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Matthew Hopkins, Ann-Marie Lambert

Tortworth Court, South Gloucestershire

SIMULIA Tutorial

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Agenda

• ATOM – Abaqus Topology Optimisation Module

• Introduction and demonstration

• Latest Enhancements in Abaqus/CAE

• A summary of enhancements and demonstration

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Abaqus Topology Optimisation Module (ATOM)

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ATOM

• What is ATOM?

• ATOM stands for Abaqus Topology Optimization Module

• It allows for convenient setup and postprocessing of two classes of

Structural optimization problems

1. Topology optimization

2. Shape Optimization

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Topology Optimization

• Given an initial material distribution (left), topology optimization produces

a new landscape (right) by scaling the relative densities of the elements

in the design domain.

• Elements with large relative densities are retained whilst those

elements whose relative densities have become sufficiently small

are assumed to be voids. Thus a new “landscape” is obtained.

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Shape Optimization

• Shape optimization refers to procedures that result in the prediction of a

boundary (or shape) of the design domain of the structural/mechanical system

to be optimized.

• In a finite element analysis, nodes on the boundary are displaced in order

to achieve an objective (minimise the stress on the surface for example).

• Thus, a new shape is obtained.

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ATOM

• Both Topology and Shape Optimisation support:

• Contact

• Geometric non-linearity

• Nonlinear Materials:

• Within the design area: *plastic, *hypoelastic, most *hyperelastic

• Outside design area: all

• Manufacturing restrictions

• Export smoothed shape to STL or INP

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ATOM Workflow: Setup

• The flow chart on the left shows the user

actions required to setup the optimization

• Each user action is associated with a

manager in the Optimization module

accessible from the Optimization

Module Toolbox or the Model Tree

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ATOM: Basic Terminology

• Design Responses provide variables for the optimization

solver

• For example: Strain Energy, Displacement etc.

• Objective Functions define how those

Design Responses should be used

(sum/min/max/formula/etc)

• Minimise Strain Energy (maximise stiffness)

• Constraints determine bounds for the optimization solver

• For example: Constraint the volume to be less than

35% of the original volume

• Geometric Restrictions provide for manufacturing

restrictions

• For example: de-molding direction with draft angle

• Stop conditions

• Maximum number of iterations

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ATOM Workflow: Execution and Monitoring

• Once an Optimization Task is setup, an Optimization Process needs to be defined to execute the optimization

• Users may have multiple Abaqus models and optimization tasks defined. An optimization process refers to a unique Model and Task combination.

• Right-click on the optimization process to access: Validate, Submit, Restart, Monitor, Extract and Results postprocessing

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ATOM Workflow: Results

• The Abaqus Visualization module allows for convenient visualization of optimization results

• Postprocessing will be shown in more detail during the demonstration

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ATOM Workflow: Extraction

• Optimization

results can be

smoothed and then

extracted as

Abaqus input files

or STL files

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SIMULIA’s Design Exploration and Optimization Tools

ATOM Isight

Tuned for topology and shape

optimization

A general purpose design exploration

and optimization package

Non parametric Parametric

Can handle a very large number of

design variables. (~100K-1000K)

Meant for small number of design

variables(~10-100)

Multiple objectives are summed up to

single objective

Multi-objective, multi-discipline

optimizations possible

ATOM Isight

DOE

Monte Carlo

Exporation

Taguchi RD

Six Sigma

Optimization

Topology

optimization

Shape

optimization

Test Data

Match

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Optimisation of a Brake Pedal

Demonstration

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ATOM Brake Pedal Demonstration

• Linear elastic Steel material

• Nonlinear Geometry

• Loading causes out of plane warping effects

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ATOM Brake Pedal Demo

• Objectives

• To maximise the stiffness (minimise Strain Energy)

• Constraints

• Final volume <=40% of original volume

• Lateral Displacement <=2mm

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Leveraging the Latest Enhancements

in Abaqus/CAE

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Summary

• CAD Interfaces

• Demonstration: CATIA V5 bidirectional

• Midsurfacing and meshing

• Demonstration

• Results visualisation

• Demonstration: Contour of beam stresses

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CATIA V5 Bidirectional Associative Interface

Abaqus 6.10-EF

One directional associatively for

• CATIA V5

• SolidWorks

• Pro/ENGINEER (Wildfire)

• UG NX

Bidirectional associatively for

• Pro/ENGINEER (Wildfire)

New in 6.11

• Bidirectional associative interface for

CATIA V5

• Both R19 & R20 version

• CATIA parameters can be modified from

within Abaqus/CAE

• Model is updated in Abaqus/CAE.

