The photoelasticity experimental technique is developed, which extends the topology optimization method to realistic engineering design problems. The new approach enables the efficient design of complex engineering structures by allowing the designer to control the material distribution among the design areas during the optimal design process, thereby allowing the use of multiload mechanical components in a variety of applications. This study enables a novel approach to topology optimization using the photoelasticity method. The primary objective of this research is to demonstrate the viability and efficacy of using photoelasticity in topology optimization for stress-constrained design problems. The proposed methodology involves of a number of essential steps, including material selection, specimen preparation, photoelastic testing, image processing, and optimization algorithms. The integration of photoelasticity into the optimization process permits more accurate and insightful evaluations of stress distributions within structures as well as more realistic stress constraints, resulting in designs that are not only structurally efficient but also resistant to failure. The methodology presented here provides an innovative and practical approach to solving real-world engineering problems, particularly in fields where accurate stress analysis is crucial, including aerospace engineering, civil engineering, and biomechanics. The photoelasticity experimental method is demonstrated for the linking plate design problem associated with the brake drum end. The case study illustrates the potential significance of the newly developed capability for a wide variety of engineering design problems, which reduces the amount of material by 50%. This methodology expands upon conventional topology optimization techniques that rely solely on numerical simulations.

Topology optimization is esoteric. Computer-aided design includes. Design objectives and feasibility are the goals. This study optimizes the crane hook, a common mechanical component with complex geometry, using topology. The crane hook should be light but strong. Photoelasticity allows experimental verification of the design’s stress distribution by visualizing and stress patterns in birefringent property materials. Formulating the topology problem, design space, objective function, and constraints starts the study. The initial design and photoelasticity optics iterations are simulated using finite element analysis. Density method Isotropic Material with Penalization algorithm optimizes by iteratively updating the density distribution to improve the objective function while satisfying constraints. The design is then prototyped using a Photoelastic birefringent material. A known load and boundary conditions under polariscope experimental set-up stress the crane hook prototype. Computational topology and finite element analysis stress distributions are compared to isochromatic fringe principal stress patterns (1–2). Experimental and simulated results validate the design’s stress, displacements, and reliability. The study showed 23.45% weight reduction while maintaining crane hook structural integrity. Photoelasticity experimentally verifies stress distribution, boosting confidence in the design. Computational simulations and photoelasticity allow mechanical component validation.

Resource constraints have necessitated design and development of machines and structures that are more efficient and have minimum weight. Optimisation procedures are widely used for this purpose. Topology optimisation technique has wider area of applications, like design and compliant mechanisms. Extensive studies have been carried out employing computational method with finite element analysis to carry out topology optimisation. The computational method essentially consists of density approach which assigns 0 (no material) and 1 (with material) at low stress and high stress region respectively. Final topology of the machine or structural member is arrived at after a number of iterations. However, the scope for using an experimental methods like photoelasticity for topology optimisation has not received due attention. During this research, experimental photo elasticity approach has been used to carry out topology optimisation. Photo elastic method, being a whole field technique has been widely used for stress analysis purpose and can be used with advantage to carry out topology optimisation. When the photo elastic model of a machine or structural member under load is viewed in the polariscope, the isochromatic fringe pattern observed from the model can be used to estimate the stress levels at a given location. The elements which of high and low stress can be forecast with reasonable accuracy. The sequential removal of material from the low stress region results in a topologically optimised model. For the purpose of this study, both numerical and experimental analysis is carried out on a crane hook under tensile loading. Optimisation analysis of crane hook is carried out using Hyperwork, Optitruct software. Final geometry is arrived at after 21 iterations. The weight reduction obtained from numerical analysis is 23.52%. The photoelasticity approach required only 7 iterations to arrive at the final geometry. Weight reduction obtained by experimental approach is 19.15%. The stress level in the experimentally obtained model is verified by carrying out finite element analysis. The weight reduction and optimisation is achieved without significant reduction in strength of the crane hook.