In cooperation with the Hongik University in Seoul/South Korea and a partner of the automotive industry the chair and institute for engineering design (ikt), RWTH Aachen annually operates the course “Cooperative Product Design”. In this one-semester course a group of German and Korean students has to fulfil the task to develop an e-mobility car concept. Each year a particular task is given by the industrial partner. The student group consists of 10 Korean car design students as well as 10 Korean and 10 German mechanical engineering students. Part of the course is a 10-day-visit of each nationality to both Germany and Seoul. In between the visits the students communicate using web-conference tools and a PDM-System. In 2014 Audi, as the industrial partner, assigned the task of a minimal mobility e-car concept. Since mini mobility concepts tend to have a bad image considering safety, the main focus was to develop a safe and sound body – structure wise and design wise. The way to accomplish that aim was to build a lightweight but stiff cabin. To achieve this goal the students made use of the software Solid Thinking Inspire (Version 9.5). All students were firstly coached about some theoretical background to get a better understanding of how Topology Optimization works numerically and how it can be integrated into the design process. Subsequently they began to work with basic tutorials before referring their design proposals to Solid Thinking Inspire. The presentation will focus on the how the students were able to integrate the software into their project work. Markedly different approaches of design and engineering students could be detected. These results as well as difficulties that occurred during the process will be highlighted. The final optimized structures as well as how they were included into the overall concepts considering software and design will be presented. Eventually it will be discussed how the tool “Topology Optimization” can be successfully integrated into future projects in education. Speakers Anna-Lena Beger, Scientific Assistant, RWTH Aachen University

1. Topology Optimization As A
Technique In Multidisciplinary
Student Projects
Dipl.-Ing. Anna-Lena Beger
Sept. 29th, 2015
3rd European Altair Academic User Day

2. Chair and Institute for Engineering Design
RWTH Aachen University – Univ.-Prof. Dr.-Ing. Jörg Feldhusen
• ikt – RWTH Aachen University
• Collaborative Product Development (CoPro)
• Application of TO in CoPro
• Outcome/Discussion
• Value of Work and Conclusion
Agenda
2

3. Chair and Institute for Engineering Design
RWTH Aachen University – Univ.-Prof. Dr.-Ing. Jörg Feldhusen
As an institution in Design Methodology, ikt develops
optimal solutions for any set of requirements, regardless of
the industry, be it Automotive, Aerospace, Plant Engineering
or consumer goods.
Our Innovation Methodology guarantees for robust and
efficient solutions for any technical problem or task.
ikt - Chair and Institute for Engineering Design
3

4. Chair and Institute for Engineering Design
RWTH Aachen University – Univ.-Prof. Dr.-Ing. Jörg Feldhusen
…in a creative setting
Innovative Engineering Design…
Chair and Institute for Engineering Design
Selected classes:
• Applied Engineering Design (AKL)
• Industrial Design (ID)
• Design of Machines and Devices (KvMG)
• Systematic Engineering Design I (KL I)
• Systematic Engineering Design II (KL II)
• Collaborative Product Development (CoPro)
• Processes and Principles for Lightweight Design
Team:
• Prof. Dr.-Ing. Feldhusen
• 2 Senior Engineers
• 16 Research Associates
• 6 IT-Staff
• 2 Workshop Staff
• 2 Secretaries
• ~40 Student Assistants
Research
 Innovation Methodology
 Engineering Design Methodology
 Multi-Material Structures
 PLM – Product Lifecycle Management
Consulting
 Concept Development
 Modular Design
 Introduction and Support for PDMS
 Training
+ 3D-Printing Lab (Scanning and Printing)
and Mechanical Workshop
Education
 1st semester to Final Thesis (B. Sc. & M. Sc.)
 Classes from 10 – 1500 students
 Ten different courses
4

5. Chair and Institute for Engineering Design
RWTH Aachen University – Univ.-Prof. Dr.-Ing. Jörg Feldhusen
• ikt – RWTH Aachen University
• Collaborative Product Development (CoPro)
• Application of TO in CoPro
• Outcome/Discussion
• Value of Work and Conclusion
Agenda
5

6. Chair and Institute for Engineering Design
RWTH Aachen University – Univ.-Prof. Dr.-Ing. Jörg Feldhusen
• Hongik University, Seoul; ikt, RWTH Aachen
and industrial partner (Audi in 2014/15)
• Team Set Up: 6 students in 5 teams
• 2 Car Designers (from Seoul)
• 4 Mechanical Engineers (2 from Aachen, 2 from Seoul)
• 1-semester course
• Goal: Design of a future orientated vehicle concept in a
multidisciplanary team
Collaborative Product Development
6

7. Chair and Institute for Engineering Design
RWTH Aachen University – Univ.-Prof. Dr.-Ing. Jörg Feldhusen
Course Objectives
7
• PDM and Collaboration tools and methods
• realistic project experience
• realistic challenges
• coping with realistic (unexpected) challenges
• interdisciplinarity: different terminology,
methodology, mindsets… esp. between
engineering and design
• cultural differences and implications
• cultural differences
• language, time zones, holidays…
• responsibility: planning, contents, deadlines…
• focusing, getting one’s point across…
• application of fundamental engineering/
design knowledge
• application of fundamental engineering/
design tools

