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© FE-DESIGN GmbH
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Non-parametric Optimization
in
your Ansys Environment
for
Smart Products
ANSYS Regional Conference
October 25, 2011
Dolce La Hulpe (near Brussels), Belgium
Claus B. W. Pedersen and Carsten Gerdes-Götz
FE-Design
© FE-DESIGN GmbH
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TOSCA Structure - Optimization Types
Images Courtesy
of AUDI AG
Find the design e.g.
with maximum stiffness or
minimum weight
Elements are added/removed
TOSCA.topology
Increase the stiffness or
eigenfrequency of sheet
metal structures
Nodes are moved
TOSCA.bead
Images Courtesy of
Ford Werke AG
Reduce local stresses
and increase the
durability
Nodes are moved
TOSCA.shape
© FE-DESIGN GmbH
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Approval for distributing and copying required
TOSCA Fluid - Optimization Types
Find the design
with minimized pressure drop
from inlet to outlet
Elements are added/removed
TOSCA.topology
© FE-DESIGN GmbH
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A Rough Classification into two
Groups of Optimization Methods
Non-Parametric
Methods
Parametric
Methods
Combination of
both Groups
Sizing &
par. Shape
DOE &
RSMRobustness
Reliability
Geometric
Parameter
MDO
Structural
Topology
Non-par.
Shape Bead
Fluid
Topology
Both groups have their strengths.
The right method is dependent on the given optimization-task.
TOSCA Isight
ANSYS
DesignXplorer
Etc….
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FE-DESIGN Locations
FE-DESIGN Karlsruhe
Development, Sales,
Engineering
FE-DESIGN Munich
Engineering, Sales
FE-DESIGN Husum
International Sales
FE-DESIGN Nordic
Development, Sales
FE-DESIGN Sofia
Engineering, Development
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Support
and
Coaching
Software-
Development
Engineering,
Services,
Customization
FE-DESIGN
Your Partner for Structural and CFD optimization
FE-DESIGN combines development and engineering
of optimization-methods
FE-DESIGN has the ability to deliver best solutions for
our customers, benefiting from multi years of experience
Our customers improve their
optimization processes continuously due to a
permanent know-how-transfer with FE-DESIGN
Customers leverage FE-DESIGN´s knowledge,
embedded in long-term business relationships
© FE-DESIGN GmbH
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Global Distribution Partner of FE-DESIGN
RussiaOOO MES
www.mes-online.ru
JapanVINAS
www.vinas.com
TurkeyCAE Solutions
www.cae.com.tr
FIGES
www.figes.com.trBrazilVirtualCAE
www.virtualcae.com.br
Scandinavia/UKFE-DESIGN & Partner
www.fe-design.com
Czech/SlovakiaT.S.E.
www.techsoft-eng.cz
IndiaEnphiniti
www.enphiniti.com
ChinaCAEDA
www.caeda.com.cn
Kingswell
www.kingswell.com.cn
FEAonline
www.feaonline.com.cn
Road Ahead (Wisdom)
www.rat.com.tw
FLYOND
www.flyond.com
South-East AsiaDazztech
www.dazztech.com
USA/CanadaSimuTech Group
www.simutechgroup.com
KoreaSAMWON
www.cae.co.kr
CAE-CUBE
www.cae-cube.co.kr
www.simutech.com.tw
TaiwanSimutech
Germany/Austria/SwitzerlandFE-DESIGN & Partner
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© FE-DESIGN GmbH
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Customer of FE-DESIGN (extract)
Fahrwerksberechnung Betriebsfestigkeit Pkw
Berechnung Nutzfahrzeuge
© FE-DESIGN GmbH
www.fe-design.com
Corporate proprietary
Approval for distributing and copying required
TOSCA Structure - Optimization Types
Images Courtesy
of AUDI AG
Find the design e.g.
with maximum stiffness or
minimum weight
Elements are added/removed
TOSCA.topology
Increase the stiffness or
eigenfrequency of sheet
metal structures
Nodes are moved
TOSCA.bead
Images Courtesy of
Ford Werke AG
Reduce local stresses
and increase the
durability
Nodes are moved
TOSCA.shape
© FE-DESIGN GmbH
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Corporate proprietary
Approval for distributing and copying required
Topology Optimization Example
Transverse Link at AUDI
With courtesy of AUDI AG
© FE-DESIGN GmbH
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Initial Situation
With the friendly permission of the AUDI AG
A modification of the component was necessary,
because the load on the part became too high
with the new engines.
Topology optimization is used to
derive a new structure.
