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www.impactengsol.com
©2005 – IMPACT Engineering Solutions, Inc.
Presented by:
Brian King
Analysis Project Engineer
IMPACT Engineering Solutions, Inc.
Tel: 847-599-5635
E-mail: bking@impactengsol.com
Topology Optimization in ANSYS
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2
www.impactengsol.com
©2005 – IMPACT Engineering Solutions, Inc. 2
About IMPACT…
 Founded in 1987, IMPACT Engineering Solutions Inc. has grown
into a market leader, providing technology based engineering
services
 Focused on solid modeling since 1993
 Key IMPACT Product Offerings:
 Design Support
 Staff Augmentation
 Product Simulation
 Professional Services
 Analysis Services Division Initiated October 2002
 Gurnee, IL Office Opened in November 2003
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www.impactengsol.com
©2005 – IMPACT Engineering Solutions, Inc. 3
Analysis Capabilities and Expertise
 COSMOSWorks Structure/Motion
 Pro/MECHANICA Structure/Motion
 MSC.NASTRAN / NE/Nastran
 FEMAP Pre  Post-Processing
 ANSYS
 CFDesign – CFD Simulation
 LS-DYNA – Drop and Crash Testing
 FE-Fatigue (nCode) Durability Analysis
Extensive combined engineering analysis experience in a variety of
materials and industries
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www.impactengsol.com
©2005 – IMPACT Engineering Solutions, Inc. 4
What is Topological Optimization?
 Layout optimization
 Try to find the best use of material for a body
 No optimization parameters need to be defined
 The material distribution function over a body is the
optimization parameter
 The goal (objective function) is to minimize /
maximize the energy of structural compliance or
maximize the natural frequency while satisfying the
constraints specified
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www.impactengsol.com
©2005 – IMPACT Engineering Solutions, Inc. 5
What is Topological Optimization?
 The design variables are pseudo-densities
 Assigned to each finite element
 Values range from 0 to 1
 0 = material to be taken away
 1 = material to be kept
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©2005 – IMPACT Engineering Solutions, Inc. 6
Main Steps of Optimization Procedure
 Define the structural problem
 Select the element types
 Specify optimized and non-optimized regions
 Define and control the load cases or frequency
extraction
 Define and control the optimization process
 Review the results
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©2005 – IMPACT Engineering Solutions, Inc. 7
Define the structural problem
 Define the problem as you would for any linear
elastic analysis
 Single or multiple load case linear structural static analysis
 Modal frequency analysis
 Material properties to be defined
 Young’s modulus
 Poisson’s ratio
 Must be between 0.1 and 0.4
 Material density if necessary
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www.impactengsol.com
©2005 – IMPACT Engineering Solutions, Inc. 8
Element Types
 2D Planar, 3D Solid, and shell
elements are supported
 2D Solids: PLANE2, PLANE82
 3D Solids: SOLID92, SOLID95
 Shells: SHELL93
 Only Type 1 elements optimized
 Used to control which regions of the model to optimize
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©2005 – IMPACT Engineering Solutions, Inc. 9
Primary Commands Used
 TOCOMP
 Defines single or multiple load
cases as topological optimization
function for linear static problem
 TOFREQ
 Defines single or mean frequency
formulation as the topological
optimization function for modal
analysis
 TOVAR
 Specifies objective and
constraints
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www.impactengsol.com
©2005 – IMPACT Engineering Solutions, Inc. 10
Primary Commands Used
 TOTYPE
 Specifies solution method for
topological optimization
 TODEF
 defines the accuracy for the
solution
 TOLOOP
 Invokes a macro to solve, postprocess, and plot each iteration
 Process terminates once convergence is attained or the maximum iteration
number is reached
 Up to 100 iterations allowed
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©2005 – IMPACT Engineering Solutions, Inc. 11
Workbench vs. ANSYS Optimization
 Solid parts only in Workbench Topology Opt.
