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© FE-DESIGN GmbH
www.fe-design.com
Corporate proprietary
Approval for distributing and copying required
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
© FE-DESIGN GmbH
www.fe-design.com
Corporate proprietary
Approval for distributing and copying required
Ansys CADFEM User Meeting 2009
Supporting the Product Development Process
Component design in early design phase
Design Improvement
Process Capturing and Process Automation
Data-analysis and Optimization
ProductionPrototypeDesign
ImplementationValidationImprovementConcept
© FE-DESIGN GmbH
www.fe-design.com
Corporate proprietary
Approval for distributing and copying required
Ansys CADFEM User Meeting 2009
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
© FE-DESIGN GmbH
www.fe-design.com
Corporate proprietary
Approval for distributing and copying required
Ansys CADFEM User Meeting 2009
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
© FE-DESIGN GmbH
www.fe-design.com
Corporate proprietary
Approval for distributing and copying required
Ansys CADFEM User Meeting 2009
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
© FE-DESIGN GmbH
www.fe-design.com
Corporate proprietary
Approval for distributing and copying required
Ansys CADFEM User Meeting 2009
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
© FE-DESIGN GmbH
www.fe-design.com
Corporate proprietary
Approval for distributing and copying required
Ansys CADFEM User Meeting 2009
Optimization Preprocessing in ANSYS Workbench
© FE-DESIGN GmbH
www.fe-design.com
Corporate proprietary
Approval for distributing and copying required
Ansys CADFEM User Meeting 2009
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
© FE-DESIGN GmbH
www.fe-design.com
Corporate proprietary
Approval for distributing and copying required
Ansys CADFEM User Meeting 2009
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
© FE-DESIGN GmbH
www.fe-design.com
Corporate proprietary
Approval for distributing and copying required
Ansys CADFEM User Meeting 2009
Generation of Validation Files for TopologyOptimization Results
© FE-DESIGN GmbH
www.fe-design.com
Corporate proprietary
Approval for distributing and copying required
Ansys CADFEM User Meeting 2009
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
© FE-DESIGN GmbH
www.fe-design.com
Corporate proprietary
Approval for distributing and copying required
Ansys CADFEM User Meeting 2009
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.
© FE-DESIGN GmbH
www.fe-design.com
Corporate proprietary
Approval for distributing and copying required
Ansys CADFEM User Meeting 2009
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
© FE-DESIGN GmbH
www.fe-design.com
Corporate proprietary
Approval for distributing and copying required
Ansys CADFEM User Meeting 2009
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
© FE-DESIGN GmbH
www.fe-design.com
Corporate proprietary
Approval for distributing and copying required
Ansys CADFEM User Meeting 2009
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
© FE-DESIGN GmbH
www.fe-design.com
Corporate proprietary
Approval for distributing and copying required
Ansys CADFEM User Meeting 2009
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