A Topology Optimization of a Motorsport Safety Device

The work proposes a method of Topological Optimization of 3D surfaces using an algorithm that works by considering the distribution and intensity of stress on the studied component. Rather than acting on the mesh, this algorithm modifies directly the CAD, allowing its direct use avoiding any subsequent intervention. The algorithm has been developed using Rhino – Grasshopper. The FEM analyses have been performed using the Nastran solver within the Siemens NX environment. With this method the original non-optimized model is hollowed through a Voronoi tessellation that is managed through several parameters. Through an iterative process, the algorithm performs the hollowing on the original CAD, varying the size and distribution of the holes in function of the stresses. As case study, the authors considered a safety device that helps to prevent injuries to the necks of pilots of various high-speed motorsports (Head and Neck Support, HANS). The results of this work show the potentiality of this methodology, with which it is possible to obtain a much lighter device with the same mechanical performance.