TOSCA Structure 81 Short Seminar

Simulia Tosca Structure
Getting started with shape optimization

for reliable and durable designs
Dr. Claudia BANGERT

SIMULIA Senior Portfolio Introduction Specialist
Getting started with shape optimization for reliable and durable designs
1. Shape optimization
2. Setup of the optimization task:
Model, design area, objective, constraint
3. Mesh smoothing
4. Restrictions on design variables
5. Demonstration
6. Durability and nonlinearities
45 minutes
Shape optimization (1/8)
L1.3
www.3ds.com | Dassault Systmes
Modification of the surface of a design to improve its (dynamic and mechanical) behavior
Change
a set of design variables (parameters describing the design) such that
an objective (function evaluating the quality of the design) is maximized or minimized
and necessary (design) constraints are satisfied
L1.4
Design variables
One DV = thickness
Two DV = thickness, angle
Several DV = variable thickness
More design variables better solution

Best design obtained by free (non-parametric) modification
Increasing shape flexibility
Problem
L1.5
Approaches considering
Morphing
Shape basis vectors
Non parametric free form
With SIMULIA Tosca Structure
Including mesh smoothing
Increasing shape flexibility
Parametric approaches
Variation of diameters
100%
0%
Non parametric shape optimization

Displacement of selected surface nodes
Determination of the optimum contour of a
component
Consideration of all given boundary
conditions
Motivation:
Easy setup (no parameterization required)
Flexible result (maximum degree of freedom)
Local stress reduction and durability increase
L1.6
L1.7
Tosca Structure offers non-parametric structural optimization

based on finite element analysis results
in any CAE environment
CAD
CAE
preprocessing
Optimization with
SIMULIA Tosca Structure
CAE
postprocessing
Abaqus
ANSYS
MSC Nastran
Design proposals and design improvements are derived automatically

direct modification of the finite element model
No parametrization required!
CAD
L1.8
Example: Stabilizer bar link

Problem
Stiffness requirements no longer fulfilled
(changes to the front axle)
Stress reduction of 25 % required!
Solution
Parameter optimization (radius):
Stress reduction only by 18 %
Non-parametric optimization (Tosca):
Stress reduction by 30 %
New freeform contour approximated by
circular segments
100%
80%
60%
40%
20%
0%
Weight
Initial design
Max. stress
Optimization result
Images courtesy of
L1.9
Optimization strategies
Heuristic algorithms
Monte Carlo
Genetic
algorithms
Mathematical programming
Direct methods
SQP, MMFD, MFD,
Penalty methods
Newton, gradient based, ...
Approximation methods
- SLP, SCP,
Optimality criteria
Structural
optimization
Fully stressed design

Kuhn Tucker
Other OC
Tosca Structure
L1.10
Mathematical programming
+ General applicability
+ Convergence speed independent of
number of design variables
- Convergence speed depends on the type
of objective and the number of constraints
- Effort in numerical implementation
An optimized design is determined by

an iterative algorithm which changes
an initial design using sensitivities
Optimality criteria
+ Convergence speed independent of the
number of design variables
+ Fast convergence
+ Solution independent of start value
- No general approaches (very specific)
Design variables are redesigned so

they fulfill the optimality criteria
L1.11
Setup of the optimization task (1/8)

6
Stop
Stop condition
Constraint
Optimization restrictions
1
4
Model
Definition of analysis model
Objective
Optimization target
2
Groups
3
Design Area
Area for modification with
geometric restrictions
Node and element sets for

further definitions
L1.12

Model for shape optimization
Design space as finite element model
Too coarse
Important:
Realistic models
geometric details
exact boundary conditions
relevant load scenarios
exact material models (e.g. non linear)
Mesh quality
Not too fine, not too coarse
Quadratic vs linear elements
Model
Groups
Design Area
Too fine
Good mesh
Objective
Constraint
Stop
L1.13
Design area
Displaced
design nodes
Node group of surface nodes (design nodes)

Node position can be modified
Optimization displacement is calculated
during optimization
Design nodes
Design variables are the displacement values

of the design nodes
Positive:
node grows out of the structure
Negative:
node shrinks into the structure
Model
Groups
Design Area
Optimization
displacement
Optimization
displacement
direction
Objective
Constraint
Stop
L1.14
Input for the optimization: design responses

