topologioptimering i industrin¶nköping 2010-10-07/ma… · 1993 linear statics. normal modes....
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Copyright © 2009 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Magnus HermodssonAltair Engineering
Topologioptimering i industrinProOpt Jönköping 20101007
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Altair HyperWorks: A Platform for Innovation
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Different disciplines covering the entire development process
Topology (Optistruct)
Topography (Optistruct)
Size and Shape (Optistruct/HyperStudy)
DOE and Stochastic (HyperStudy)
Optimization in the Design Process
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Altair Solver and Optimization Roadmap
1993 Linear StaticsNormal Modes
2006 AMLS
2002 MotionSolve
2000 Buckling
1993 Topology
2002 Freq Response
2003 Contact
2000 Draw Direction Constraint
1999 Topography
2001 Size & Shape
2005 MBD in OS
Transient & Thermal
2005 Free Size, ShapeSix Sigma
Pro
duct
ivity 2004 Cross Section
Constraint
Impact on Product Design
20 years experience!
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FEA-based Structural Optimization
Conv ?
Sensitivity Analysis
Solve ApproximateProblem
Search ApproximateProblem
Optimum
FE Analysis
Conv ?
Calculate mass, stiffness, strength, stability
Calculate derivatives of mass, stiffness, strength, stability depending on variables Adjoint (topo) vs direct
Approximate and solve optimization problem (how to change variables to e.g. minimize mass and meet requirements)
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What is the best material distribution in the design space in search for the stiffest design for a given load?
Topology Optimization
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Material inside the design space is assumed to be non-homogeneous with a relative density between 0 and 1
Elasticity properties are a function of density
Density = 1
Density = 0
Topology Optimization
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Finite element discretization of the design space
Function between density and elasticity using penalty factor p
Density = 1
Density = 0
Topology OptimizationDensity Method
E/E0
ρ/ρ0
(ρ/ρ0)p
1
1
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Problem solution using finite elements and iterative optimization procedure
Density = 1
Density = 0
Topology Optimization
E/E0
ρ/ρ0
(ρ/ρ0)p
1
1
Optimization Problem:
• Minimize Objective
• Obey Constraints
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Manufacturing Constrains – Topology
• Min/Max Member Size
• Draw Direction
• Extrusion
• Symmetry
• Pattern Repetition
• Cyclic Repetition
No symmetry XZ, YZ symmetry
YZ symmetry XZ symmetry
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Common Topology Optimization Problems
Minimize (weighted / total / regional) compliance
with constrained (total / regional) volume / mass fraction
Minimize (total / regional) volume/ mass fraction
with constrained displacements
Maximize (weighted) frequency
with constrained (total / regional) volume / mass fraction
Minimize (total / regional) volume / mass fraction
with constrained frequencies
Minimize combined compliance and frequencies
with constrained (total / regional) volume / mass fraction
Minimize (total / regional) volume/ mass fraction
with stress constraints
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Topology Optimization with stress Constraints
• Global von mises stress constraints
• Apply to entire model including non design space
• Stress constraints for a partial domain of the structure are not allowed
• The reason is that it often creates an ill-posed optimization problem as elimination of the partial domain would remove all stress constraints
• Local stresses are still high
• This is for general stress level control
• Local stress should be taken care of by using shape/size
Stress < 50 Stress < 30
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Drivkrafter och motivation
Användarperspektivet
• Relativt ny teknologi – spännande!
• Tilltalande resultat – wow!
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Drivkrafter och motivation
Produktutvecklingsperspektivet
• Viktsbesparing – Automotive, Aero
• Materialkostnad – masstillverkning, gjutkomponenter
• Prestanda – motordetaljer, mekanismer
• Förbättring av befintlig produkt
• Reducerad utvecklingskostnad
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Radiator Mounting Bracket Design
Initial Design Package Space
Optimized Design
OptiStruct proposal and final design
Stress Displacement Mass Original Design
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Old Frame
New Frame
Mass reduction: 20%Increase torsion stiffness: 31%Weld length reduction: 50%
SUV Frame Design
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Drivkrafter och motivation
Produktutvecklingsperspektivet
• Viktsbesparing – Automotive, Aero
• Materialkostnad – masstillverkning, gjutkomponenter
• Prestanda – motordetaljer, mekanismer
• Förbättring av befintlig produkt
• Reducerad utvecklingskostnad
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Drivkrafter och motivation
Prestanda - mekanismer
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Drivkrafter och motivation
Produktutvecklingsperspektivet
• Viktsbesparing – Automotive, Aero
• Materialkostnad – masstillverkning, gjutkomponenter
• Prestanda – motordetaljer, mekanismer
• Förbättring av befintlig produkt
• Reducerad utvecklingskostnad
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Drivkrafter och motivation
Förbättring av befintlig produkt - PowerTrain
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Drivkrafter och motivation
Exempel: min(komplians)
Förbättring av befintlig produkt - PowerTrain
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Drivkrafter och motivation
Produktutvecklingsperspektivet
• Viktsbesparing – Automotive, Aero
• Materialkostnad – masstillverkning, gjutkomponenter
• Prestanda – motordetaljer, mekanismer
• Förbättring av befintlig produkt
• Reducerad utvecklingskostnad
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Concept Design
Detailed Product Design Manufacturing
Product Development Cycle
CAEToda
y
Concept Design and Optimization
Detailed Product Design Manufacturing
CAE
Idea
lStructural optimization moves CAE Upstream
CAE upstream tomitigate the classical
design paradox
Concept
Design freedom
Design knowledge
Preliminary Detailed
Time
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Drivkrafter och motivation
Invändningar
• ”Vi hinner inte sätta oss in i detta”• Programmen blir mer och mer lättanvända och integrerade i befintlig CAE-
miljö. Mycket av fokus ligger på användarvänlighet (nyheter i HW v11)
• ”Vi litar inte på resultaten”
• Resultat från topologioptimering bör alltid bedömas utifrån ingenjörsmässiga grunder.
• Verifierande beräkning bör alltid göras på nya koncept.
• Robusthet?
• Utför verifierande känslighetsanalys map laster och dimensioner
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‘In the Works’
• New Features• Multiple Start Point Optimization• Non-Linear Optimization (NLGEOM)
• Usability and Functionality• Topology Optimization for MBD using ESL• New Shape Optimization Algorithm• Manufacturing Constraints for Topology Optimization• Composite Optimization Enhancements• External Response Handling• NVH Optimization Improvements• DVPREL for ZOFFS• OSSmooth Enhancements
• Performance• Speed Up for Large Scale Optimization Problems
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Dynamic Loads – Equivalent Static Load Method
• Flexible dealing with dynamic problems considering true time history and not just worst case time step
AnalysisDynamic Problem
Load time history
OptimizationStatic Problem
Equivalent static loads
Load
Design variables
fteq = Kdt
t
d
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Topology Optimization for MBD using ESL
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No – Hole Casting
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Stamping Constraint
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OSSmooth Enhancements
• Implementation for multiple design components; preserving the component boundaries for the recovered mesh.
• Redesign of the OSSmooth panel: adding subpanels, for geometry recovery for reanalysis, and one with existing OSSmooth options.
• Provide user the option to have geometry recovery without the artificial layer of elements.
• Work on improving the quality of the recovered mesh.
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• Keep narrow layer
• Split non-design space
• Tetra Mesh Iso-surface ‘by property’
• Preserve Boundary Conditions
OSSmooth Enhancements
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Thermal Optimization
Temperature as objective function or constraints (DRESP1)• Response from other solution sequence such as volume, mass, displacement,
etc.
Shape and Sizing optimization• Topology under development
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Versailles 27-29 October