Non-parametric Optimization in your Ansys Environment · PDF fileNon-parametric Optimization...

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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

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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

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TOSCA Fluid - Optimization Types

Find the design

with minimized pressure drop

from inlet to outlet


TOSCA.topology

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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

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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

www.fe-design.com

http://www.mes-online.ru/



http://www.vinas.com/

http://www.fe-design.com/


http://www.figes.com.tr/

http://www.virtualcae.com.br/

http://www.virtualcae.com.br/




http://www.techsoft-eng.cz/



http://www.vtcasia.com/

http://www.caeda.com.cn/





http://www.rat.com.tw/

http://www.flyond.com/

http://www.vtcasia.com/

http://www.simutechgroup.com/

http://www.cae.co.kr/



http://www.cae-cube.co.kr/









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Customer of FE-DESIGN (extract)

Fahrwerksberechnung Betriebsfestigkeit Pkw

Berechnung Nutzfahrzeuge

..\..\..\..\..\..\Kontakte\Kunden_Interessenten_Partner\Kontakte\Kunden_Interessenten_Partner\S-Z\ZF\2005-01-28_Meeting-ZF_Friedrichshafen\tosca_topo_crash_FED_CONFIDENTIAL_de.ppt

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Images Courtesy

of AUDI AG



minimum weight


TOSCA.topology



metal structures

Nodes are moved

TOSCA.bead

Images Courtesy of

Ford Werke AG


and increase the

durability

Nodes are moved

TOSCA.shape

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Topology Optimization Example

Transverse Link at AUDI

With courtesy of AUDI AG

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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

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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

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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

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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


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.


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

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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

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Images Courtesy

of AUDI AG



minimum weight


TOSCA.topology



metal structures

Nodes are moved

TOSCA.bead

Images Courtesy of

Ford Werke AG


and increase the

durability

Nodes are moved

TOSCA.shape

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www.fe-design.com



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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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)

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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


TOSCA.topology

© FE-DESIGN GmbH

www.fe-design.com



• 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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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

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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.

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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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