Learning Module 8 Shape Optimization: Title Page Guide What Is A Learning Module?

Learning Module 8
Shape Optimization
Title Page Guide
What is a Learning Module?
A Learning Module (LM) is a structured, concise, and self-sufficient learning
resource. An LM provides the learner with the required content in a precise and
concise manner, enabling the learner to learn more efficiently and effectively. It has a
number of characteristics that distinguish it from a traditional textbook or textbook
chapter:
An LM is learning objective driven, and its scope is clearly defined and bounded.
The module is compact and precise in presentation, and its core material contains
only contents essential for achieving the learning objectives. Since an LM is
inherently concise, it can be learned relatively quickly and efficiently.
An LM is independent and free-standing. Module-based learning is therefore nonsequential and flexible, and can be personalized with ease.
Presenting the material in a contained and precise fashion will allow the user to learn
effectively, reducing the time and effort spent and ultimately improving the learning
experience. This is the first module on structural analysis and covers a static structural
study in FEM. It goes through all of the steps necessary to successfully complete an
analysis, including geometry creation, material selection, boundary condition
specification, meshing, solution, and validation. These steps are first covered
conceptually and then worked through directly as they are applied to an example
problem.
Estimated Learning Time for This Module
Estimated learning time for this LM is equivalent to three 50-minute lectures, or one
week of study time for a 3 credit hour course.
How to Use This Module
The learning module is organized in sections. Each section contains a short
explanation and a link to where that section can be found. The explanation will give
you an idea of what content is in each section. The link will allow you to complete the
parts of the module you are interested in, while being able to skip any parts that you
might already be familiar with. The modularity of the LM allows for an efficient use
of your time.
1. Learning Objectives
The objective of this module is to introduce the user to the process of Shape Optimization
using FEM. Upon completion of the module, the user should have a good understanding
of the necessary logical steps of a Shape Optimization simulation, and be able to perform
the following tasks:
Optimization
Key concepts in optimization
Objective
Design variables
State variables
Constraints
DVs versus SVs
A simple example: optimization of a rod
Basic and feasible design space
Feasible design space
Evaluation space
An objective in optimization is a parameter of the design that the designer seeks to

optimize (i.e., either minimize or maximize).
The objective is usually not a parameter the designer can control directly. Instead, it is
a function of the design variables that the designer specifies or controls directly.
Examples of objective
mass, volume, surface area, stress, cost, etc. (for minimization)
usable container volume, surface area, natural frequency, etc. (for
maximization)
You can define only one objective in SW Simulation optimization analysis.
The objective is a function of the design variables; that is, changing the values of the
design variables leads to change of value of the objective. In fact, this is the very
point of optimization change things under your control (design variables) to
achieve an objective that is not directly under your control.
2. Prerequisites
In order to complete the learning module successfully, the following prerequisites are
required:
By subject area:
o Optimization basics.
o Mechanics of Materials or Elasticity
By topic:
knowledge of
o Optimization
o Design Variables
2
o
o
o
o
o
o
o
o
o
State variables
constraints
feasible design
displacement
strain
stress
von Mises stress
Saint Venants principle
tension, bending, or torsion loading mode
4. Tutorial Problem Statements

A good tutorial problem should focus on the logical steps in FEM modeling and
demonstrate as many aspects of the FEM software as possible. It should also be simple in
mechanics with an analytical solution available for validation. Three tutorial problems are
covered in this learning module.
Tutorial Problem 1
A rectangular alloy steel plate has one of its ends fixed to the wall. The plate has a
width w = 5 mm and a height h = 30 mm. The length of the plate is l = 100 mm. A
load of 65 KN acts horizontally on the other end of the plate as shown in the figure.
Find the optimal dimensions of the plate using Shape optimization.
Figure 1. A Rectangular plate subjected to tensile loading.
Tutorial Problem 2
A rectangular alloy steel plate with a hole at its center has one of its ends fixed to the
wall. The plate has a width w = 5 mm and a height h = 50 mm. The hole dimensions
are shown in the below figure. The length of the plate is l = 100 mm. A tensile load of
46 KN magnitude acts horizontally on the other end of the plate. Find the optimal
dimensions of the plate using Shape optimization.
Figure 2. A rectangular plate with a hole at its center, rigidly fixed on one end and
loaded on the other end
Tutorial Problem 3
A rectangular alloy steel plate with a hole at its center has one of its ends fixed to the
wall. The plate has a width w = 5 mm and a height h = 50 mm. The hole dimensions
are shown in the below figure. The length of the plate is l = 100 mm. A tensile load of
46 KN magnitude acts horizontally on the other end of the plate. Find the optimal
dimensions of the plate using Shape optimization.
Figure 3. A rectangular plate with a hole at its center rigidly fixed at one end and
subjected to bending forces on the other end
Pre-test:
The pre-test should be taken before taking other sections of the module. The purpose of
the pre-test is to assess the user's prior knowledge in subject areas relevant to shape
optimization such as Mechanics of Materials and optimization techniques. Questions are
focused towards fundamental concepts including stress, strain, displacement, kinematic
relationship, constitutive relationship, equilibrium, and material properties, design
variables, static variables, constraints, feasible design space, evaluation space.
1.
The internal force per unit area acting inside a body when forces are applied to the
body is called
O
O
O
O
2.
Shape optimization may result in:

