2007 03 tosca nx designprocess

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1© UGS Corp. 2007. All rights reserved.


The optimization company

Topology optimization

Design process with TOSCA and NX

Matthias Friedrich, FE-DESIGN GmbHSteven Vickers, UGS

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Topics

FE- DESIGNCompany introductionProduct overview

Example Topology OptimizationOverview of lever design processIdentifying working environment and defining task

NX in-context construction of the work space modelDetermining loads with NX Motion SimulationPreparing data in NX Advance Simulation

Optimizing shapeTOSCA – topology optimization

Modeling the answerNX model from TOSCA output STL file


FE-DESIGN - The Optimization Company

TOSCA OPTIMUS PLMO

GLview Inova/API NuTech ES

Engineering

Customization

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s m o o t h

FE-DESIGN - The Optimization Company

Workflow: From Design Space to Optimum Design


FE-DESIGN GmbHHeadquarterHaid-und-Neu-Str. 776131 KarlsruheGermany

Tel.: +49 (0)721/9 64 67-0Fax: +49(0)721/9 64 67-290

E-Mail: [email protected] www.fe-design.de

FE-DESIGN Locations

FE-DESIGN GmbHOfficesFE-Design NordicDr.-Ing. Claus PedersenDiplomvej 3732800 LyngbyDenmark Phone: +45 7026/5235 Fax: +45 7026/5237

Home Office HusumManfred FritschChristine-Petersen-Str. 2325813 HusumGermanyPhone: +49 (0)4841/7728 72Fax: +49 (0)4841/7728 74Cell: +49 (0)170/3165569

Husum

Copenhagen

IOM Business Center MunichDr. Christoph KatzenschwanzStefan-George-Ring 2981929 MunichGermanyPhone: +49 (0)89/33 98 29-81Fax: +49 (0)89/33 98 29-99Cell: +49 (0)176/62 11 16 50

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Overview: Optimization Methods

TopologyTopology Non-par.Shape

Non-par.Shape BeadBead DOE &

RSMDOE &RSM MDOMDO Robustness

ReliabilityRobustnessReliability

GeometricParameterGeometricParameter

TOSCANon-parametric optimization

TOSCANon-parametric optimization

OPTIMUS & NuTech process automation,

parameter based optimization

OPTIMUS & NuTech process automation,

parameter based optimization

Integration in the existing CAE environment Integration in the existing CAE environment

Integration in CAD environment Integration in CAD environment

FE-DESIGN –the optimization companyFEFE--DESIGN DESIGN ––the optimization companythe optimization company


FE-DESIGN - Partnerships

PermasPermas

ANSYSANSYSMSC.NastranMSC.MarcMSC.PatranMSC.AdamsMSC.Fatigue

MSC.NastranMSC.MarcMSC.PatranMSC.AdamsMSC.Fatigue

Virtual.LabFALANCSDADS

Virtual.LabFALANCSDADS

GLviewGLview

MEDINAMEDINA

MagmasoftMagmasoft

ABAQUSABAQUS

FEMFATFEMFAT

NX NastranI-DEASFEMAP

NX NastranI-DEASFEMAP

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Distribution Partners of FE-DESIGN

Germany, AT, CH: direct distribution FE-DESIGN

Italy: www.enginsoft.it EnginSoft

USA, Canada: www.processopt.com Process Opt.

People‘s Rep. China: www.caeda.com.cn CAEDA

South Korea: www.cae.co.kr Samwon

Japan: www.vinas.com VINAS

Turkey: www.figes.com.tr FIGES

Great Britain www.tecosim.com TECOSIM


FE-DESIGN Customers

Fahrwerksberechnung Betriebsfestigkeit Pkw

Berechnung Nutzfahrzeuge

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© UGS Corp. 2007. All rights reserved.

Objective:„The topology and the shape of a component has to be determined in such a way, that its mechanical behavior is an optimum for the specified design criteria. Only the available boundary conditions, the forces and the design area for the component has to be defined. “ [Maute 98]A continuous solution cannot be easily found, so the design area is discretized.

What is Topology Optimization

The design variables are the densities of each finite element.

Target Volume: 70%


Topology Optimization for Audi

Predecessor designDesign space model

Topology optimization

Cutting splines

Redesign

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Design Comparison

From: VDI Berechnung und Simulation im Automobilbau, Würzburg 2000

Result:Speed-up of the development process45% Stress reduction, 10% weight reductionThe 1st prototype passed all mechanical tests !

(Image ATZ MTZ extra, August 2002)

Weight Max. stress Max. displacement

AdmissibleStress

Existing designNew design


Overview of process

Model Requirements

Simulate System

Define Loadings

Optimize Shape

Construct Component

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Construction of the work space model

Sketch environment

Extrude of space volume

Subtract holes and clearances


NX Motion Simulation

Analysis to determine loads

Modification for collisions

Loading passed to simulation

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NX Advanced Simulation

Mesh creation

Load cases defined

Fixed faces identified


Lever Example – Design Space

Finite Element Model

Blue – Design VolumeRed – Frozen Elements

Frozen Elements defined as SET

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Optimization Setup

Start Animationor

Live Demo


GLview 3D Plug-in

Optimization Result and Progress

Animation File automatically created with TOSCA.smooth

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Lview 3D Plug

Effect of Casting Restriction

Smoothed Results automatically created with TOSCA.smooth

w 3D PNo Casting Restriction

Casting Restriction:

Deformable pos. X-Direction

Not manufacturable !


NX modeling of optimized shape

Import STL result from TOSCA

Create basic blocks and ribs

Dynamic creation with Extrude/Draft/Draft/Sketch

Merge and align faces

Direct Modeling to refine part

Blends for component features

Manufacturing detail

Taper/Draft features

Blends for manufacturability

Material removal

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Comparison of designs

Material usage optimized for stiffness

Reduced stress hotspots


Comparison of designs

Optimized for increased stiffness and/or material reduction

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The optimization company

www.ugs.com

www.fe-design.com

2007 03 tosca nx designprocess

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