Application of structure optimization technique to aluminium beverage bottle design

This paper deals with shape optimization of two-piece aluminium beverage bottle bottoms by applying the structural optimization technique. Nonlinear finite element analyses were performed to study the influence of the design parameters on the buckling strength and the stiffness of the bottom under an axial load and internal pressure, respectively. On the basis of sensitivity analyses, the most effective dimensions are selected as design variables in the first stage design optimization, while the dimensions with relatively small influences are optimized in the secondary and following stages. In the design optimization of the bottom shape, the column strength is maximized subject to the bottom growth and the axial displacement constraints, while the bulge strength is restricted to fall into a predetermined range. Optimizing the design variables progressively can avoid unrealistic geometrical connectivity problems during the arrangement of design points using the orthogonal array in the design-of-experiment, and can ensure the design space for the important design variables as well as the reduction of optimization cost.