Abstract
Recent economic conditions and technological developments in manufacturing methods have necessitated the use of advanced engineering design and analysis methods, such as topology optimization to increase efficiency and reduce costs in structural designs in the shipbuilding industry, as in many manufacturing sectors. Finite element method-based topology optimization aims to optimize a lightweight design without compromising the desired strength in ship structural designs, thus increasing efficiency in postmanufacturing functionality. Thus, it helps to create innovative products that can meet the sustainable design and manufacturing needs in the shipbuilding industry. In this study, the design of a foldable hatch cover for a feeder container ship was improved using topology optimization. Based on the premise geometry obtained by topology optimization, the model design was updated and an optimum design with the desired strength at minimum mass was obtained through iterative analyses. The optimization study resulted in a weight reduction of 2.49 tons and a material cost saving of $3.635 for a hatch cover. Thus, a total saving of $50.890 is expected from raw materials, labor, and consumables for 14 hatch covers on a sample ship. In addition, due to reduced draft and consequently lower drag, a 6-kW reduction in main engine power will result in approximately 6.6 tons less annual fuel consumption. Furthermore, an 8-mm vertical reduction in the ship's center of gravity increases stability by approximately 0.6% according to International Maritime Organization (IMO) stability criteria.
