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051805_maug_topology_optimization_presentation.pdf
1.
1 1 www.impactengsol.com ©2005 – IMPACT
Engineering Solutions, Inc. Presented by: Brian King Analysis Project Engineer IMPACT Engineering Solutions, Inc. Tel: 847-599-5635 E-mail: bking@impactengsol.com Topology Optimization in ANSYS
2.
2 2 www.impactengsol.com ©2005 – IMPACT
Engineering Solutions, Inc. 2 About IMPACT… Founded in 1987, IMPACT Engineering Solutions Inc. has grown into a market leader, providing technology based engineering services Focused on solid modeling since 1993 Key IMPACT Product Offerings: Design Support Staff Augmentation Product Simulation Professional Services Analysis Services Division Initiated October 2002 Gurnee, IL Office Opened in November 2003
3.
3 3 www.impactengsol.com ©2005 – IMPACT
Engineering Solutions, Inc. 3 Analysis Capabilities and Expertise COSMOSWorks Structure/Motion Pro/MECHANICA Structure/Motion MSC.NASTRAN / NE/Nastran FEMAP Pre Post-Processing ANSYS CFDesign – CFD Simulation LS-DYNA – Drop and Crash Testing FE-Fatigue (nCode) Durability Analysis Extensive combined engineering analysis experience in a variety of materials and industries
4.
4 4 www.impactengsol.com ©2005 – IMPACT
Engineering Solutions, Inc. 4 What is Topological Optimization? Layout optimization Try to find the best use of material for a body No optimization parameters need to be defined The material distribution function over a body is the optimization parameter The goal (objective function) is to minimize / maximize the energy of structural compliance or maximize the natural frequency while satisfying the constraints specified
5.
5 5 www.impactengsol.com ©2005 – IMPACT
Engineering Solutions, Inc. 5 What is Topological Optimization? The design variables are pseudo-densities Assigned to each finite element Values range from 0 to 1 0 = material to be taken away 1 = material to be kept
6.
6 6 www.impactengsol.com ©2005 – IMPACT
Engineering Solutions, Inc. 6 Main Steps of Optimization Procedure Define the structural problem Select the element types Specify optimized and non-optimized regions Define and control the load cases or frequency extraction Define and control the optimization process Review the results
7.
7 7 www.impactengsol.com ©2005 – IMPACT
Engineering Solutions, Inc. 7 Define the structural problem Define the problem as you would for any linear elastic analysis Single or multiple load case linear structural static analysis Modal frequency analysis Material properties to be defined Young’s modulus Poisson’s ratio Must be between 0.1 and 0.4 Material density if necessary
8.
8 8 www.impactengsol.com ©2005 – IMPACT
Engineering Solutions, Inc. 8 Element Types 2D Planar, 3D Solid, and shell elements are supported 2D Solids: PLANE2, PLANE82 3D Solids: SOLID92, SOLID95 Shells: SHELL93 Only Type 1 elements optimized Used to control which regions of the model to optimize
9.
9 9 www.impactengsol.com ©2005 – IMPACT
Engineering Solutions, Inc. 9 Primary Commands Used TOCOMP Defines single or multiple load cases as topological optimization function for linear static problem TOFREQ Defines single or mean frequency formulation as the topological optimization function for modal analysis TOVAR Specifies objective and constraints
10.
10 10 www.impactengsol.com ©2005 – IMPACT
Engineering Solutions, Inc. 10 Primary Commands Used TOTYPE Specifies solution method for topological optimization TODEF defines the accuracy for the solution TOLOOP Invokes a macro to solve, postprocess, and plot each iteration Process terminates once convergence is attained or the maximum iteration number is reached Up to 100 iterations allowed
11.
11 11 www.impactengsol.com ©2005 – IMPACT
Engineering Solutions, Inc. 11 Workbench vs. ANSYS Optimization Solid parts only in Workbench Topology Opt. Type 1 and Type 2 elements driven by boundary conditions in Workbench Preprocessing commands can change defaults Only Basic Opt from ANSYS is available Single load case Maximize stiffness, reduce volume Preprocessing commands for Advanced Top. Opt.
