automatisierung multidisziplinärer optimierung- und

NAFEMS

Automatisierung Multidisziplinärer

Optimierung- und Analyseprozesse zur

Verbesserung von Karosseriestrukturen

Dr.-Ing. Lars Gräning

Dynardo GmbH

[email protected]

2L. Gräning, Automatisierung Multidisziplinärer Optimierung- und Analyseprozesse zur Verbesserung von

Karosseriestrukturen, NAFEMS DACH Conference 18, 14.-16. Mai Bamberg, Germany

© Dynardo GmbH

Introduction MDO (Multi-disciplinary optimization)

Durability- Drive train stiffness

- BIW stiffness

- Door opening /

closing

- Component stresses

- …

Car Safety- Front crash

- Side crash

- Occupant safety

- Pedestrian safety

- …

NVH- Static & dynamic

stiffness car body

- Body noise transfer

- Seat vibrations

- Drive train noise

…

MDO



© Dynardo GmbH

• Assumption: optimal design is superior to the

optimization of all disciplines in a sequence by

exploiting interaction between disciplines and groups

• Identification of trade-offs and conflicts early in the

design process

• Including multiple disciplines simultaneously increases

complexity of the optimization task

• Connection of different engineers and teams

Introduction MDO (Multi-disciplinary optimization)



© Dynardo GmbH

1. Process automation and customization

2. Efficient algorithms: meta-modeling, sensitivities,

optimization, robustness analysis and opt. …

3. Simulation and Process Data Management (SPDM)

4. Knowledge and data exchange

5. Re-use of models, workflows and scripts

Concepts and tools for an efficient and successful MDO:



© Dynardo GmbH

Dynardo

• Founded: 2001

• More than 60 employees,

offices at Weimar and Vienna

• Leading technology companies Daimler,

Bosch, ZF/TRW, Siemens are supported

Software Development

Dynardo is engineering specialist for

CAE-based sensitivity analysis,

optimization, robustness evaluation

and robust design optimization

• Mechanical engineering

• Civil engineering &

Geomechanics

• Automotive industry

• Consumer goods industry

• Power generation

CAE-Consulting



Openness – open and programmable architecture

• Plugins

• CAx Toolintegrations

• Algorithms

• (PLM-) Databases

• Interfaces

• Batch

• Scriptable (.py)

• Shared libraries (.dll, .so)

• Remote control (TCP/IP)

© Dynardo GmbH

CAx Tools

Algorithms

Databases



© Dynardo GmbH

Customization overview

• optiSLang provides plugin mechanisms via Python scripting

• Define own integration nodes

• Implement own algorithms

• Customize Solver Wizard and Postprocessing

• Implement Data Mining functions



© Dynardo GmbH

MidasEdyson

Adams

TurboOpt

optiSLang v7.1: Integrations

Win-BatchMATLAB Linux-Shell

Plug-in and WB node

LMS Amesim

Octave

LS-DYNA

Python



© Dynardo GmbH

Reduced Crash Box modelCrash can

Traverse

Front bumperMounting points

• ANSA: LS-Dyna Tutorial example

• Beams are connected with a

cylindric traverse

• Front connected with double

traverse

• Evaluation of NVH: static stiffness &

Safety: front crash

• Crumble zones to control

buggling



© Dynardo GmbH

Vertical offset 1...4

Vertical Width 1...4

Width_Extend_Front_Sym

Width_Extend_Base_Sym

Height_Extend_Front_Sym

Height_Extend_Base_Sym

Design variables (Shape morphing with ANSA)

• ANSA morphing to parameterize

double beam geometry

• Compact representation to generate

geometric variations

• Elongation of front and rear can be

controled independently

• Direct morphing is used to vary

crumble zones

• Morphing techniques facilitate a

smooth deformation of the surface –

suited for design optimization tasks



© Dynardo GmbH

ANSA integration into optiSLang



© Dynardo GmbH

I. NVH: Stiffness

2:Fz = -10.0 kN1:Fy = 10.0 kN

II. Safety: Front Crash

Objective: minimize mass

Constraints:

• dy < 1.5 mm

• dz < 2.5 mm

Simulation: MSC Nastran

Vx=12m/s

Objective: minimize mass

Constraints:

• Fmax < 100 kN

• dmax < 340 mm

Simulation: LS Dyna



© Dynardo GmbH

META integration into optiSLang



© Dynardo GmbH

ANSA Solver META post

wall

crash box structure

Signed von Mises

Process automation for direct MDO



© Dynardo GmbH

- Simulation results

- Pictures, movies, …

- Meta-model

- Workflow + settings

- Meta-model

- …

- CAD geometry

- FE mesh

- Boundary conditions

- Material properties

- Meta-model

- …

EKMProcess Execution & Data Management

Simulation process data management (SPDM)



© Dynardo GmbH

Re-use and version control of processing scripts



Tutorial optiSLang © Dynardo GmbH

…

Workflow management, re-use and exchange



© Dynardo GmbH

ANSA Solver META post

wall

crash box structure

Signed von Mises

Process automation for direct MDO



© Dynardo GmbH

Results direct optimization with Evolutionary Algorithm

Resulting mass: 8.99 kg Computational costs: 282 simulations



© Dynardo GmbH

Process data /

information

Design data /

information



© Dynardo GmbH

EKM

Process Execution& Data

Management

Meta-model

assisted

MDO

Discipline:

DurabilityDiscipline:

Crash (Car Safety)

Meta-model assisted MDO



Automatic workflow with a minimum of solver runs to:

• identify the important parameters for each response

• understand and reduce the optimization task

• check solver and extraction noise

© Dynardo GmbH

Sensitivity Analysis: build MOP and identify most important design variables



Meta-model: Meta-model of Optimal Prognosis (MOP)

• Objective measure of prognosis quality

• Determination of relevant parameter subspace

• Determination of optimal approximation model

• Approximation of solver output by fast

surrogate model without over-fitting

• Evaluation of variable sensitivities

© Dynardo GmbH

Total CoP

82%



© Dynardo GmbH

Results meta-model assisted optimization with Evolutionary Algorithm

Resulting mass: 8.68 kg (-3.7%) Computational costs: 161 simulations (Sensi + validation) (-75%)



© Dynardo GmbH

1. Process automation and customization

2. Efficient algorithms: meta-modeling, sensitivities,

optimization, robustness analysis and opt. …

3. Simulation and Process Data Management (SPDM)

4. Knowledge and data exchange

5. Re-use of models, workflows and scripts

Concepts for an efficient and successful MDO:



© Dynardo GmbH

[email protected]

phone +49 (0) 3643 9008-32

Many thanks to Serafim Chatzimoisiadis and Vassilios Mazis from BETA CAE Systems for

there support regarding ANSA and META.

Acknowledgement:

Vielen Dank!Besuchen Sie uns am Stand

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