Topology optimization for ship structures with manufacturing constraints

Currently, most ships are designed on the basis of rules and reference ships for which often only the critical structural parts are calculated and designed in detail. This process can result in an over-dimensioned ship with the standard structural outcome of longitudinal stiffeners, transverse stiffeners, and bulkheads with a fixed distance due to ease of manufacturing. With the use of finite element analysis (FEA), the complete structure of a ship is analyzed against prescribed loads, which facilitates the determination of the detailed dimensions of all stiffeners and plates within a reasonable lead time and could result in better engineering in the form of a lighter ship. In addition, the most common structural forms could be optimized by replacing them with unique and optimal shapes. Topology optimization (TO) uses FEA, and it facilitates unique structural shapes. TO generates an optimized material distribution for a set of loads and constraints within a given design domain. The result can be used to inform the design of an improved part. Although the results provide helpful insight, they often cannot be used literally, as they are organic and cannot be manufactured with typical steel shipbuilding methods. The objective of this study is to research the possibility to design the structure of a steel midship with TO where the resulting structural form is manufacturable using steel-cut plates and cost-effective from a shipbuilding perspective. However, constraints that result in a manufacturable structure that can be made cost-effectively from steel-cut plates have not been developed and implemented in TO. To meet the objective, this project was initiated in cooperation with C-Job and the University TU Delft. The methodology was established based on a software comparison followed by an extensive trial and errortesting process. The study was executed in a case study for which the domain concerned the midsection of a 203m offshore vessel named Orion, as TO could resul
Marine Technology