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Easy creation and validation of beads using OptiStruct® and CATIA V5
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Easy creation and validation of beads using OptiStruct® and CATIA V5

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The dimensioning of thin walled parts within automotive construction is highly influenced by Finite Element Analysis and Optimization. The common targets are to improve stiffness or eigenfrequencies …

The dimensioning of thin walled parts within automotive construction is highly influenced by Finite Element Analysis and Optimization. The common targets are to improve stiffness or eigenfrequencies by changing the Finite Element Mesh with a Topography optimization. The results are non-parametric CAD-surfaces which have to be rebuilt in CAD by hand to create parametric geometry. This so called “reverse engineering” is very time consuming for the designer. Within the research project “Automation of optimization tasks inside the construction process of thin walled parts” (funded by BMBF), at the University of Applied Sciences Zwickau (Germany) we have developed a new solution. In association with Volkswagen AG and FES GmbH Zwickau, we created a new workflow which allows easy reverse engineering. Therefore a step by step process is used to create parametric CAD geometry out of distorted Finite Element shapes by using a CATIA User-Feature. The method focus on producibility where the designer themselves can define what the bead looked with respect to optimization results. Validation of the beads effectiveness can be done by using a so called “Hybrid FE-Model”. This consists of two parts, a non-geometry associative FE-Mesh created with HyperMesh® and a geometry associative Mesh created in CAD. Therefore the design cycle is much more efficient what is very beneficial. Nevertheless, our aim is not to create a one-click solution but to support the designer in his daily workflow and to reduce time consuming steps.

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  • 1. Altair Technology Conference, June 24-26, 2014, Munich Dipl.-Ing.(FH) Alexander Krauß 1 Easy creation and validation of beads using OptiStruct ® and CATIA V5 ® The dimensioning of thin walled parts within automotive construction is highly influenced by Finite Element Analysis and Optimization. The common targets are to improve stiffness or eigenfrequencies by changing the Finite Element Mesh with a Topography optimization. The results are non-parametric CAD-Surfaces, which have to be rebuilt by hand to create parametric CAD-Geometry. This so called “reverse engineering” is very time consuming for the designer. Within the research project “Automation of optimization tasks inside the construction process of thin walled parts”, at the University of Applied Sciences Zwickau (Germany), in association with Volkswagen AG and FES GmbH Zwickau, we created a new workflow which allows easy reverse engineering. Therefore a step by step process is used to create parametric CAD geometry out of distorted Finite Element shapes by using a CATIA User-Feature. The method focus on producibility, where the designer themselves can define what the bead looked with respect to optimization results. Validation of the beads effectiveness can be done by using a so called “Hybrid FE-Model”. This consists of two parts, a non-geometry associative FE Mesh created with HyperMesh® and a geometry associative Mesh created in CAD. So the design cycle is much more efficient what a big advantage is. Nevertheless, our aim is not to create a one-click solution, but to support the designer in his daily workflow and to reduce time consuming steps. Alexander Krauß, Christoph Schleicher, Uwe Fischer
  • 2. Altair Technology Conference, June 24-26, 2014, Munich Dipl.-Ing.(FH) Alexander Krauß 2 /1/ Krauß, T., Strobel, T. ; Optimierung strukturdynamischer Kenngrößen, Studienarbeit WH Zwickau, 2013 /1/ /1/ /1/ Producibility Optimization Results COMPROMISE Approximation of the results CAD - Model Introduction - State of the Art
  • 3. Altair Technology Conference, June 24-26, 2014, Munich Dipl.-Ing.(FH) Alexander Krauß 3 1. How can you realize a easy data transfer to CAD? 2. How can you create parametric CAD - geometry with the optimization results? 3. How can you provide a quick validation of the designed beads? Introduction - Problem How can you find a good compromise in a short time?
  • 4. Altair Technology Conference, June 24-26, 2014, Munich Dipl.-Ing.(FH) Alexander Krauß 4 0. Example cover hood Easy data transfer Initial CAD-Model Optimization Results ISO-Surface Optimization of eigenfrequencies with beads (red) Annoying harmonic excitation
  • 5. Altair Technology Conference, June 24-26, 2014, Munich Dipl.-Ing.(FH) Alexander Krauß 5 1. Data transfer . . . Modular STL-Toolbox ISO Surface Imported CAD-Surface STL-Surface (single domain) Filter Smoothing Shape portioning + Rework STL to IGES
  • 6. Altair Technology Conference, June 24-26, 2014, Munich Dipl.-Ing.(FH) Alexander Krauß 6 2. Creation of parametric CAD-Geometry Bead UDFImported CAD-Surface User-Feature (UDF) Catalog Connection to inital surface Contour approximation Parameters Shape approximation
  • 7. Altair Technology Conference, June 24-26, 2014, Munich Dipl.-Ing.(FH) Alexander Krauß 7 2. Creation of parametric CAD-Geometry
  • 8. Altair Technology Conference, June 24-26, 2014, Munich Dipl.-Ing.(FH) Alexander Krauß 8 3. Easy validation with hybrid FE-Models CAD-ModelFE-Optimization model Import into CATIA associative mesh created with CATIA hybrid FE-Model - No-Design Area (red) - Boundary conditions - Parametric area Associative FE-Mesh Imported FE-Mesh CATIA - FE-Model FE-Mesh
  • 9. Altair Technology Conference, June 24-26, 2014, Munich Dipl.-Ing.(FH) Alexander Krauß 9 Eigenfrequencies close to excitation frequency Inital Model FE-Optimization First CAD-design after Optimization Final Design 472Hz 463Hz 486Hz 422Hz 522Hz 594Hz 572Hz 588Hz 4. Optimization of the cover hood Excitation frequency: 515Hz Target: no eigenfrequencies between 465 – 565Hz Eigenfrequencie within restricted zone Eigenfrequencie out of restricted zone
  • 10. Altair Technology Conference, June 24-26, 2014, Munich Dipl.-Ing.(FH) Alexander Krauß 10 Conclusions 1. STL-Shape 2. Datatransfer 3.Bead UDF 4. Validation modification  Quick data transfer and easy management of different optimization results.  Creation of parametric CAD-Features which can be modified to find the best compromise between producibility and approximation of the results.  Easy validation by reusing the optimization FE-Model within a hybrid FE-Model.
  • 11. Altair Technology Conference, June 24-26, 2014, Munich Dipl.-Ing.(FH) Alexander Krauß 11 Contact Dipl.-Ing. (FH) Alexander Krauß Westsächsische Hochschule Zwickau Dr.-Friedrichs-Ring 2a 08056 Zwickau alexander.krauss@fh-zwickau.de Dipl.-Ing. (FH) Christoph Schleicher Westsächsische Hochschule Zwickau Dr.-Friedrichs-Ring 2a 08056 Zwickau christoph.schleicher@fh-zwickau.de Prof. Dr.-Ing. Uwe Fischer Westsächsische Hochschule Zwickau Fakultät Kraftfahrzeugtechnik Dr.-Friedrichs-Ring 2a 08056 Zwickau uwe.fischer@fh-zwickau.de