Non-parametric Optimization in your Ansys Environment for Smart Products

Transcription

1 Non-parametric Optimization in your Ansys Environment for Smart Products ANSYS Regional Conference October 25, 2011 Dolce La Hulpe (near Brussels), Belgium Claus B. W. Pedersen and Carsten Gerdes-Götz FE-Design

2 TOSCA Structure - Optimization Types TOSCA.topology TOSCA.shape TOSCA.bead Images Courtesy of AUDI AG Images Courtesy of Ford Werke AG Find the design e.g. with maximum stiffness or minimum weight Elements are added/removed Reduce local stresses and increase the durability Nodes are moved Increase the stiffness or eigenfrequency of sheet metal structures Nodes are moved

3 TOSCA Fluid - Optimization Types TOSCA.topology Find the design with minimized pressure drop from inlet to outlet Elements are added/removed

4 A Rough Classification into two Groups of Optimization Methods Structural Topology Fluid Topology Non-Parametric Methods TOSCA Non-par. Shape Bead Combination of both Groups Parametric Methods ANSYS DesignXplorer Isight Etc. Robustness Reliability DOE & RSM Sizing & par. Shape Geometric Parameter MDO Both groups have their strengths. The right method is dependent on the given optimization-task.

5 FE-DESIGN Locations FE-DESIGN Karlsruhe Development, Sales, Engineering FE-DESIGN Munich Engineering, Sales FE-DESIGN Husum International Sales FE-DESIGN Nordic Development, Sales FE-DESIGN Sofia Engineering, Development

6 FE-DESIGN Your Partner for Structural and CFD optimization Support and Coaching FE-DESIGN combines development and engineering of optimization-methods FE-DESIGN has the ability to deliver best solutions for our customers, benefiting from multi years of experience Our customers improve their optimization processes continuously due to a permanent know-how-transfer with FE-DESIGN Software- Development Engineering, Services, Customization Customers leverage FE-DESIGN s knowledge, embedded in long-term business relationships

7 Global Distribution Partner of FE-DESIGN Scandinavia/UK FE-DESIGN & Partner Taiwan Simutech Japan VINAS USA/Canada SimuTech Group Germany/Austria/Switzerland FE-DESIGN & Partner Turkey CAE Solutions Korea SAMWON Brazil VirtualCAE Czech/Slovakia T.S.E. Russia OOO MES FIGES South-East Asia Dazztech India Enphiniti CAE-CUBE China CAEDA Kingswell FEAonline Road Ahead (Wisdom) FLYOND

8 Customer of FE-DESIGN (extract) Berechnung Nutzfahrzeuge Fahrwerksberechnung Betriebsfestigkeit Pkw

9 TOSCA Structure - Optimization Types TOSCA.topology TOSCA.shape TOSCA.bead Images Courtesy of AUDI AG Images Courtesy of Ford Werke AG Find the design e.g. with maximum stiffness or minimum weight Elements are added/removed Reduce local stresses and increase the durability Nodes are moved Increase the stiffness or eigenfrequency of sheet metal structures Nodes are moved

10 Topology Optimization Example Transverse Link at AUDI With courtesy of AUDI AG

11 Initial Situation A modification of the component was necessary, because the load on the part became too high with the new engines. Topology optimization is used to derive a new structure. With the friendly permission of the AUDI AG

12 Topology Optimization of a Transverse link at AUDI Predecessor design Design space model Topology optimization Redesign Cutting splines

13 Result of topology optimization of a transverse link of the new Audi A8 Images courtesy of AUDI AG

14 Comparison Existing Design New Design Admissible Stress Existing design New design Result: Speed-up of the development process 45 % Stress reduction, 10 % weight reduction The 1st prototype passed all mechanical tests! Weight Max. stress Max. displacement From: VDI Berechnung und Simulation im Automobilbau, Würzburg 2000

15 TOSCA Structure Topology Optimization Ansys Modeling: For linear/nonlinear problems All contact types allowed Geometry non-linearities Material nonlinearities e.g. non-linear springs Optimization formulations: Choice of objective function and multiple constraints: Static load cases: Stiffness, displacements, forces Modal load cases: Eigenfrequencies Mass, COG, Inertia Arbitrary number of loadcases Stiffer Designs Lighter Designs Various manufacturing and symmetry constraints

16 Example: Topology optimization of an engine bracket Feasible design Infeasible design Optimization target: Maximization of the stiffness with a volume constraint of 60% without manufacturing constraints with manufacturing constraints

17 TOSCA.smooth: Export to CAD TOSCA.ANSA.environment: Validation model environment

18 Model - Mesh - Loading Moment and forces Mesh Clamped

19 Optimization setup and design area Optimization target: Maximization of the stiffness with a volume constraint of 60% Chose design-variables in Ansys Workbench

20 Topology Example: Hub A modification of the component is necessary because the load on the part become higher with increase in loads Topology optimization is used to derive a new structure. Front view Back view Optimization target: Maximizing stiffness subject to a volume constraint of 60% Chose designvariables predefined in Ansys

21 Symmetry constraint Enforce 120 degree symmetry

22 Manufacturing constraints No casting constraints Minimum casting member size Casting directions Both minimum casting member size and casting directions Infeasible design Feasible design

23 Topology optimization result Discrete distribution of Young s modulus as optimization result Conversion to continuous distribution using iso-lines Two options after smoothing: Export the results into CAD Generating a validation model

24 Smoothing and CAD export Transfer to CAD: FE-Data (no standard CAD-input) Calculation of Isosurfaces Smoothing CAD-compatible Output: STL or IGES Slices through the isosurface splines