 Type 1 and Type 2 elements driven by boundary
conditions in Workbench
 Preprocessing commands can change defaults
 Only Basic Opt from ANSYS is available
 Single load case
 Maximize stiffness, reduce volume
 Preprocessing commands for Advanced Top. Opt.
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www.impactengsol.com
©2005 – IMPACT Engineering Solutions, Inc. 12
Textbook Problem
Vertical Edge
Constrained
Tx, Ty, Tz = 0
Rx, Ry, Rz = 0
Load Applied to
Keypoint at 10°
Angle from Vertical
Constraint - 60%
Volume Reduction
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www.impactengsol.com
©2005 – IMPACT Engineering Solutions, Inc. 13
Textbook Problem
Type 2 Elements
Type 1 Elements
ANSYS Mesh
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©2005 – IMPACT Engineering Solutions, Inc. 14
Textbook Problem
Type 2 Elements
Type 1 Elements
Workbench Default Mesh
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www.impactengsol.com
©2005 – IMPACT Engineering Solutions, Inc. 15
Textbook Problem
Density Plot - Averaged
Blue = pseudo-density 0  0.5
Red = pseudo- density 0.5 ≥ 1.0
Density Plot - Unaveraged
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www.impactengsol.com
©2005 – IMPACT Engineering Solutions, Inc. 16
Textbook Problem
ANSYS Density Plot Workbench Density Plot
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©2005 – IMPACT Engineering Solutions, Inc. 17
Textbook Problem
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©2005 – IMPACT Engineering Solutions, Inc. 18
Textbook Problem
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www.impactengsol.com
©2005 – IMPACT Engineering Solutions, Inc. 19
Vertical Edges
Constrained in
Tx, Ty, Tz
(Both Sides)
Horizontal Edges
Constrained in
Tx, Ty, Tz
(Both Sides)
Topology Model – Problem Definition
Load applied at 10° from longitudinal
Uniform on surface
Case Study – Bumper Project
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www.impactengsol.com
©2005 – IMPACT Engineering Solutions, Inc. 20
Topology Model - Mesh
Type 1 Elements
Type 2 Elements
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www.impactengsol.com
©2005 – IMPACT Engineering Solutions, Inc. 21
Density Plots
Blue = pseudo-density 0  0.5
Red = pseudo- density 0.5 ≥ 1.0
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www.impactengsol.com
©2005 – IMPACT Engineering Solutions, Inc. 22
Elements with density 0.5 or greater only
Density Plots
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©2005 – IMPACT Engineering Solutions, Inc. 23
Vertical Edges
Constrained in
Tx, Ty, Tz
(Both Sides)
Horizontal Edges
Constrained in
Tx, Ty, Tz
(Both Sides)
Model Created Based on Topology Results
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www.impactengsol.com
©2005 – IMPACT Engineering Solutions, Inc. 24
Displacement (in)
Back Bumper
Surface Removed
Maximum Principal Stress (psi)
Analysis Results
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www.impactengsol.com
©2005 – IMPACT Engineering Solutions, Inc. 25
363.5 lbs
204.5 lbs
New Prototype Current Design
Comparison to Current Design
159 lb Difference!
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www.impactengsol.com
©2005 – IMPACT Engineering Solutions, Inc. 26
Hints and Comments
 Results are sensitive to the load configuration
 Results are sensitive to the density of the mesh
 When a large (80% or greater) volume reduction is
requested and a very fine mesh is used a truss-like
solution may occur
 A linear structural static analysis or a modal analysis must
be performed during optimization looping
 Inputs and commands are not saved in the ANSYS
database
27
27
www.impactengsol.com
©2005 – IMPACT Engineering Solutions, Inc. 27
Questions?
