Topology optimization and dimensional optimization design of test bench fixtures

WANG Jiongteng; YANG Guangwu; XIAO Shoune; ZHU Tao; YANG Bing; CAI Songcen

doi:10.16579/j.issn.1001.9669.2026.03.007

Abstract：[Objective]Topology optimization is a widely used optimization method that optimizes material construction,finds the optimal shape of structural design under given design space and constraints,achieves lightweighting,and satisfies constraints.Based on the idea of variable density topology optimization method,taking the fixture structure of a certain test bench as the analysis object,and the establishment of a mathematical model and solution method for topology optimization were elaborated in detail,in order to provide reference for structural design based on advanced design methods.[Methods]Firstly,a finite element model of the tooling was established in the HyperMesh simulation software using the OptiStruct module.With the minimum mass and maximum first-order frequency as the optimization objectives,topology optimization and size optimization were conducted on the tooling structure under a single working condition.The material distribution was reasonably arranged and the thickness of the plates was optimized to improve the quality of tooling design.Secondly,based on the optimization results and the practicality of manufacturing and processing,a new tooling structure was designed.Finally,in the Nastran module,the strength check of the tooling model was carried out in accordance with the GB/T 21563-2018 standard.After the actual processing of the tooling structure was completed,the tooling was placed on a vibration table,and longitudinal,transverse and vertical sweep frequency tests were conducted respectively.Subsequently,the test results were compared with the simulation results.[Results]The results show that the first-order modal frequency has increased from 766 Hz to 1 009 Hz,representing a rise of 31.72%.Meanwhile,the fixture mass has decreased from 51 kg to 44.26 kg,a reduction of approximately 13.24%,its strength meets the design standards and the overall objective is successfully achiered.