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Topology Optimization of a Transverse link at AUDI
Predecessor designDesign space model
Topology optimization
Cutting splines
Redesign
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Result of topology optimization of a transverse link of
the new Audi A8
Images courtesy of AUDI AG
© FE-DESIGN GmbH
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Comparison
Existing Design – New Design
From: VDI Berechnung und Simulation im
Automobilbau, Würzburg 2000
Result:
Speed-up of the development process
45 % Stress reduction, 10 % weight reduction
The 1st prototype passed all mechanical tests !
Weight Max. stress Max. displacement
Admissible
Stress
Existing design
New design
© FE-DESIGN GmbH
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Ansys Modeling:
For linear/nonlinear problems
All contact types allowed
Geometry non-linearities
Material nonlinearities e.g. non-linear springs
Optimization formulations:
Choice of objective function and multiple constraints:
Static load cases: Stiffness, displacements, forces
Modal load cases: Eigenfrequencies
Mass, COG, Inertia
Arbitrary number of loadcases
Various manufacturing and symmetry constraints
TOSCA Structure Topology Optimization
Stiffer Designs
Lighter Designs
© FE-DESIGN GmbH
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Example: Topology optimization of an engine bracket
without manufacturing constraints
Optimization target:
Maximization of the
stiffness with a
volume constraint
of 60%
with manufacturing constraints
Feasible design Infeasible design
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TOSCA.smooth: Export to CAD
TOSCA.ANSA.environment:
Validation model
environment
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Model - Mesh - Loading
Clamped
Moment and forces
Mesh
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Optimization setup and design area
Optimization target:
Maximization of the stiffness
with a volume constraint
of 60%
Chose design-variables in
Ansys Workbench
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Topology Example: Hub
A modification of the
component is necessary
because the load on the
part become higher with
increase in loads
Topology optimization is
used to derive a new
structure.
Optimization target:
Maximizing stiffness
subject to a volume
constraint of 60%
Chose design-
variables predefined
in Ansys
Front view Back view
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Symmetry constraint
Enforce 120 degree symmetry
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Manufacturing constraints
Minimum casting
member size
Casting
directionsNo casting
constraints
Bothminimum casting
member size
and
casting
directions
Feasible
design
Infeasible
design
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Topology optimization result
Discrete distribution of Young’s
modulus as optimization result
Conversion to continuous
distribution using iso-lines
Two options after smoothing:
Export the results into CAD
Generating a validation model
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Smoothing and CAD export
Transfer to CAD:
FE-Data
(no standard CAD-input)
Calculation of
Isosurfaces
Smoothing
CAD-compatible Output:
STL or IGES
Slices through
the isosurface
splines
© FE-DESIGN GmbH
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TOSCA.ANSA.environment:
Verification and validation of new conceptual design
Topology
optimization
Automated
validation model:
- Remeshing
- Apply existing
loads
Smoothing;
CAD surfaces
Verification and
documentation
of new
conceptual
design
environment
© FE-DESIGN GmbH
www.fe-design.com
Corporate proprietary
Approval for distributing and copying required
TOSCA Structure - Optimization Types
Images Courtesy
of AUDI AG
Find the design e.g.
with maximum stiffness or
minimum weight
Elements are added/removed
TOSCA.topology
Increase the stiffness or
eigenfrequency of sheet
metal structures
Nodes are moved
TOSCA.bead
Images Courtesy of
Ford Werke AG
Reduce local stresses
and increase the
durability
Nodes are moved
TOSCA.shape
© FE-DESIGN GmbH
www.fe-design.com
Corporate proprietary
Approval for distributing and copying required
Shape Optimization
Design Variables
Coordinates of surface nodes.
Large number of design variables possible
No shape basis vectors and/or morphing required
Just define a node set defining the surface
to be optimized
Position of surface
nodes as design
variables.
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Corporate proprietary
Approval for distributing and copying required
Tosca Structure Shape Optimization
Shape optimization of hubs under
consideration of fatigue influence by
integrating in-house fatigue codes
Shape optimization of the tooth of
gear wheels under consideration of
non-linearities (contact, material)
Shape optimization formulations:
Minimize the maximum stresses of several loadcases.
Minimize damage and increase durability.
Manufacturing constraints.
Enforce a desired mass.
Ansys Modeling:
All contact types allowed
Including geometry non-linearities
All material definitions allowed (including material nonlinearities and non-linear springs)
© FE-DESIGN GmbH
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With TOSCA.shape you do NOT have to define
shape basis vectors
left view right view Design area
Fixed area
No shape basis vectors and/or
morphing required
Just define a node set
defining the surface
to be optimized
Courtesy by Daimler AG
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Shape optimization of a wheel carrier
Simultaneous consideration of all relevant loadcases (normal loadcases and misuse loadcases).The user do not have to chose the most critical loadcase(s) among the total 9 loadcases.