CAD geometry and parameters

exported to Abaqus/CAE

Updated parameters

export to CATIA V5

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CATIA V5 Bidirectional Associative Interface

Create/Define Parameters in CATIA V5

• Parameters defined in CATIA with “ABQ_” prefix are exported

• Parameters should be defined at part level

• Only Real, Integer, Length and Angle type parameters with single value are

supported.

• User parameters will appear in the specification tree under “Parameters”

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CATIA V5 Bidirectional Associative Interface

Exporting the Geometry and Parameters from CATIA

1) Ensure that CATIA V5 connection is enabled

2) In CATIA, use Abaqus plug-in or Abaqus/CAE icon to export the model.

3) CATIA writes a parameter file(.par_abq) and exchange (.eaf) file.

4) Parameter file is xml based

• Contains parts and parameters information

Quick Export Menu which allows user to set/change the

export option and export the model

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CATIA V5 Bidirectional Associative Interface

Viewing/Modifying parameters

• Parameters can be viewed in

Part/Assembly module.

• In the Part module, /CAE will

display parameters of active

part only.

• In the assembly level, /CAE

will display parameters of all

the parts in the assembly.

• In Part module use,

ToolsCAD Parameters…

• In the Part module use

ToolsCAD InterfacesCAD

Parameters…

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CATIA V5 Bidirectional Associative Interface

Viewing/Modifying parameters

• Selecting a row in CAD

Parameters dialog will highlight

the geometric faces associated

the selected parameter.

• To modify the values from

/CAE, change one or more

parameters values and click

update.

• “Update” will propagate the

changes to the CATIA model

and re-export the model to

/CAE.

• /CAE will regenerate the

assembly/part.

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CATIA V5 Bidirectional Interface

Demonstration

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Midsurfacing and Meshing

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Mid-surfacing

• Manually create mid-surface representation

of thin solids using geometry edit tools:

• Face offset

• Face extend/blend

• Auto-trim

• Benefits beyond mid-surfacing

• Mechanism for capturing thickness of

parent solid geometry and association with

shell mesh.

• Thickness query and display tools

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Mid-surfacing

• Examples: Wheel hub (shown with view cut)

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Mid-surfacing enhancements

• Reduce picking needed to create mid-surface

• Improved robustness

• Offset operation performance

• Feature regeneration

• New tool for partitioning faces by edge projection

• Enhanced heuristics for Extend and Blend geometry tools

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Midsurfacing Enhancements

Auto-selection of Target Faces

• Selection of target faces can be time-consuming

• Option to automatically select target faces based on proximity

• Manual modification of selection

• Available only if faces being offset belong to reference representation

Target faces auto-selected

Source face to be offset

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Midsurfacing Enhancements

Option to Extend Target Faces Before Trimming

• Using target faces to limit extension is a useful way to fill gaps between

neighboring shell faces

• Target faces may sometimes need to be extended (internally) for the

purposes of trimming the selected faces

• Allows user to decide whether to extend target faces

• OFF by default. Turn ON only when needed

Target face needs to be

extended for trimming

Extend

target

face

Target face need not

be extended

Selected face

being extended

Target face

gap

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Midsurfacing Enhancements

Thickness Attributes on Faces Created by Blend/Cover

• Faces created by Blend or Cover will have thickness automatically assigned to

them if the neighboring faces have thickness attributes

2 Offset Faces Thickness data on

the Offset Faces

New blend face with

thickness inherited

from neighbors

GUI to verify

assigned thickness

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Mesh Editing

• New mesh edit functions

• Merge/subdivide elements

• Grow/collapse short element edges

• Bottom-up meshing

• Now available for orphan meshes

• Generate elements by offsetting

• Additional options for extrude method

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Midsurfacing and Meshing

Demonstration

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Results Visualisation

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Contour of beam stresses

• New field output identifier

“BEAM_STRESS”

• Mises = Von Mises stress

• S11 = Axial stress

• S12 = Shear stress along local

beam section 2-axis

• S13 = Shear stress along the

local beam section 1-axis

• Stress distributions derived using

section/moment values from

linear elastic beam theory

• SF (section force) and SM (section

moment) required

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Beam Contouring Demonstration

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Presented at the

2011 SIMULIA UK RUM

Leveraging the Latest Enhancements

in Abaqus/CAE