Riccardo Bianco Topology optimization - Altair suite tecnologia, scenari e scelte strategiche per la transizione digitale dell'industria manifatturiera

1. SIMULATION DRIVEN DESIGN Riccardo Bianco
CEO of WEISOFTDesign for the Freedom of Additive Manufacturing

2. Additive
Manufacturing
Free Form
Optimization
Geometric Freedom
Increase Performance
Accelerated Product
Development
+
Cost and Mass reduction
Opportunity and targets
TARGETS

3. How we can find the best shape ?
The greater freedom, given by the lesser production constraints, makes it possible to
produce components whose shape may be closest to the most mechanically optimal
shape.

4. How we can find the best shape ?
#solution: USE TOPOLOGICAL OPTIMIZATION

5. Origin of Topology Optimization
“As a consequence of primary shape variations and continuous loading, or
even due to loading alone, bone changes its inner architecture according
to mathematical rules and, as a secondary effect and governed by the
same mathematical rules, also changes its shape.”
Dr. Julius Wolff
19 century orthopedic surgeonBerlin 1892
This forms the basis for our topology
optimization technology

6. Difference between Topological Optimization and Generative Design
• The OT is a process of optimization of the material of the
arrangement within a circumscribed space, with the aim
to better respond to the design stresses with the least
possible amount of material.
• The variables which influence on the form may be
returned:
• Security factor
• Production Technology
The result with the same variables will be the best
form
• The GD deals with exploring the different shapes that
meet the boundary conditions and spaces, without the
use of restrictive algorithms.
• The result is a large number of forms presented to the
designer, leaving the choice of the best to the latter, who
will choose according to subjective criteria

7. How draw/modelling an organic shape?
Without wasting the indications of topological optimization

8. How draw/modelling an organic shape?
#solution: USING INNOVATIVE DESIGN SOFTWARE INSTEAD TRADITIONAL CAD
Keeping compatibility with TRADITIONAL CADs

9. Draw-based design - Yesterday
THE SEPARATION OF INSTRUMENTS AND COMPETENCIES CAUSES DISCONTINUITY IN
DESIGN PROCESS
Complexity and limitations of the tools.
- The traditional CAD setting does not allow fast creation of elements with innovative forms and, even
more restrictive, does not allow for a quick change
- Normally, concept design, optimization and simulation tools require experts with different skills

10. Simulation-based design - Today
Integration of all 3 disciplines (design, simulation and optimization) into a single
easy-to-use software
. Advanced technology for optimization
. Advanced technology for simulation
. Advanced technology for concept design (PolyNURBS)
. Geometric engine compatible with most popular software CAD (PARASOLID)
FOCUS:
- Simple to use
- Integration CAD-CAE
- Fast

11. Inspire Design Process
Traditional Design Process
Develop
Concept
Detailed
Design
Production
Validation &
Prototyping
Documentation
Product
Definition
Validation &
Prototyping
Documentation
Product
Definition
Inspire Design Process
Production
Detailed
Design
Inspire

12. Challenges of Additive Manufacturing Design
1
Find the best
shape
2
Model
optimized
shapes
3
Include new
Technologies
in the design
process
Cost and Mass reduction
Increase Performance
Accelerated Product Development

13. There are 2 approaches
Start from Design Space Start from Current Project

14. 1st example
Start from Design Space

15. Design Package Space Final Design
Courtesy of Exact Engineering

16. Problem Statement – Aerospace Bracket AM Design
• Example from Dave Anderson – Exact Engineering
• Redesign a bracket to mount a sensitive component to an existing
structural interface.
• Optimize the bracket for minimum mass given the following
performance requirements.
• 1g sag displacement: < .00015” (furthest mounting point of component)
• 250 Hz 1st mode minimum.
• Existing bracket performance specifications
• .170 lbs
• 1st mode 225Hz
• 1g sag: .0001 (furthest mounting point of component)

17. Inspire Shape
Courtesy of Exact Engineering

18. Simulate the topology shape
• Directly in Inspire, FEA is performed on the created shape to predict results.
• These are shown below and are within specification. The resulting mass of the topology
model is .08lbs
Displ: 3.4e-5in 1st Mode: 515 Hz

19. Inspire to Tradition CAD
• “Fit” Inspire results were then brought into CAD
and a solid model was produced.
• The solid model is not an exact replica and
need not be, but structure for the load paths
need to be similar.

20. Final CAD Design
• Further refinements were made to
facilitate post machining
operations and part stability.
• Part weight: .11 lbs.
• Original part weight: .17 lbs
• Weight Redux: 35%

21. Inspired Design Comparison
Traditional CAD
Inspire
PolyNurbs Design
See this design at our booth

22. Performance Comparison
PolyNurbs Traditional CAD
388 Hz 1st Frequency 310 Hz
427 pi (1.68 MPa) Max Stress 491 psi (1.75 MPa)
6.06e-5 in (1.54e-6 m) Max Displacement 7.54e-5 in (1.92e-6 m)
.100 lb (.045 kg) Weight .108 lb (.049 kg)
8 hours Design Time 24 hours

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2nd example
Start from current project

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Designing with Inspire

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Create a Package Space and Assign Operating Conditions

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Generate the Ideal Concept

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Explore Design Concepts

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Validate the Concept Shape

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Develop CAD from Inspire Results

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30% Weight Reduction

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3rd example
Support optimization

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Aeronautical plate – Analyse the current project
• Material : Aluminum 7075
• 6 supports
• 4 load conditions
• Current mass : 0.34926 kg
• Displacement max : 2.069 mm

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Aeronautical plate – Create optimized variants and analyze the
behavior

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Aeronautical plate – Select the best result
Comparison of the main results

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Aeronautical plate – Realize the CAD of the best design

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Aeronautical plate – Final results
original optimized
Mass (kg) 0.349 0.219 (38%)
Displacement max (mm) 2.069 0.91 (57%)
Number of fixing 6 4

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• Lattice Optimization
LATTICE

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Inspire Lattice Structure Optimization

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Where do we get the loads from? #1
Unit Loads Project Loads

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Where do we get the loads from? #2 Inspire Motion
• Inspire Motion simulates dynamic
forces in assemblies
• Loads from motion simulation can be
automatically transferred to load
cases for topology optimization
• Transfer motion loads to structural
simulation
• Innovate faster exploring more
design alternatives

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Inspire Motion - Demo

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Where do we get the loads from? #3 Digital Twin Platform

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Altair Digital Twin Platform: Complete, Open & Flexible

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ALTAIR DIGITAL TWIN PLATFORM: Where Can You Get The Most Value?​
Asset Management
Conduct advanced monitoring
and predictive maintenance
Product
Performance
Optimize design to improve
product performance
Extend
Product Life
Reduce operating cost and
extend product life
Operational Insight
Gain visibility in the
in-service life of the product

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So many calculations? We save time
Extreme geometric complexity
Part gaps and overlaps
Assemblies with big/small
or thick/thin parts
Small geometry features
Odd face transitions or small
splinter surfaces

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Meshless: Altair SIMSOLID
simsolid
Altair SimSolid
introduces a new
technology
that operates on
original, un-
simplified CAD
geometry directly,
and does not
create a mesh

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Calcoli meshless
“We have found SimSolid to be an invaluable aid to our research work. Its ability to analyze complex bone geometry is a capability that is not practical
with other FEA methods.”
– Louis Ferreira, Associate professor – Western University, Canada

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