Application Optimization with TOSCA and ANSYS · PDF fileANSYS Workbench and TOSCA Structure...

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Ansys CADFEM User Meeting 2009

From Setup to automatic Validation– Efficient Structural Optimization with

TOSCA Structure and ANSYS Workbench

ANSYS CADFEM User Meeting 2009

FE-DESIGN GmbH

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Supporting the Product Development Process

Component design in early design phase

Design Improvement

Process Capturing and Process Automation

Data-analysis and Optimization

ProductionPrototypeDesign

ImplementationValidationImprovementConcept

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Integration of TOSCA Structure in theANSYS Environment

• Design spacemodelling

• FEA-Preprocessing

• Validation of FE-Analysis

• OptimizationPreprocessingComponents

CDB File

Batch - Solver Optimization Module

• Postprocessing of smoothedoptimization resuts

• Result transfer to CAD Systems using TOSCA Structure transferfunctionality

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ANSYS WorkbenchDefinition of Named Selections

Volume

TOSCA Structure

Element-Group

TOSCA Structure

Element-Group

Area

Line

Point

TOSCA Structure

Node-Group

TOSCA Structure

Node-Group

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Manufacturing Constraints for Topology Optimization

� Frozen Areas

� Keep Functional Areas

� Symmetry Constraints

� Non symmetric loading

� Symmetry for Manufacturing

� Demoulding Constraint

� Casted components

� Forged Components

� Minimum / Maximum Membersize

� Wallthickness Constraints for Casting

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Generation of Design Space Model in ANSYS Workbench

Mesh Generation and definition of all loadcases

Definition of Named Selections

(to be transferred to TOSCA Structure)

FE-Analysis of maximum design

space model

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Optimization Preprocessing in ANSYS Workbench

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Setup of Topology Optimization Task in TOSCA Structure

Optimization Target

� Minimization of compliance (resp. Maximization of stiffness)

� Target volume = 40% of initial design space

� Casting Constraint (0,0,1) and parting plane

� Frozen Elements in Bearing domain

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Topology Optimization ResultsSmoothing and Generation of Validation Input

Rough Topology

Optimization result Smoothed design

representationSolid Mesh with transferred

boundary conditions for validation run

� Generation of homogenious solid mesh based upon smootheddesign representation

� Consideration of feature lines of initial design space

� Automatic transfer of loadcasesto the validation file

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Generation of Validation Files for TopologyOptimization Results

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Postprocessing of validation resultsin ANSYS Workbench

� Input Files of Smoothed design representation with all loadcase definitions are

automatically generated in TOSCA Structure

� ANSYS Validation run may be executed automatically

� The resulting RST Databases are imported to Workbench for postprocessing

Results of Loadcase 1 Results of Loadcase 2

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Result - Transfer to CAD Systems

1. TOSCA Smooth generates cutting-surfaces through the Smoothed model.

The boundaries of these cutting

splines can be exported as IGES or

STEP Spline information, that may be

read into CAD systems.

2. The patched surfaces may beexported as STL or IGES Faces to be

imported directly to CAD systems.

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Shape Optimizationwith TOSCA Structure Shape

Superimposed

Stresses of

Loadcase 1 & 2

Eqv. Stress Input for Shape Optimization

Optimization Target

� Minimization of maximum von Mises Stress (considering all Loadcases)

� Constant Volume

� Design Space of Topology Optimization must not be exceeded

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Shape OptimizationDesign space and Manufacturing Constraints

Design Area for Shape Optimization Restriction Solids to keep functionality

Surface of Initial design space is used as Restriction surface for Shape Optimization

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Structural Optimization – Design Process withANSYS Workbench and TOSCA Structure

Topology Optimization

Smoothing and Generation

of Validation File

Validation Run

Optimized Design

Geometry

Initial Design

Space Geometry

Finite Element Model

Optimization Model

Shape Optimization

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Conclusions

� The Combination of Topology and Shape Optimization allows to optimize

components considering global stiffnes aims as well as local stresses.

� The Optimization workflow is supported completely including thegeneration of Validation files.

� A fully automatic generation of validation files based upon the smoothed

results from topology optimization is available.

� The optimization process is documented and can be stored in order to

execute it on similar optimization tasks.

� The presented workflow extremely simplifies the Optimization Setup

Application Optimization with TOSCA and ANSYS · PDF fileANSYS Workbench and TOSCA Structure...

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