25 TOSCA.ANSA.environment: Verification and validation of new conceptual design Topology optimization Smoothing; CAD surfaces Automated validation model: - Remeshing - Apply existing loads Verification and documentation of new conceptual design environment

26 TOSCA Structure - Optimization Types TOSCA.topology TOSCA.shape TOSCA.bead Images Courtesy of AUDI AG Images Courtesy of Ford Werke AG Find the design e.g. with maximum stiffness or minimum weight Elements are added/removed Reduce local stresses and increase the durability Nodes are moved Increase the stiffness or eigenfrequency of sheet metal structures Nodes are moved

27 Shape Optimization Design Variables Coordinates of surface nodes. Large number of design variables possible Position of surface nodes as design variables. No shape basis vectors and/or morphing required Just define a node set defining the surface to be optimized

28 Tosca Structure Shape Optimization Shape optimization formulations: Minimize the maximum stresses of several loadcases. Minimize damage and increase durability. Manufacturing constraints. Enforce a desired mass. Shape optimization of hubs under consideration of fatigue influence by integrating in-house fatigue codes Ansys Modeling: All contact types allowed Including geometry non-linearities All material definitions allowed (including material nonlinearities and non-linear springs) Shape optimization of the tooth of gear wheels under consideration of non-linearities (contact, material)

29 With TOSCA.shape you do NOT have to define shape basis vectors left view right view Design area Fixed area No shape basis vectors and/or morphing required Just define a node set defining the surface to be optimized Courtesy by Daimler AG

30 Shape optimization of a wheel carrier Simultaneous consideration of all relevant loadcases (normal loadcases and misuse loadcases). The user do not have to chose the most critical loadcase(s) among the total 9 loadcases. A 20% reduction of the maximum stress reached in only 10 optimization steps. Nonlinear misuse load cases and contacts can be considered in the optimization. Courtesy by Daimler AG

31 Manufacturing Constraints for Shape Optimization Minimum/maximum member size Casting constraints r=3 r=3 Stamping/turning constraints

32 Drive-train Controller Main shaft and main bearings Brake Gearbox Coupling/shaft Courtesy by

33 Examples of critical spots on shaft for stress minimization Notch stress Main shaft stress at curvature Bearing pressure distribution Spherical roller bearing

34 Optimized shape of notch Optimized shape Initial shape Stress for original shape Stress for optimized shape ~300 MPa ~200 MPa

35 x x y y z z x y y z x z Shape Optimization for Fatigue: Motivation Durability analysis is state of the art and allows to consider complex loading histories and detailed material data for simulation The results of fatige analysis give detailed information on critical zones of cyclic loaded components Improvement of the components may be achieved by the use of optimization tools Static results The fatigue problem Load history INFLUENCE OF THE ST Modification of component S/N-curve S t t t t t t STRESS AMPLITUDE (log) Material data Rainflow-count of each stresstensor-compone A 1 NUMBER OF CYCLES N (log) A 2 Difficult for the user to know which loadcase is critical as given positions. Solved by the optimization algorithm Life Solver N Workflow supported for in-house fatigue solvers Workflow supported for commercial fatigue solvers modification Images courtesy of Magna Steyr Engineering

36 Planet carrier shape optimization for durability Boundaries Loading Design nodes

37 Fatigue shape optimization result Iter 0: Damagemax = 1.17 Iter 6: Damagemax = 0.93 Cross section slice: Green - original geometry Braun - optimized geometry

38 TOSCA Fluid - Optimization Types TOSCA.topology Find the design with minimized pressure drop from inlet to outlet Elements are added/removed

39 Topology optimization with TOSCA Fluid Outflow 1 Outflow 2 Define the Design Space in Fluent Meshing as usual Define your Boundary Conditions Run the Optimization Inflow Design Space

40 HVAC Flow Splitter Manifold Behr GmbH & Co. KG

41 Topology optimized HVAC Flow Splitter Fluent model: Dimensions = 0,2 m x 0,14 m x 0,12 m Boundary Conditions: Inflow = INLET Outflow = OUTLET Fluid AIR Isothermal turbulent (Std k-e) stationary h = kg/(m s) r = kg/m 3 Optimized Design Proposal OUT2 OUT1 IN Design Space

42 Performance of Optimized Flow Splitter rel. mean Total Pressure Drop p 26 % -26,1% Existing Design Optimized Design

43 TOSCA supports the workflow in the existing CAE-environment CAD & Preprocessing ANSYS CATIA ANSA LMS Virtual.Lab FEMAP Hypermesh I-DEAS MEDINA MSC.Patran UG NX and other FEA Solver ANSYS Optimization CAD & Postprocessing ANSYS CATIA ANSA LMS Virtual.Lab FEMAP Hypermesh I-DEAS MEDINA MSC.Patran UG NX and other

44 The key notes of TOSCA Technology Leadership in technology for optimization by customer focused development and joint strategic research projects Focus on optimization with non-linear analysis, durability and/or manufacturing constraints Integration Support of the workflow in the preferred CAE-environment. Direct use of existing CAE (e.g. ANSYS WB, ANSYS Classic) models in the optimization. Pre- and Postprocessing in your familiar CAE environment (e.g. ANSYS WB, ANSYS Classic). Strong partnership with the leading CAE software vendors. Performance Fast, parallel and reliable solver technology guarantees the optimization technology even for very large non-linear models. Utilization of existing IT investments.

45 FE-DESIGN the optimization company Many thanks for your attention! For additional questions, material and solutions for your specific design issues then contact us directly