Design of a Pusher for a Crimp Using Finite Element Shape Optimization

Design analysts, who work with finite element shape optimization, face a daunting task of handling cylindrical parts like a pusher for a crimp. The shape vectors generated by any of the existing methods/tools cannot constrain nodes to move in a circular path. Since the pusher is not a complete cylinder and the loading is only along axial direction, shape optimization was performed after flattening out the cylindrical pusher. The existing shape optimization tools could now be applied to the flat plate. A numerical interpolation method, based on 'Autodv', has been used to generate shape vectors. Both weight and stresses have been brought down and the final design was verified with solid finite element analysis.