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A practical shape optimization technique is presented. We employed the basis vector method to parameterize the shape of the structural domain that is usually discretized by the finite element method. VMA/GENESIS software, the optimization system with finite element analysis, sensitivity analysis, and numerical optimization capabilities, was used for this study. Various design problems such as body, chassis, and engine parts design are solved to demonstrate the effectiveness and the robustness of the present approach for automotive applications.

In various practical structural design problems, decision of a layout of material or stiffeners in the given design space satisfying some design constraints is the most difficult task for design engineers. Also, they must consider many possible cases for safety, performance and some other requirements. But it is very difficult to solve this type of layout (topology) problem by any conventional structural optimization techniques because its mathematical modeling of topology is so complex. To solve this problem, we employed the new topology optimization technique using the homogenization method that was recently introduced by Bensøe and Kikuchi. The method gives the minimum compliance design under certain material constraint. This technique was also extended to three dimensional shells and three dimensional solids by Suzuki and Kikuchi. In this paper, shape and topology optimization problem under multi-loading conditions is discussed.