive Bodies Using LS-TASC & LS-DYNA

Topology optimization plays a crucial role in generating initial design concepts during the early stages of vehicle development. It is a Finite Element Analysis (FEA) based technique that helps to optimize the shape and distribution of the material in a desired packaging space. This paper explores the application of LS-TaSC and LS-DYNA for topology optimization of giga casting in a vehicle’s underbody. This paper touches on the importance of topology optimization in the design development process and elaborates how the LS-TaSC tool can be used to get directional guidance before initiating detailed design (CAD) work. BIW (Body-in-White) global static bending and torsional stiffness load cases were considered while setting up the optimization model. Various optimization setting parameters, constraints, and post-processing tools available in LS-TaSC were explored and have been elaborated in the paper. The use of LS-TaSC and LS-DYNA in this project enabled the generation of an initial giga casting design concept, indicating the critical areas where material is needed or can be removed. These design concepts were further refined by the design team using CAD tools, considering more realistic manufacturing and performance constraints.