Finite element analysis
Stiffness, stresses, eigenfrequencies,
displacements, etc.
For given load scenarios
For given areas in the model
Extract values
Combine load scenarios
Model geometry
Weight, volume
COG, inertia
Position of nodes
Element layout
Model
Groups
Combine areas
Restrict
Design Area
Objective
Constraint
Optimize
Stop
L1.15

Maximum
Targets: objective and constraints

The objective is maximized or minimized
Maximize overall stiffness
Minimize stresses
Minimum
The constraints are

geometrical manufacturing requirements
or
design limitations on structural
responses from a FE analysis
Constraint
Feasible
Infeasible
Active constraint
Model
Groups
Design Area
Objective
Constraint
Stop
L1.16
Some possible objectives
Temp. [C]
High
Finite element solver:

Different stress criteria
Strain density
Nodal plastic strains (Abaqus, ANSYS)
Different strain criteria (Abaqus)
Nodal contact pressure (Abaqus)
Maximizing the natural frequency
Fatigue results:
Damage
Safety
Model
Low
Plasticity /
Fatigue
Pin mounted as
shrink fit
Max. contact pressure

reduced by 50 %
Groups
Design Area
Objective
Constraint
Stop
L1.17

Constraint
restricts certain values dependent upon the design variables (design responses)
only volume constraint with equality value defined on element groups admitted
Manufacturing restrictions and other geometric constraints independent of the optimization run
can be defined as design variable constraints (later)
Model
Groups
Design Area
Objective
Constraint
Stop
L1.18
Global stop criterion

Number of iterations
Standard tasks 5-10
Local stop criterion
Change in certain variables, e.g. change of optimization displacement is smaller than 1%
of previous iteration (see manual)
not required, just resume your optimization with some more iterations
Model
Groups
Design Area
Objective
Constraint
Stop
L1.19
Example (1/3)
LC 1
LC 2
LC 2= 2*LC1
LC 1
L1.20
Example (2/3)
Shape optimization by homogenization of the

stresses
Update rule:
Node stress > reference value
Growth in order to reduce stress
Node stress < reference value
Shrinkage in order to increase stress
Result: homogeneous stress distribution
to the level of the reference value
100%
100%
0%
0%
ref
Reference value is normally mean stress in

design area
Homogeneous stress distribution results in a
minimization of the stresses in the design
area.
Growth
Shrinkage
L1.21
Example (3/3)
Optimized design
Path for
stress
distribution
100%
100%
0%
0%
Initial design
Optimized design
8
7
6
5
4
3
2
1
0
1
10 11 12 13 14 15 16 17 18 19 20 21
Node position (Theta=[0,90])

Loadcase 1
Loadcase 2
Von Mises Stress (mpa)
Von Mises Stress (mpa)
Start model
8
7
6
5
4
3
2
1
0
1
10
11
12
13
14
15
16
17
Node position (Theta=[0.90])

Loadcase 1
Loadcase 2
18
19
Mesh smoothing (1/3)
Displacement of the surface nodes due to the local stresses

Strongly distorted elements on the surface layer
Quality of the finite element analysis is affected
Smoothing of the mesh of the internal structure (MESH_SMOOTH)

the optimization displacement is passed to the inner nodes
Performed on an user defined element group (mesh smooth area)
All design nodes must be at surface of mesh smooth area
Element qualities are considered during mesh smoothing
L1.22
L1.23

Layer
Automatic definition of the mesh smooth area
Starting on a surface node group
All elements in the defined number of element
layers are grouped
The MESH_SMOOTH area should contain at
least 4-6 element layers.
The mesh smooth element group should be as
large as necessary but as small as possible to
guarantee:
The best possible mesh quality
The lowest possible calculation time
Design_nodes
Element layers
L1.24

FREE_SF
Automatic fixation of free surface nodes
Free surface nodes are all nodes, that
are not design nodes
are not fixed due to another restriction
(DVCON_SHAPE)
The number of transition nodes that are used
for mesh adaption has to be defined
Transition nodes
Design
nodes
No transition
With transition
Restrictions on design variables (1/5)
Non parametric shape optimization generates freeform surfaces

processing in CAD systems may take some time
complex surfaces are not always producible
external constraints often require additional restrictions
Restrict the movement of nodes to

avoid the change of border areas to other components
ensure the ability to manufacture the component
control the design and look of the part
L1.25
L1.26

Displacement restrictions
Restricting the absolute optimization

displacement amount
Restricting the displacement direction
Variation and restriction areas
my_cs
FIX
Element groups
Minimum/Maximum member size
FREE
L1.27

