Application of topology optimization to light-weight design of single cylinder engine

In order to apply the 3D topology optimization to the light-weight design of engine block,the topology optimization based on the variable density was studied.When performing topology optimization,the boundary condition was taken when the engine was at the moment of gas explosion,the minimum compliances of the cylinder block were taken as the single objective,and the mass as the constraint.Considering the factors of machining and assembling,CAD model of the cylinder block was rebuilt.The stress distribution of the optimized cylinder block was analyzed at the load of gas explosion and maximum piston knocking.At both load cases the maximum stress of the optimized cylinder block was lower than the original one,and the stress distribution was more even.Therefore,the structure optimization used in the light-weight design can determine the shape of the cylinder block easily and decrease the repetitions of design and validation.