12.
12 12 www.impactengsol.com ©2005 – IMPACT
Engineering Solutions, Inc. 12 Textbook Problem Vertical Edge Constrained Tx, Ty, Tz = 0 Rx, Ry, Rz = 0 Load Applied to Keypoint at 10° Angle from Vertical Constraint - 60% Volume Reduction
13.
13 13 www.impactengsol.com ©2005 – IMPACT
Engineering Solutions, Inc. 13 Textbook Problem Type 2 Elements Type 1 Elements ANSYS Mesh
14.
14 14 www.impactengsol.com ©2005 – IMPACT
Engineering Solutions, Inc. 14 Textbook Problem Type 2 Elements Type 1 Elements Workbench Default Mesh
15.
15 15 www.impactengsol.com ©2005 – IMPACT
Engineering Solutions, Inc. 15 Textbook Problem Density Plot - Averaged Blue = pseudo-density 0 0.5 Red = pseudo- density 0.5 ≥ 1.0 Density Plot - Unaveraged
16.
16 16 www.impactengsol.com ©2005 – IMPACT
Engineering Solutions, Inc. 16 Textbook Problem ANSYS Density Plot Workbench Density Plot
17.
17 17 www.impactengsol.com ©2005 – IMPACT
Engineering Solutions, Inc. 17 Textbook Problem
18.
18 18 www.impactengsol.com ©2005 – IMPACT
Engineering Solutions, Inc. 18 Textbook Problem
19.
19 19 www.impactengsol.com ©2005 – IMPACT
Engineering Solutions, Inc. 19 Vertical Edges Constrained in Tx, Ty, Tz (Both Sides) Horizontal Edges Constrained in Tx, Ty, Tz (Both Sides) Topology Model – Problem Definition Load applied at 10° from longitudinal Uniform on surface Case Study – Bumper Project
20.
20 20 www.impactengsol.com ©2005 – IMPACT
Engineering Solutions, Inc. 20 Topology Model - Mesh Type 1 Elements Type 2 Elements
21.
21 21 www.impactengsol.com ©2005 – IMPACT
Engineering Solutions, Inc. 21 Density Plots Blue = pseudo-density 0 0.5 Red = pseudo- density 0.5 ≥ 1.0
22.
22 22 www.impactengsol.com ©2005 – IMPACT
Engineering Solutions, Inc. 22 Elements with density 0.5 or greater only Density Plots
23.
23 23 www.impactengsol.com ©2005 – IMPACT
Engineering Solutions, Inc. 23 Vertical Edges Constrained in Tx, Ty, Tz (Both Sides) Horizontal Edges Constrained in Tx, Ty, Tz (Both Sides) Model Created Based on Topology Results
24.
24 24 www.impactengsol.com ©2005 – IMPACT
Engineering Solutions, Inc. 24 Displacement (in) Back Bumper Surface Removed Maximum Principal Stress (psi) Analysis Results
25.
25 25 www.impactengsol.com ©2005 – IMPACT
Engineering Solutions, Inc. 25 363.5 lbs 204.5 lbs New Prototype Current Design Comparison to Current Design 159 lb Difference!
26.
26 26 www.impactengsol.com ©2005 – IMPACT
Engineering Solutions, Inc. 26 Hints and Comments Results are sensitive to the load configuration Results are sensitive to the density of the mesh When a large (80% or greater) volume reduction is requested and a very fine mesh is used a truss-like solution may occur A linear structural static analysis or a modal analysis must be performed during optimization looping Inputs and commands are not saved in the ANSYS database
27.
27 27 www.impactengsol.com ©2005 – IMPACT
Engineering Solutions, Inc. 27 Questions? Contact Information: Brian King Brookfield, WI Office: (262) 317-8118 Gurnee, IL Office: (847) 599-5635 E-mail: bking@impactengsol.com
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