O
O
O
O
3.
Stress
Strain
Displacement
Reaction
Maximization of Volume
Minimization of Volume
Minimizing mass
All of the above
Usage of constraints is of not much importance in shape optimization

O True
O False
4.
Which of the following are not useful in shape optimization.

O
O
O
O
5.
State Variables
Design Variables
Goals
None of the above
Bending moment applied to a beam induces mostly

O
O
O
O
Tensile stress
Compressive stress
Both tensile and compressive stress
Shear stress
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6.
When the structure is made of same material, which of the following is true?
O Minimizing mass and maximizing volume is same.
O Minimizing mass and minimizing volume is same.
O Mass and Volume are not related
O None of the above.
7.
For a bar of uniform cross-section under axial loading in x direction, the shape can
be optimized by considering the following constraints.
O
O
O
O
8.
For a bar of uniform cross-section under axial loading in x direction, the Youngs
modulus is equal to
O
O
O
O
9.
Von-Mises stress, Displacement as variables & mass or volume as goal.

Only volume or mass as goal.
Only Von-Mises Stress, Displacement as variables.
None of the above.
The ratio of the axial displacement to the axial normal stress

The ratio of the x-normal stress to the x-normal strain
The ratio of the xy-shear stress to the x-normal stress
The ratio of the xy-shear stress to the xy-shear strain
What is feasible design space?
10. Explain state variables, design variables and constraints
Conceptual Analysis of Shape Optimization:

Conceptual analysis for a Shape Optimization problem using finite element analysis
reveals that the following logical steps and sub-steps are needed:
Prerequisite (Associated) Study:
1. Preprocessing
Geometry creation
Material property assignment
Boundary conditions and loading
Mesh generation
2. Solution
3. Postprocessing
4. Validation
Optimization Study:
1. Preprocessing
Objective
Design variables
Constraints on state variables
2. Solution iterations
The above steps are explained in some detail as follows.

