TOSCA ANSYS Optimization of machine tools · Topology Optimization of Machine Tools to improve the...
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Stand: 28.10.05 EM5/ALH 09.11.05 1 Copyright HELLER Topology Optimization of Machine Tools to improve the Stability in high performing Metal Cutting Processes Gebr. HELLER Maschinenfabrik GmbH Dr. Gerhard Kehl, Harald Altstädter
Transcript of TOSCA ANSYS Optimization of machine tools · Topology Optimization of Machine Tools to improve the...
Stand: 28.10.05 EM5/ALH 09.11.05 1
Copyright HELLER
Topology Optimization of Machine Tools to improve the
Stability in high performing Metal Cutting Processes
Gebr. HELLER Maschinenfabrik GmbHDr. Gerhard Kehl, Harald Altstädter
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Manufacturing Systems for Automotive Industry
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MCH 250 G
MCH 350 GE
MCH 250 C
MCH 250 HSM
Simulation Disciplines at Machine Tools
Static Dynamic
Thermal
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Mechanical Structures in complex Systems
Designspace
Non-Desigarea
2 Volumes
3 Couplings
17 Volumes
12 elastic Couplings
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Modeling of the mechanical Structure for Optimization
+ =
Non-Design Area Designspace Simulation Model
+ =
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Optimization Strategies
Combined Topology Optimizationstatic loads + eigenfrequencies
specific frequency constraints
f1= 60 Hz > f
1*
f2= 90 Hz > f
2*
f3= 120 Hz > f
3*
Static Topology Optimization with weighted load cases (up to now max. 44)
• moving loads (weight)
• acceleration loads (quasi-static)
• process loads
Frequenz
Am
plitu
de
Ausgangsmodell
Opt imierungsergebnis
(Nachgiebigkeitsf requenzgang)
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Initial model for head (Realistic boundary conditions)
Loadcase 1(x-direction)
Flexible beam elements for
boundary conditions
Beam elements
attached
to rigid mass
Loadcase 2 (y-direction)
Beam elements
attached
to rigid mass
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Static optimization
Minimize: Maximize of { abs(ux), abs(uy)}
Mass < Mass* = 35%
Important: the static optimization
showed that the frequency responses also
have to be considered in the optimization.
The rigid mass is no
more
attached to structure !!!!
Number Eigenfrequency
1 ~0
2 ~0
3 ~0
4 2.4
5 3.0
6 3.5
}
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0
0.05
0.1
0.15
0.2
0.25
0.3
0.35
0.4
1 3 5 7 9
11
13
15
17
19
21
23
25
27
29
31
33
35
37
39
41
Frequency optimization
Maximize the eigenfrequencies from f1 to f6
Mass < Mass* = 35%
Mass constraint is not active
Important: Model the correct physical
boundary conditions. The optimization
should include static and frequency results.
Number Eigenfrequency
1 83
2 105
3 112
Shaft hardly attached to structure.
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Combined static and frequency optimization
Purpose: To improve the static stiffness for both loadcases including constraints
on the eigenfrequencies.
Objective: Minimize: Maximize of { abs(ux), abs(uy)}
Constraints: Mass < Mass* = 35%
f1> f
1* = 60 Hz f
1> f
1* = 75 Hz
f2> f
2* = 90 Hz f
2> f
2* = 100 Hz
f3> f
3* = 120 Hz f
3> f
3* = 125 Hz
f4> f
4* = 150 Hz f
4> f
4* = 150 Hz
f5> f
5* = 180 Hz f
5> f
5* = 175 Hz
f6> f
6* = 210 Hz f
6> f
6* = 200 Hz
Example 1
Example 2
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Combined static and frequency optimization: Topology
Example 1:
Number Initial example 1
1 48 60
2 60 90
3 94 137
4 137 181
5 260 256
6 265 345
Example 2:
Number Initial example 2
1 48 75
2 60 101
3 94 145
4 137 191
5 260 268
6 265 377
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Examples for Topology optimized Machine Components
Tool Changer Arm Rod and Plain Eye hydr. Rundtisch Brake
p
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Examples for Topology optimized Machine Components
Machine Stand
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Examples for Topology optimized Machine Components
Machine Stand
Milling and Boring Carriage
