Gradient-based multi-component topology optimization for stamped sheet metal assemblies (MTO-S)

A collection of interacting systems, such as a fleet of military vehicles, can have a life-cycle benefit from sharing interoperable modules. Defining the modules that maximize such benefits must be addressed at the early stages of system design. We present a multi-objective optimization framework for conceptual modular design. We use a functional representation of the supersystem, i.e., the interacting systems collection, to make module design decisions informed by supersystem requirements and life-cycle objectives. The resultant modules are configured into a variety of architectures and form a set of systems with distinct capabilities that meet supersystem requirements. We apply this approach on a fleet of military vehicles. Computational results quantify the intuition that designing a large number of smaller modules reduces overall fleet weight and increases required personnel resources because of larger demand for vehicle reconfiguration.