Contenu connexe Similaire à Reengineering of Topology Optimization Results - Inspire and PolyNURBS (20) Reengineering of Topology Optimization Results - Inspire and PolyNURBS1. 2015 European Altair Technology Conference
September 29 to October 1 | Paris
Technical Seminar
Reengineering of Topology
Optimization
Alejandro Cervantes – cervantes@altair.de
Join, Contribute, Exchange
See full agenda at www.altairatc.com/europe
2. Copyright © 2015 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
• How to be more competitive using high-end technology?
• New manufacturing processes, like ALM, allows high level of design
freedom, which could lead to:
• Cost savings
• Weight savings
• Performance increase
Innovation
Cost
PerformanceWeight
Source: http://www.lzn-hamburg.de/technologien/weitere-
qualifikationen/konstruktion/bionische-gestaltung.html
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Simulation Leading Design
CAD
CAD
CAE CAE
CAD
Defeaturing
Modeling Results
Too late!
Traditional Approach
Time
Design Performance
Maturity
Details
CAD
CAD CAE
CAE
CAD
CAE-Driven Design
Time
Design Performance
Maturity
Details
CAE
Previous Design
CAE
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• Optimization Driven Design process uses a CAE based conceptual
optimization (e.g. topology optimization) to define the best structural
concept upfront (first time right).
• Combined with manufacturing freedom of ALM can dramatically:
• Reduce cost
• Increase performance
• Reduce weight
Optimization Driven Design
Source: http://www.airbusgroup.com/
7. Copyright © 2015 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
• Classical design
• Optimization Driven Design
Design processes
Concept Design
Stress
Analysis
Detailed Sizing
Detailed
Design
PDM/DMU Stress certification Manufacturing
Topology freeze Concept freeze Design freeze
FEM/STRESS CAD/DESIGNERCAD/DESIGNER
Product
Development
Design Stress Optimization
STRESS/OPTIMIZATION
Model
preparation
Conceptual
Optimization
Concept
Interpretation
Concept
Design
Detailed
Optimization
Detailed
Design
PDM/DMU Stress
certification
Manufacturing
Topology freezeConcept freeze Design freeze
CAD CADCAD/OPTIMIZATION OPTIMIZATION STRESS/OPTIMIZATIONCAD/OPTIMIZATION
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• Separation of tools and expertise cause discontinuity of the workflow in
the engineering process.
• Complexity and limitations of tools.
• Subtractive parametric CAD modeling limit the speed of generation and
modification of concepts.
• Design, stress and optimization tools requires an expert on each area to be used
properly.
Optimization Driven Design Today
9. Copyright © 2015 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
• To integrate 3 disciplines (Design, stress and optimization) in a non-
expert, yet robust tool
• State-of-Art Optimization platform (Powered by OptiStruct Optimization).
• State-of-Art Stress platform (Powered by OptiStruct Analysis).
• State-of-Art Design platform (Powered by PolyNURBS).
• Focus
• Ease of use.
• Seamless integration of CAD-CAE.
• Speed.
Solution
10. Copyright © 2015 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
• Aircraft bracket
• Material Aluminum 7075
• 8 fasteners
• 4 load cases
• Current mass: 0.34926 kg
• Max displacement 2.069 mm
• Buckling factor 1.11
Aerospace bracket
11. Copyright © 2015 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
• Topology optimization provides initial concept ideas
• No one-click solution
• Input required to create optimal designs
• Experience
• Engineering criteria
Design Optimization
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Design Optimization
Generate design
variants
• Multiple
optimization
results
Understand
structural behavior
• Abstraction
of structural
principles
Selection winning
design
• Discard
designs
Realize winner
into geometry
• Apply
engineering
principles to
create
geometry
13. Copyright © 2015 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
• Define different optimization settings
• Minimize mass
• Maximize stiffness
• Volume fraction 10%, 15%, 20%....
• Stress constraint
• Displacement constraint
• Manufacturing constraints
• Submit jobs
• Local
• HPC environment
Generating design variants
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• Generating variants
Demo 1
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• Abstract function of the obtained structure.
Understand the function of the design
• Main load path
• Shear members
• Compression/Tension members
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• Compare performance parameters of several designs
• Stiffness
• Mass
• Stress
• Etc…
• Support with raw numbers your idea
Selection of winning idea
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• Understanding structure and Down selection
Demo 2
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• Create a virtual representation (geometry) of the selected design.
• Different methods
• 3D parametric modeling
• Direct modeling
• Mesh
• NURBS
• Hybrid
Realizing designs
"CAD Modeling" by Nicola L.K. - Own work. Licensed under CC BY-SA 3.0 via Commons -
https://commons.wikimedia.org/wiki/File:CAD_Modeling.gif#/media/File:CAD_Modeling.gif
"Freeform1". Licensed under CC BY-SA 3.0 via Commons -
https://commons.wikimedia.org/wiki/File:Freeform1.gif#/media/File:Freeform1.gif
19. Copyright © 2015 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
• Which method suits best?
Realizing a design
Method History tree
(parametric)
Speed/ease
of use
PLM
compatible
Organic
modeling
3D parametric
Direct Mesh
Direct NURBS
Hybrid
K K
20. Copyright © 2015 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
• PolyNURBS is a type of 3D Direct NURBS geometry that can be
generated and modified directly by managing a polygon bounding box
that has 3 different control entities: Points, Edges and Faces.
• Allows easy generation of organic geometries
• Surface continuity (G2 continuity).
PolyNURBS Technology
21. Copyright © 2015 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
• Creating PolyNURBS
Demo
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• PolyNURBS allows quick modifications to test new ideas
• Allows user to learn from experience
• Manual fine tuning optimization effortless
Improving design
Critical area
Test idea
Low stress structure.
Where to remove further
weight?
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• Detailed shape
Demo
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Final result
Design Baseline ALM
Mass (kg) 0.349 0.219 (38%)
Max Displacement
(mm)
2.069 0.91 (57%)
Min Buckling 1.11 3.34 (300%)
25. Copyright © 2015 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
• Optimization driven design is a feasible reality
• Inspire reduces drastically time from concept to a final design
• Simplified processes of design, stress and optimization
• Reduce non added value work
• Reduce repetition of tasks
• Creating topology optimized designs is a time consuming task.
• Traditional tools:
• Require expert users
• Modifications downstream are expensive
• PolyNURBS offers speed, freedom, flexibility and ease of use.
• Perfect tool for organic optimized design
• ALM
• Also for other manufacturing methods
Conclusion
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• Thank you
Questions?