Prerequisite (Associated) Study:
1. Pre-processing
The pre-processing in FEM simulation is analogous to building the structure or making
the specimen in physical testing. Several sub-steps involved in pre-processing are
geometry creation, material property assignment, boundary condition specification, and
mesh generation.
The geometry of the structure to be analyzed is defined in the geometry creation step.
After the solid geometry is created, the material properties of the solid are specified in the
material property assignment step. The material required for the FEM analysis depends
on the type of analysis. For example, in the elastic deformation analysis of an isotropic
material under isothermal condition, only the modulus of elasticity and the Poissons
ratio are needed.
For most novice users of FEM, the boundary condition specification step is probably the
most challenging of all pre-processing steps. Two types of boundary conditions are
possible. The first is prescribed displacement boundary condition which is analogous to
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holding or supporting the specimen in physical testing. The second is applied force
boundary condition which is analogous to loading the specimen. Several factors
contribute to the challenge of applying boundary conditions correctly:
1) Prescribed displacement boundary conditions expressed in terms such as
u
const are mathematical simplifications, and
u boundarya const or
x boundaryb
frequently only represent supports in real structures approximately. As a result,
choosing a good approximate mathematical representation can be a challenge.
2) How a boundary is restrained depends also on the element type. For example, for
the "clamped" or "built-in" support, a boundary should be restrained as having
zero nodal displacement if solid element is used, while for the same support, the
boundary should be restrained as having zero nodal displacement and zero nodal
rotation if shell element is used.
3) Frequently, the structure to be analyzed is not fully restrained from rigid body
motion in the original problem statement. In order to obtain an FEM solution,
auxiliary restraints become necessary. Over-restraining the model, however, leads
to spurious stress results. The challenge is then adding auxiliary restraints to
eliminate the possibility of rigid body motion without over-restraining the
structure.
Because of the above challenges, one learning module will be devoted to boundary
condition specification.
Mesh generation is the process of discretizing the body into finite elements and
assembling the discrete elements into an integral structure that approximates the original
body. Most FEM packages have their own default meshing parameters to mesh the model
and run the analysis while providing ways for the user to refine the mesh.
2. Solution
The solution is the process of solving the governing equations resulting from the
discretized FEM model. Although the mathematics for the solution process can be quite
involved, this step is transparent to the user and is usually as simple as clicking a solution
button or issuing the solution command.
3. Post-processing
The purpose of an FEM analysis is to obtain wanted results, and this is what the postprocessing step is for. Typically, various components or measures of stress, strain, and
displacement at any given location in the structure are available for putout. Additional
quantities for output may include factory of safety, energy norm error, contact pressure,
reaction force, strain energy density, etc. The way a quantity is outputted depends on the
FEM software.
Optimization Study:
1. Pre-processing
The objective of the optimization study is to get the optimized design for the given model
using the FEM package.
Select the desired optimization type (Minimize or Maximize), and the desired
objective from the dropdown menu (Mass, Volume, Frequency, Buckling)
In Response window, select the correct associated study
To define a Design Variable:
In the Design Variables column select Add parameter.

In the Lower Bound box, enter the smallest allowable dimension.
In the Upper Bound box, enter the largest allowable dimension.
Click OK.
To define Constraints on state variables:
Select the sensor type like simulation data, mass type and all.
Select the appropriate type of sensor.
Under Bounds, do the following:
Select the desired Units
In the Lower Bound box, enter the lowest allowable value for the SV.
In the Upper Bound box, enter the highest allowable value for the SV.
Click OK.
To define goals:
Sensor for goal is to be selected from the list of the sensors for mass or volume
which is to be maximized or minimized.
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Overview: In this section, three tutorial problems will be solved using the commercial
FEM software SolidWorks. Although the underlying principles and logical steps of an
FEM simulation identified in the Conceptual Analysis section are independent of any
particular FEM software, the realization of conceptual analysis steps will be software
dependent. The SolidWorks-specific steps are described in this section.
This is a step-by-step tutorial. However, it is designed such that those who are familiar
with the details in a particular step can skip it and go directly into the next step.
Tutorial Problem 1. A rectangular beam subjected to tensile loading
0. Launching SolidWorks
SolidWorks Simulation is an integral part of the SolidWorks computer aided design
software suite. The general user interface of SolidWorks is shown in Figure 1.
Main menu
Frequently used command icons
Help icon
Roll over to
display
File,
Tools and
other menus
Figure 1: general user interface of SolidWorks.

In order to perform FEM analysis, it is necessary to enable the FEM component,
called SolidWorks Simulation, in the software.
Step 1: Enabling SolidWorks Simulation
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o Click "Tools" in the main menu. Select "Add-ins...". The Add-ins dialog
window appears, as shown in Figure 2.
o Check the boxes in both the Active Add-ins and Start Up columns
corresponding to SolidWorks Simulation.
o Checking the Active Add-ins box enables the SolidWorks for the
current session. Checking the Start Up box enables the SolidWorks for
all future sessions whenever SolidWorks starts up.
Check
SolidWorks
Simulation boxes
Figure 2: Location of the SolidWorks icon and
the boxes to be checked for adding it to the panel.
1. Pre-Processing
Purpose: The purpose of pre-processing is to create an FEM model for use in the next
step of the simulation, Solution. It consists of the following sub-steps:
Geometry creation
Boundary condition specification
Mesh generation.
1.1 Geometry Creation
The purpose of Geometry Creation is to create a geometrical representation of the solid
object or structure to be analyzed in FEM. In SolidWorks such a geometric model is
called a part. In this tutorial, the necessary part has already been created in SolidWorks.
The following steps will open up the part for use in the FEM analysis.
Step 1: Opening the part for simulation.
Download the part file tutorial1.SLDPRT from the web site
http://www.femlearning.org/. Use the File menu in SolidWorks to open the
downloaded part.
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The SolidWorks model tree will appear with the given part name at the top. Above the
model tree, there should be various tabs labeled Features, Sketch, etc. If the
Simulation tab is not visible, go back to steps 1 and 2 to enable the SolidWorks
Simulation package.
Step 2: Creating a Study
o Click the Simulation tab above the model tree
o Click on the drop down arrow under Study and select New Study as in
Figure 3
o In the Name panel, give the study the name Static Study
o Select Static in the Type panel to study the static equilibrium of the part
under the load
o Click OK
to accept and close the menu
Figure 3: The SolidWorks Study menu.