Contact Information:
Brian King
Brookfield, WI Office: (262) 317-8118
Gurnee, IL Office: (847) 599-5635
E-mail: bking@impactengsol.com

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051805_maug_topology_optimization_presentation.pdf

  • 1. 1 1 www.impactengsol.com ©2005 – IMPACT Engineering Solutions, Inc. Presented by: Brian King Analysis Project Engineer IMPACT Engineering Solutions, Inc. Tel: 847-599-5635 E-mail: bking@impactengsol.com Topology Optimization in ANSYS
  • 2. 2 2 www.impactengsol.com ©2005 – IMPACT Engineering Solutions, Inc. 2 About IMPACT… Founded in 1987, IMPACT Engineering Solutions Inc. has grown into a market leader, providing technology based engineering services Focused on solid modeling since 1993 Key IMPACT Product Offerings: Design Support Staff Augmentation Product Simulation Professional Services Analysis Services Division Initiated October 2002 Gurnee, IL Office Opened in November 2003
  • 3. 3 3 www.impactengsol.com ©2005 – IMPACT Engineering Solutions, Inc. 3 Analysis Capabilities and Expertise COSMOSWorks Structure/Motion Pro/MECHANICA Structure/Motion MSC.NASTRAN / NE/Nastran FEMAP Pre Post-Processing ANSYS CFDesign – CFD Simulation LS-DYNA – Drop and Crash Testing FE-Fatigue (nCode) Durability Analysis Extensive combined engineering analysis experience in a variety of materials and industries
  • 4. 4 4 www.impactengsol.com ©2005 – IMPACT Engineering Solutions, Inc. 4 What is Topological Optimization? Layout optimization Try to find the best use of material for a body No optimization parameters need to be defined The material distribution function over a body is the optimization parameter The goal (objective function) is to minimize / maximize the energy of structural compliance or maximize the natural frequency while satisfying the constraints specified
  • 5. 5 5 www.impactengsol.com ©2005 – IMPACT Engineering Solutions, Inc. 5 What is Topological Optimization? The design variables are pseudo-densities Assigned to each finite element Values range from 0 to 1 0 = material to be taken away 1 = material to be kept
  • 6. 6 6 www.impactengsol.com ©2005 – IMPACT Engineering Solutions, Inc. 6 Main Steps of Optimization Procedure Define the structural problem Select the element types Specify optimized and non-optimized regions Define and control the load cases or frequency extraction Define and control the optimization process Review the results
  • 7. 7 7 www.impactengsol.com ©2005 – IMPACT Engineering Solutions, Inc. 7 Define the structural problem Define the problem as you would for any linear elastic analysis Single or multiple load case linear structural static analysis Modal frequency analysis Material properties to be defined Young’s modulus Poisson’s ratio Must be between 0.1 and 0.4 Material density if necessary
  • 8. 8 8 www.impactengsol.com ©2005 – IMPACT Engineering Solutions, Inc. 8 Element Types 2D Planar, 3D Solid, and shell elements are supported 2D Solids: PLANE2, PLANE82 3D Solids: SOLID92, SOLID95 Shells: SHELL93 Only Type 1 elements optimized Used to control which regions of the model to optimize
  • 9. 9 9 www.impactengsol.com ©2005 – IMPACT Engineering Solutions, Inc. 9 Primary Commands Used TOCOMP Defines single or multiple load cases as topological optimization function for linear static problem TOFREQ Defines single or mean frequency formulation as the topological optimization function for modal analysis TOVAR Specifies objective and constraints
  • 10. 10 10 www.impactengsol.com ©2005 – IMPACT Engineering Solutions, Inc. 10 Primary Commands Used TOTYPE Specifies solution method for topological optimization TODEF defines the accuracy for the solution TOLOOP Invokes a macro to solve, postprocess, and plot each iteration Process terminates once convergence is attained or the maximum iteration number is reached Up to 100 iterations allowed
  • 11. 11 11 www.impactengsol.com ©2005 – IMPACT Engineering Solutions, Inc. 11 Workbench vs. ANSYS Optimization Solid parts only in Workbench Topology Opt. Type 1 and Type 2 elements driven by boundary conditions in Workbench Preprocessing commands can change defaults Only Basic Opt from ANSYS is available Single load case Maximize stiffness, reduce volume Preprocessing commands for Advanced Top. Opt.