Coupling restrictions
Symmetry
Demolding
Stamping
Drilling
Turning
Part
Mold
L1.28

Design area
Without symmetry link
Symmetrical
meshing
L1.29
With symmetry link
Symmetry
plane
Y
Z
Live demo (1/2)

Wind turbine hub model
Objective function
Minimize maximum stress
within the design area
Design and manufacturing driven
constraints:
Cyclic symmetry constraint (120 degree)
Frozen area constraint (Exclusion of certain
nodes from the design area)
Tosca Structure wind hub example is provided

with each Tosca Structure installation
L1.30
Live demo (2/2)

L1.31
Durability and nonlinearities (1/5)
Shape optimization improves already existing designs:

Quality of optimization result depends on quality of analysis model
Avoid time-consuming and error-prone linearization
Exploit the full optimization potential through realistic models
No safety margin required
Nonlinear behaviour and durability aspects need to be considered in the optimization!
L1.32
L1.33
Determination of the equivalent stress for optimization

Static loading
Superimposed von Mises

equivalent stress
(max function)
Cyclic loading
Damage distribution
after durability analysis
L1.34
max = 0.7 0
dmax = 5.6 d0
Shape optimization
based on static loading
dmax = 0.13 d0
0 = 100 %
Shape optimization
based on cyclic loading
If the location of maximum damage and maximum stress are not matching,
fatigue life simulation should always be included in the optimization loop.
L1.35
Directly supported durability solvers

fe-safe
Femfat
Customization required:
ncode Designlife
MSC Fatigue
LMS Virtual.Lab Durability
FE-fatigue
FEMSite
SIMULIA
Tosca Structure
Abaqus
ANSYS
MSC Nastran
Fatigue solver
L1.36
Geometrical
nonlinearities
Abaqus
ANSYS
MSC Nastran
YES
YES
YES
YES
YES
Torque support
(rubber material)
YES
Contact
(including nonlinear
responses)
Constitutive material
laws in design area
ALL
ALL
Constitutive material
laws outside design
area
ALL
ALL
ALL
(no strain responses)
Exhaust manifold
(plastic strain)
ALL
Tooth of gear wheels

(contact, material)
Thank you!
Q&A
Please ask questions using the chat window
Recording will be available in the Simulia Learning Community

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Simulia Tosca Structure

Getting started with shape optimization

Dr. Claudia BANGERT

Shape optimization (1/8)

www.3ds.com | Dassault Systmes

Shape optimization (2/8)

www.3ds.com | Dassault Systmes

Two DV = thickness, angle

Several DV = variable thickness

More design variables better solution

Increasing shape flexibility

Shape optimization (3/8)

www.3ds.com | Dassault Systmes

Increasing shape flexibility

Shape optimization (4/8)

www.3ds.com | Dassault Systmes

Non parametric shape optimization

Shape optimization (5/8)

www.3ds.com | Dassault Systmes

Tosca Structure offers non-parametric structural optimization

Design proposals and design improvements are derived automatically

Shape optimization (6/8)

www.3ds.com | Dassault Systmes

Example: Stabilizer bar link

Shape optimization (7/8)

www.3ds.com | Dassault Systmes

Fully stressed design

Shape optimization (8/8)

www.3ds.com | Dassault Systmes

An optimized design is determined by

Design variables are redesigned so

Setup of the optimization task (1/8)

www.3ds.com | Dassault Systmes

Node and element sets for

Setup of the optimization task (2/8)

www.3ds.com | Dassault Systmes

Setup of the optimization task (3/8)

www.3ds.com | Dassault Systmes

Node group of surface nodes (design nodes)

Design variables are the displacement values

Setup of the optimization task (4/8)

www.3ds.com | Dassault Systmes

Input for the optimization: design responses

Combine load scenarios

Setup of the optimization task (5/8)

www.3ds.com | Dassault Systmes

Targets: objective and constraints

The constraints are

Setup of the optimization task (6/8)

www.3ds.com | Dassault Systmes

Some possible objectives

Finite element solver:

Max. contact pressure

Setup of the optimization task (7/8)

www.3ds.com | Dassault Systmes

Setup of the optimization task (8/8)

www.3ds.com | Dassault Systmes

Global stop criterion

www.3ds.com | Dassault Systmes

www.3ds.com | Dassault Systmes

Shape optimization by homogenization of the

Reference value is normally mean stress in

Node position (Theta=[0,90])

Von Mises Stress (mpa)