1.2 Material Property Assignment
The Material Property Assignment sub-step assigns materials to different components of
the part to be analyzed. All components must be assigned with appropriate material
properties.
Step 3: Opening the material property manager
o In the upper left hand corner, click Apply Material.
o The Material window appears as shown in Figure 4.
13
Figure 4: The Material window.

This will apply one material to all components. If the part is made of several components
with different materials, open the model tree and apply this process to individual
components.
1.3 Boundary Condition Specification
In the Boundary Condition Specification sub-step, the restraints and loads on the part are
defined. Here, the face of the beam attached to the wall needs to be restrained, and the
force in the proper direction needs to be applied on the other end of the beam.
Step 5: Opening the fixtures property manager
o Right click on Fixtures in the model tree and select Fixed Geometry
o Move the cursor into the graphic window.
As the cursor traverses the image of the model, notice a small icon accompany the cursor,
and this icon change shapes when the cursor is at different locations. This indicates that
the SolidWorks is in graphical selection mode, and different shapes indicate different
identities would be selected: a square (icon) indicates the surface underneath the cursor
will be selected if the mouse is clicked, a line (icon) for an edge or a line, and a dot (icon)
for a point. In this tutorial problem, the entire end surface is restrained.
14
Figure 5: Applying an immovable restraint to the beam.

At the initial orientation, however, the end to be restrained is not visible, and could not be
selected. The model should be rotated to make the fixed end visible. To rotate the model
either hold down the scroll bar and rotate with the mouse or change the orientation by
clicking on the View Orientation icon in the top middle area of the workspace.
Once the desired face is visible, select the face on which to apply the restraint. Note that
in the display panel, within the second box in the Type panel, Face<1> appears,
indicating that one surface is being selected. Clicking on this face in the graphics panel
would deselect the face.
Step 6: Restraining the member
o Select the face as in Figure 5
o Once the face has been selected, click the green check mark to close the
Fixture menu
The next step is to load the beam with the applied force. The total force applied is 65000
N in the direction as shown in the figure 6.
15
Figure 6: Applying the tensile force.

Step 7: Applying the Tensile Force:
o Right click on External Loads in the model tree and select Force.
o Under the Force/Torque tab, click the Faces, Edges, Vertices, Reference
Points for Force input field box to activate it, if not already active.
o Click on the face on which the force is applied in the graphics window. Make
sure the face is highlighted (turns blue) and appears in the input field box.
o Use SI units and type in a force of 65000 N.
o Check the Reverse direction box if the force is pointing in the wrong
direction, as shown in Figure 6.
o Click OK to close the menu.
1.4 Mesh Generation
Purpose: The purpose of the Mesh Generation sub-step is to discretize the part into
elements. The mesh consists of a network of these elements.
Step 9: Creating the mesh
o Right click Mesh in the model tree and select Create mesh
o Leave the mesh bar on its default value
o Drop down the Advanced menu and make sure the mesh is high quality, not
draft quality, by making sure the Draft Quality Mesh checkbox is not
clicked
o Figure 7 shows the completed mesh
o Click OK to close the menu and generate the mesh.
16
Figure 7: A completed mesh.

