Abstract: To reduce the environmental impact of mechanical parts, an approach integrating structural design and material selection was studied. Adding the discrete variable of material, a hybrid optimization model was built with the aim of minimizing environmental impact and based on an ordinary structure optimization model. An optional material set was built by combining measures of qualitative and quantitative screening, while the lifecycle environmental impact of the materials was quantified using the method of Eco-indicator 99. Two groups of structurally optimal solutions were calculated with ideal and negative-ideal materials selected respectively, and then the hybrid model was simplified by comparing the solutions. A material environmental performance index was calculated using an analytic method. By comparing this index for every material in the optional material set, the optimal material can be found and the structural solutions calculated. This method was applied to a dowel bar design process as a case study. The results show that the environmental impact of each material has a significant effect on the optimal structural solution, and it is necessary to study the integration of structural design and material selection.

Key words: Green design, Structure optimization, Material selection, Environmental performance index

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