BESO Topology Optimization Driven by an ABAQUS-MATLAB Cooperative Framework with Engineering Applications

The Bi-directional Evolutionary Structural Optimization (BESO) method, owing to its algorithmic simplicity and strong scalability, has emerged as one of the most prevalent topology optimization methodologies in current research and industrial applications. To overcome the limitations of existing commercial finite element software (e.g., ABAQUS), particularly regarding the closed architecture of topology optimization modules and low efficiency in 3D complex structure optimization, this study proposes an ABAQUS–MATLAB cooperative framework. This innovative approach implements direct read/write operations via Python scripts on CAE/ODB model databases, coupled with MATLAB-based master control programs for sensitivity analysis, mesh filtering, and design variable updating. Compared with conventional integration methods employing INP/FIL file interactions, the proposed framework reduces computational time through MATLAB’s advanced matrix operations while maintaining solution accuracy. Validation cases including 2D cantilever beams and 3D wheel hubs demonstrate the method’s precision and computational efficiency. Practical applications in lightweight design of a hydraulic transmission test bench adapter support achieved 31% volume reduction while satisfying strength and stiffness requirements, significantly lowering material costs. The developed cooperative framework provides an extensible solution for high-efficiency topology optimization of complex engineering structures, balancing algorithmic transparency with practical applicability.