Mesh Control in SolidWorks may be used to refine the mesh locally. The guiding
principle is to refine mesh at locations of high stress gradient, such as regions around
stress concentrators and locations of geometric changes. For the current problem, local
mesh refinement is not pursued.
2. Solution
Purpose: The Solution is the step where the computer solves the simulation problem and
generates results for use in the Post-Processing step.
Step 1: Running the simulation
o At the top of the screen, click Run
o When the analysis is finished, the Results icon will appear on the model tree
3. Post-Processing
Purpose: The purpose of the Post-Processing step is to process the results of interest. For
this problem, the von Mises stress and the displacement is of interest.
Step 1: Creating a stress plot
o Right click Results on the model tree and select Define Stress Plot
o Select von Mises as the stress type and Mpa as the unit
o Unclick the Deformed Shape box and click OK to close the menu
17
Figure 8: The von Mises stress plot.

Step 2: Plotting Displacement plot:
o Select the plot for Resultant displacement.
Figure 9: The displacement plot.

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Optimization Study:
To create an Optimization Design Study:
1. Right-click the Static study tab and select Create New Design Study.
Figure 10: Creating News Design Study.
2. Right-click the Design Study tab and select Rename. Rename the study as
Designstudy1.
3. On the MinVolume tab, click Design Study Options .
4. In the PropertyManager, under Design Study Quality, select High quality
(slower).
Figure 11: Design study window showing various variables and constraints.
19
The program finds the optimal solution using many iterations with a BoxBehnken design and displays the initial scenario, optimal scenario, and all
iterations. For more information about the quality of the study, see SolidWorks
Simulation Help: Properties for the Optimization Design Study.
5. Click Ok.
To define the parameter DV1:
1. On the Variable View tab of the Designstudy1 study tab, in the Variables
section, select Add Parameter. The Add Parameters dialog box appears.
Figure 12: Defining Design Variables.

2.
3.
4.
5.
In the Add Parameters dialog box, type DV1 for Name.

Set Filter to Model dimensions.
In the graphics area, click the D11 dimension shown in the figure.
Click OK to close the Add Parameters dialog box. DV1 appears in the
Parameters dialog box.
6. Click OK to close the Parameters dialog box.If needed, click to close the
Dimension PropertyManager. The parameters DV2 and DV3 are also defined in
the same above mentioned procedure.
20
To define the variables:

We define the three parameters named DV1, DV2, and DV3 as the variables.
1. On the Variable View tab of the Designstudy1 study tab, under Variables, select
DV1 (D11@Sketch1 in the sketch) from the list.
The selected variable appears in the Variables section.
32
Figure 13: Defining all Design Variables.
2. For the DV1 variable, select Range.

The program defines the
parameter as a continuous
variable for optimization. A
continuous variable is one
which can take any value
between the limits. For
example, 14.1567mm is a valid
value
between
a
minimum value of 25mm and a
maximum value of 35mm.
Figure 14: Defining type of

variable.
21
3. For Min, type 25mm and for Max, type 35mm.
Figure 15: Defining the Minimum and Maximum values for DV.
The program varies the model dimension between 25mm and 35mm to find the
optimal value for the variable.
4. Repeat steps 1-3 to add the parameter named DV2 (D12@Sketch1 in the
sketch) as a variable. Use 95 as minimum and 105 as maximum values for
DV2.
5. Repeat steps 1-3 to add the parameter named DV3 (D13@Sketch1 in the
sketch) as a variable. Enter 4 and 6 for Min and Max, respectively.
The Variables section lists three design variables.
Figure 16: Defining the Minimum and Maximum values for all DVs.
We need to define sensors to use them as constraints in a Design Study. The Design
Study runs the corresponding initial Simulation study to update a sensor's value. For
example, it runs the frequency study to track the resonant frequency values.
You define a sensor to track the value of the von Mises stress.
1. On the Variable View tab of the Designstudy1 study tab, in the Constraints
section, select Add Sensor.
2. In the Property Manager, for Sensor Type, select Simulation Data.
3. Under Data Quantity, for Results, select Stress.
4. For component, select VON: von Mises Stress.
5. Under Properties, for Units, select N/mm^2 (MPa) or Psi.
6. For Criterion, select Model Max and click OK.
7. In the Feature Manager Design tree, under Sensors, rename the sensor as Stress1.
22
Figure 17: Defining the sensors for constraints.
8. Similarly the sensor Displacement1 is also defined.

We impose a constraint on the maximum von Mises stress that it should not exceed a
value of 620.4 MPa or 89981 Psi. You can use any sensor or driven global variable to
define constraints for an Optimization Design Study. For more information about
defining sensors as constraints in a Design Study see SolidWorks Simulation Help:
Defining Constraints.
Figure 18: Defining the Minimum and Maximum values of sensors for
constraints.
1. On the Designstudy1 Design Study tab, in the Constraints section, make sure
Stress 1 is selected.
The sensor appears in the Constraints section.
2. For Mises, select Is less than.
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3. For Max, type 620.4 N/mm^2.

