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Virtual engineering in lightweight design
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het collectief centrum van de Belgische technologische industrie
Virtual engineering in lightweight designBart Teerlinck
Virtual Engineering
driving industry by virtuality
Content
• Virtual engineering • Design• Topology optimization• Shape optimization• Manufacturing• Sirris Virtual Engineering
04/10/2011© sirris 2007 | www.sirris.be | [email protected] | 2
What is virtual engineering
Virtual engineering will become a key technology in the industry. No other technology has more potential to improve your product design or optimize the efficiency of your proces (study from Vlaamse raad voor Wetenschapsbeleid)
• Detailed insight • Relatively low cost• Short lead time• Window of opportunities
© sirris 2007 | www.sirris.be | [email protected] | 304/10/2011
The power of virtual engineering
© sirris 2007 | www.sirris.be | [email protected] | 404/10/2011
The power of virtual engineering (ctd.)
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Classical design rules and finite elements
• For complex geometries the implementation of classical design rules is fairly impossible.
• Classical design rules lead to oversizing• The weight is not in the right place => Software support
• Finite element tools can offer the solution• Knowledge of stresses facilitates the improvement of a geometry
• Design errors are revealed and excess material can be removed • Design changes are easily evaluated • Physical prototypes are not needed.
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Importance of good design
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Costs of repairing a design errorincrease exponentialy with time before it is discovered
Types of structural optimization
© sirris 2007 | www.sirris.be | [email protected] | 804/10/2011
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Manual parametric optimization of a tower crane.
• with a small increase in material realize a 33% increase in capacity• thickness of plates are parameter for optimization
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The theory of non- parametric topologyoptimization
• Goal: given a predefined domain space (2D or 3D) with boundary conditions and load definitions, distribute a given mass (as % of initial mass) such that a global measure takes a minimum (max.)
© sirris 2007 | www.sirris.be | [email protected] | 1004/10/2011
Types of objective responses
• Displacements (stiffness)• Volume of material• Strain energy• Moments of inertia• Eigenfrequencies• Reaction forces/moments• Acoustics• …
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movie
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Case: manual topology optimization of support
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Automatic topology optimization of support
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Comparaison of optimization results
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Topology optim. of windturbine main frame
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Automated design of structural parts: topology versus shape optimization
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Topology optimization Shape optimization
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Topology versus shape optimization
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TOPOLOGY OPTIMIZATION
SHAPE OPTIMIZATION
Courtesy of
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Shape optimization of a notch in a shaft
© sirris 2007 | www.sirris.be | [email protected] | 1804/10/2011
Manufacturing and design
• Automated design tools generate in general doubly curved shapes• Freedom of shape in manufacturing is necessary
• Generated shapes by automated tools need to be instructed to take manufacturing constraints into account
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(Bron: JEC Composites)
Typical manufacturing constraints
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From weld to near net shape manufacturing
Design space
Final casted part: 29% saving
Original welded support Topology optimisation
Casting simulation
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The cost of virtual engineering
Hardware: 3000 ~ 7000 € /year
Software: 10000€ ~ 25000€ /year
Engineer: ... € / jaar (min. 50% time on engineering simulations) + CAD-engineers
=> Invest or outsource ?
04/10/2011© sirris 2007 | www.sirris.be | [email protected] |
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Conclusions
• Optimization tools have a large potential for lightweight design
• Maximal strength/fatigue resistance at a minimal weight
• Will make the difference in the near future for the structural functionality of products
• Residual stresses due to the production should be taken into account.
• A boundary condition is the assumption of an error free production• Eg. no shrinkage in a casting - no air inclusions in composites• Consider tolerances of proces and material
• Are relatively expensive for SME’s( ca. 100 kEur/jr )
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Sirris Virtual Engineering
• Offering “Engineering Solutions”
• Strongly integrated within other SIRRIS expertises (SMALL lab, SLC lab)
• Close collaboration with universities and third parties
• www.sirris.be/virtual_engineering
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SIRRIS Virtual Engineering Private Sessions
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• Expensive prototypes
or test environment?
• Long time to market?
• Trial and error?
• Quantative output?
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Closure
"Nobody trusts a computer simulation except the guy who did it, and everybody trusts experimental data, except the guy who did it.“
Thank you for your attention
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