  • 12. 12 12 www.impactengsol.com ©2005 – IMPACT Engineering Solutions, Inc. 12 Textbook Problem Vertical Edge Constrained Tx, Ty, Tz = 0 Rx, Ry, Rz = 0 Load Applied to Keypoint at 10° Angle from Vertical Constraint - 60% Volume Reduction
  • 13. 13 13 www.impactengsol.com ©2005 – IMPACT Engineering Solutions, Inc. 13 Textbook Problem Type 2 Elements Type 1 Elements ANSYS Mesh
  • 14. 14 14 www.impactengsol.com ©2005 – IMPACT Engineering Solutions, Inc. 14 Textbook Problem Type 2 Elements Type 1 Elements Workbench Default Mesh
  • 15. 15 15 www.impactengsol.com ©2005 – IMPACT Engineering Solutions, Inc. 15 Textbook Problem Density Plot - Averaged Blue = pseudo-density 0 0.5 Red = pseudo- density 0.5 ≥ 1.0 Density Plot - Unaveraged
  • 16. 16 16 www.impactengsol.com ©2005 – IMPACT Engineering Solutions, Inc. 16 Textbook Problem ANSYS Density Plot Workbench Density Plot
  • 17. 17 17 www.impactengsol.com ©2005 – IMPACT Engineering Solutions, Inc. 17 Textbook Problem
  • 18. 18 18 www.impactengsol.com ©2005 – IMPACT Engineering Solutions, Inc. 18 Textbook Problem
  • 19. 19 19 www.impactengsol.com ©2005 – IMPACT Engineering Solutions, Inc. 19 Vertical Edges Constrained in Tx, Ty, Tz (Both Sides) Horizontal Edges Constrained in Tx, Ty, Tz (Both Sides) Topology Model – Problem Definition Load applied at 10° from longitudinal Uniform on surface Case Study – Bumper Project
  • 20. 20 20 www.impactengsol.com ©2005 – IMPACT Engineering Solutions, Inc. 20 Topology Model - Mesh Type 1 Elements Type 2 Elements
  • 21. 21 21 www.impactengsol.com ©2005 – IMPACT Engineering Solutions, Inc. 21 Density Plots Blue = pseudo-density 0 0.5 Red = pseudo- density 0.5 ≥ 1.0
  • 22. 22 22 www.impactengsol.com ©2005 – IMPACT Engineering Solutions, Inc. 22 Elements with density 0.5 or greater only Density Plots
  • 23. 23 23 www.impactengsol.com ©2005 – IMPACT Engineering Solutions, Inc. 23 Vertical Edges Constrained in Tx, Ty, Tz (Both Sides) Horizontal Edges Constrained in Tx, Ty, Tz (Both Sides) Model Created Based on Topology Results
  • 24. 24 24 www.impactengsol.com ©2005 – IMPACT Engineering Solutions, Inc. 24 Displacement (in) Back Bumper Surface Removed Maximum Principal Stress (psi) Analysis Results
  • 25. 25 25 www.impactengsol.com ©2005 – IMPACT Engineering Solutions, Inc. 25 363.5 lbs 204.5 lbs New Prototype Current Design Comparison to Current Design 159 lb Difference!
  • 26. 26 26 www.impactengsol.com ©2005 – IMPACT Engineering Solutions, Inc. 26 Hints and Comments Results are sensitive to the load configuration Results are sensitive to the density of the mesh When a large (80% or greater) volume reduction is requested and a very fine mesh is used a truss-like solution may occur A linear structural static analysis or a modal analysis must be performed during optimization looping Inputs and commands are not saved in the ANSYS database
  • 27. 27 27 www.impactengsol.com ©2005 – IMPACT Engineering Solutions, Inc. 27 Questions? Contact Information: Brian King Brookfield, WI Office: (262) 317-8118 Gurnee, IL Office: (847) 599-5635 E-mail: bking@impactengsol.com