The program automatically selects the Staticstudy study to run and track the
sensor's value since only one static study is defined.
Defining the Displacement constraint:
The maximum resultant displacement should not exceed 0.2056 mm.
1. On the Designstudy1 Design Study tab, in the Constraints section, from the list,
select URES.
The sensor appears in the Constraints section. This pre-defined sensor tracks
the value of resultant displacement.
2. For URES, select Is less than.
3. For Max, type 0.2056 mm.
sensor's value.
Defining a goal:
The objective of this Optimization Design Study is to minimize the volume of the part.
Figure 19: Defining the Goal.
1. On the Designstudy1 Design Study tab, in the Goals section, from the list, select
the Volume1 sensor.
2. The sensor appears in the Goals section.
3. For Volume1, select Minimize.
4. On the Designstudy1 Design Study tab, select Run.
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Figure 20: Figure showing the run command for iterations.
5. The program runs some iterations (excluding the initial and optimal scenarios)
since you defined a High quality study and three design variables. After running
the experiments, the program calculates the optimal design variables by forming a
response function relating the goal to the variables.
Figure 21: Figure showing the process of iterations.
Viewing the Results:

1. Review the Initial column. The column is highlighted in red because the constraints
on von Mises stress and displacement are violated.
2. Review the Optimal column. The column is highlighted in green because
optimization was performed successfully.
25
Figure 22: Figure showing the iterations.
The program updates the model with the optimal dimensions in the graphics window.
Figure 23: Figure showing the updated models with optimal values.
Study Results
15 of 15 iterations ran successfully.
Component
name
DV1
DV2
DV3
Stress1
Units
Current
Initial
Optimal
Iteration1
Iteration2
mm
mm
mm
psi
30.21393
95.06622
4.9267
81015
30
100
5
89877
30.21393
95.06622
4.9267
81015
35
105
5
73282
35
95
5
78930
26
Displacement1
Volume1
mm
mm^3
0.19697
14151.0696
0.20565
15000
0.19697
14151.0696
0.18508
18375
0.1674
16625
Component
name
DV1
DV2
DV3
Stress1
Displacement1
Volume1
Units
Iteration3
Iteration4
Iteration5
Iteration6
Iteration7
mm
mm
mm
psi
mm
mm^3
25
105
5
97103
0.2592
13125
25
95
5
1.0274e+005
0.23449
11875
35
100
6
68618
0.14682
21000
35
100
4
96292
0.2203
14000
25
100
6
89803
0.20566
15000
Component
name
DV1
DV2
DV3
Stress1
Displacement1
Volume1
Units
Iteration8
Iteration9
Iteration10
Iteration11
Iteration12
mm
mm
mm
psi
mm
mm^3
25
100
4
1.2623e+005
0.30858
10000
30
105
6
69844
0.17993
18900
30
105
4
1.0965e+005
0.26998
12600
30
95
6
77742
0.16274
17100
30
95
4
1.0874e+005
0.24417
11400
Component name
DV1
DV2
DV3
Stress1
Displacement1
Volume1
Units
mm
mm
mm
psi
mm
mm^3
Iteration13
30
100
5
89877
0.20565
15000
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Tutorial Problem 2. A rectangular plate with a hole subjected to tensile loading
3. Launching SolidWorks
Main menu
Help icon
Roll over to
display
File,
Tools and
other menus

28
Check
SolidWorks
Simulation boxes
1. Pre-Processing
Geometry creation
Mesh generation.
downloaded part.
Simulation package.
29
Figure 3
under the load
o Click OK

properties.
30

components.
31

Fixture menu
The next step is to load the beam with the applied force. The total force applied is 46000
N in the direction as shown in the figure 6.
32

1.4 Mesh Generation
clicked
33

2. Solution
3. Post-Processing
34


35
Optimization Study:
Designstudy1.
3. On the MinVolume tab, click Design Study Options .
(slower).
5. Click Ok.
36

7. In the Add Parameters dialog box, type DV1 for Name.
8. Set Filter to Model dimensions.
9. In the graphics area, click the D11 dimension shown in the figure.
10. Click OK to close the Add Parameters dialog box. DV1 appears in the
11. Click OK to close the Parameters dialog box. If needed, click to close the
Dimension Property Manager. The parameters DV2 and DV3 are also defined in
Figure 12: Defining type of variable.