8. Chair and Institute for Engineering Design
RWTH Aachen University – Univ.-Prof. Dr.-Ing. Jörg Feldhusen
CoPro 2008
• Electric/hybrid special purpose
vehicles
• Presented at the 2008 PACE Annual
Forum, Detroit
8

9. Chair and Institute for Engineering Design
RWTH Aachen University – Univ.-Prof. Dr.-Ing. Jörg Feldhusen
CoPro 2014
9
• Minimal Mobility:
Electric/hybrid vehicles
• Safety as major functional and
design issue

10. Chair and Institute for Engineering Design
RWTH Aachen University – Univ.-Prof. Dr.-Ing. Jörg Feldhusen
• ikt – RWTH Aachen University
• Collaborative Product Development (CoPro)
• Application of TO in CoPro
• Outcome/Discussion
• Value of Work and Conclusion
Agenda
10

11. Chair and Institute for Engineering Design
RWTH Aachen University – Univ.-Prof. Dr.-Ing. Jörg Feldhusen
Use of a TO-software tool since 2014.
• Generate innovative, safe and sound structures at the
beginning of the design process
• Challenges for students:
TO is only a small part within the whole course
 Little time for practicing
 Little experience with TO software;
wanted: „immediate“ results
 solidThinking Inspire 2014
Topology Optimization (TO) in CoPro
11
Source: ALTAIR

12. Chair and Institute for Engineering Design
RWTH Aachen University – Univ.-Prof. Dr.-Ing. Jörg Feldhusen
• Lecture about theory of TO (90 min)
• Numerical backround
• Workflow
• Basic Tutorial (90 min)
• Advanced Tutorial (90min)
• Application within their
own project group
• All students (Design and Engineering) get the same task
Approach
12

13. Chair and Institute for Engineering Design
RWTH Aachen University – Univ.-Prof. Dr.-Ing. Jörg Feldhusen
• Basic
• Geometries and exact loadcases given.
Tutorials
13
Source: ALTAIR

14. Chair and Institute for Engineering Design
RWTH Aachen University – Univ.-Prof. Dr.-Ing. Jörg Feldhusen
• Advanced
• Geometries and qualitative loadcase given.
Tutorials
14
80% of 800N
20% of 800 N
60 Nm

15. Chair and Institute for Engineering Design
RWTH Aachen University – Univ.-Prof. Dr.-Ing. Jörg Feldhusen
• Information on possible loadcases
• Information on Simplified Equivalent Static Loadcase
Application in Car Concept
15
Source: DLR, Proceedings of the World Congress on Engineering 2011 Vol III, WCE 2011
Bending Torsion
Frontcrash Sidecrash

16. Chair and Institute for Engineering Design
RWTH Aachen University – Univ.-Prof. Dr.-Ing. Jörg Feldhusen
• ikt – RWTH Aachen University
• Collaborative Product Development (CoPro)
• Application of TO in CoPro
• Outcome/Discussion
• Value of Work and Conclusion
Agenda
16

17. Chair and Institute for Engineering Design
RWTH Aachen University – Univ.-Prof. Dr.-Ing. Jörg Feldhusen
Process Team A 2014
17
Concept
Design of
structure
using TO
Implementation
of TO results
Final Design

18. Chair and Institute for Engineering Design
RWTH Aachen University – Univ.-Prof. Dr.-Ing. Jörg Feldhusen
Process Team C 2014
18
Concept Design of
single
functional
elements
using TO
Implementation of TO results
Final Design

19. Chair and Institute for Engineering Design
RWTH Aachen University – Univ.-Prof. Dr.-Ing. Jörg Feldhusen
• TO could be succesfully integrated into early design phase
• Helpful to get a better understanding of “stable” structures
BUT:
• Mainly used by German mechnical engineers from higher semesters
 Experience in structural mechanics/FEA helpful even with simplified
software such as SolidThinking Inspire
• If design of dynamic loadcases necessary
 only imprecise, qualitative results of structures
• Results:
Qualitative functional structures for further specification of design
Discussion
19

20. Chair and Institute for Engineering Design
RWTH Aachen University – Univ.-Prof. Dr.-Ing. Jörg Feldhusen
• ikt – RWTH Aachen University
• Collaborative Product Development (CoPro)
• Application of TO in CoPro
• Outcome/Discussion
• Value of Work and Conclusion
Agenda
20

21. Chair and Institute for Engineering Design
RWTH Aachen University – Univ.-Prof. Dr.-Ing. Jörg Feldhusen
• SolidThinking Inspire is intutive to learn and results are achieved easily
• Common understanding of structural mechanics necessary
• Possible „bridge“ between engineers and designers
• Enhancement of 3D-printing allows novel organic geometries of TO to
be manufactured
• Ikt will increase application of TO software in student projects as well
as in the consulting area
Conclusions for ikt
21
Source: http://www.die-zeitgenossen.com/

22. Chair and Institute for Engineering Design
RWTH Aachen University – Univ.-Prof. Dr.-Ing. Jörg Feldhusen
Ende der Bildschirmpräsentation
Thank you!
Questions?
Contact: beger@ikt.rwth-aachend.e