A 20% reduction of the maximum stress reached in only 10 optimization steps.
Nonlinear misuse load cases and contacts can be considered in the optimization.
Courtesy by Daimler AG
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Manufacturing Constraints for Shape Optimization
Stamping/turning constraints
Minimum/maximum member size Casting constraints
r=3r=3
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Drive-train
Main shaft and main bearings
Courtesy by
www.talentfactory.dk
Gearbox
Coupling/shaft
Brake
Controller
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Examples of critical spots on shaft
for stress minimization
Notch stress
Bearing pressure
distribution
Main shaft stress
at curvature
Spherical roller
bearing
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Optimized shape of notch
Stress for original shape Stress for optimized shape
Initial shape
Optimized shape
~300 MPa ~200 MPa
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Shape Optimization for Fatigue: Motivation
Durability analysis is state of the art and allows to consider complex loading histories and detailed material data for simulation
The results of fatige analysis give detailed information on critical zones of cyclic loaded components
Improvement of the components may be achieved by the use of optimization tools
Difficult for the user to know which loadcase is critical as given positions. Solved by the optimization algorithm
Workflow supported for in-house fatigue solvers
Workflow supported for commercial fatigue solvers
Life Solver
Static results
INFLUENCE OF THE STRESS-GRADIENT
Modification of component S/N-curve
S
N
Calculation of an average
stress-gradient over time
a =*
1
a , M i s e s
a
l
x x
y y
z z
x y
y z
x z
t
t
t
t
t
t
Rainflow-counting
of each stress-
tensor-component
A2
A1
t
Calculation of an average
amplitude-tensor over time
and the modified
von Mises-stress a
j k , a =
N
i=1
Ai
N
1
Load history
ST
RE
SS
AM
PL
ITU
DE
(lo
g)
NUMBER OF CYCLES N (log)
Material data
modification
The fatigue problem
Images courtesy
of Magna Steyr Engineering
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Planet carrier shape optimization for durability
Boundaries Loading
Design nodes
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Fatigue shape optimization result
Cross section slice:
Green - original geometry
Braun - optimized geometry
Iter 0:
Damagemax = 1.17
Iter 6:
Damagemax = 0.93
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TOSCA Fluid - Optimization Types
Find the design
with minimized pressure drop
from inlet to outlet
Elements are added/removed
TOSCA.topology
© FE-DESIGN GmbH
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Approval for distributing and copying required
• Meshing “as usual”
Design Space
Topology optimization with TOSCA Fluid
• Define the Design
Space in Fluent
Outflow 1
Outflow 2
Inflow
• Define your
Boundary
Conditions
• Run the
Optimization
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HVAC Flow Splitter Manifold
Behr GmbH & Co. KG
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Topology optimized HVAC Flow Splitter
IN
OUT1
OUT2
Design Space
Optimized Design ProposalDimensions = 0,2 m x 0,14 m x 0,12 m
Boundary Conditions:
Inflow = INLET
Outflow = OUTLET
Fluid AIR
Isothermal
turbulent (Std k-e)
stationary
h = 1.81 · 10-5 kg/(m·s)
r = 1.205 kg/m3
Fluent model:
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Performance of Optimized Flow Splitter
rel. mean Total Pressure Drop
-26,1%
p 26 %
Existing
DesignOptimized
Design
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CAD & Postprocessing
LMS Virtual.Lab
MSC.Patran
ANSYS
ANSA
I-DEAS
FEMAP
MEDINA
Hypermesh
UG NX
and other
CATIA
TOSCA supports the workflow in the
existing CAE-environment
ANSYS
FEA Solver
Optimization
CAD & Preprocessing
LMS Virtual.Lab
MSC.Patran
ANSYS
ANSA
I-DEAS
FEMAP
MEDINA
Hypermesh
UG NX
and other
CATIA
© FE-DESIGN GmbH
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The key notes of TOSCA
Technology
Leadership in technology for optimization by customer focused development and joint strategic research projects
Focus on optimization with non-linear analysis, durability and/or manufacturing constraints
Integration
Support of the workflow in the preferred CAE-environment.
Direct use of existing CAE (e.g. ANSYS WB, ANSYS Classic) models in the optimization.
Pre- and Postprocessing in your familiar CAE environment (e.g. ANSYS WB, ANSYS Classic).
Strong partnership with the leading CAE software vendors.
Performance
Fast, parallel and reliable solver technology guarantees the optimization technology even for very large non-linear models.
Utilization of existing IT investments.
© FE-DESIGN GmbH
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FE-DESIGN
the optimization company
Many thanks for your attention !
For additional questions, material and solutions
for your specific design issues then
contact us directly
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