37
3. The program defines the parameter as a continuous variable for optimization. A

continuous variable is one which can take any value between the limits. For
example, 14.1567mm is a valid value between a minimum value of 45mm and a
4. The program varies the model dimension between 25mm and 35mm to find the
5. Repeat steps 1-3 to add the parameter named DV2 through DV6.
example, it runs the frequency study to track the resonant frequency values.
We define a sensor to track the value of the von Mises stress.
8. Similarly the sensor Displacement1 is also defined as like in the tutorial1.
38
Defining Constraints:
Figure 14: Defining the Maximum value of sensors for constraints.

select URES.
sensor's value.
Defining a goal:

39
the Volume1 sensor.
Figure 17: Figure showing the process of iterations.
40

Figure 19: Figure showing the updated models with optimal values.
41
Study Results
Component
name
DV1
DV2
DV3
DV4
DV5
DV6
Displacement1
Stress1
Volume1
Component
name
DV1
DV2
DV3
DV4
DV5
DV6
Displacement1
Stress1
Volume1
Component
name
DV1
DV2
DV3
DV4
DV5
DV6
Displacement1
Stress1
Volume1
Component
name
DV1
DV2
Units
Current
Initial
Optimal
Iteration1
Iteration2
mm
mm
mm
mm
mm
mm
mm
N/mm^2
(MPa)
mm^3
50
100
50
25
5
15
0.09812
619.37
53.63739
95.82489
49.86481
24.87213
4.24872
12.73483
0.10017
641.2
50
100
50
25
5
15
0.09812
619.37
60
110
50
30
5
15
0.08779
486.52
60
110
50
20
5
15
0.09517
542.83
24116.42707
21296.37871
24116.42707
32116.42707
32116.42707
Units
Iteration3
Iteration4
Iteration5
Iteration6
Iteration7
mm
mm
mm
mm
mm
mm
mm
N/mm^2
(MPa)
mm^3
60
90
50
20
5
15
0.081
530.73
40
90
50
20
5
15
0.11553
832.33
40
90
50
30
5
15
0.1889
1594.8
40
110
50
30
5
15
0.20796
1571.1
60
90
50
30
5
15
0.07325
497.45
26116.42707
17116.42707
17116.42707
21116.42707
26116.42707
Units
Iteration8
Iteration9
Iteration10
Iteration11
Iteration12
mm
mm
mm
mm
mm
mm
mm
N/mm^2
(MPa)
mm^3
40
110
50
20
5
15
0.13726
817.05
50
110
60
25
7
15
0.07599
437.4
50
110
60
25
3
15
0.17742
1034.4
50
110
40
25
3
15
0.18
1026.6
50
90
40
25
3
15
0.15098
1033.3
21116.42707
37262.99789
15969.85624
15969.85624
12969.85624
Units
Iteration13
Iteration14
Iteration15
Iteration16
Iteration17
mm
mm
50
90
50
90
50
110
50
90
50
100
42
DV3
DV4
DV5
DV6
Displacement1
Stress1
mm
mm
mm
mm
mm
N/mm^2
(MPa)
mm^3
40
25
7
15
0.06467
438.66
60
25
7
15
0.06347
432.71
40
25
7
15
0.07711
440.62
60
25
3
15
0.14821
1024.2
60
30
5
20
0.12659
795.98
30262.99789
30262.99789
37262.99789
12969.85624
23429.20367
Units
Iteration18
Iteration19
Iteration20
Iteration21
Iteration22
mm
mm
mm
mm
mm
mm
mm
N/mm^2
(MPa)
mm^3
50
100
60
30
5
10
0.09487
567.74
50
100
60
20
5
10
0.09486
545.79
50
100
40
20
5
10
0.09366
559.3
50
100
40
20
5
20
0.11952
793.98
50
100
40
30
5
20
0.11948
789.36
24607.30092
24607.30092
24607.30092
23429.20367
23429.20367
Units
Iteration23
Iteration24
Iteration25
Iteration26
Iteration27
mm
mm
mm
mm
mm
mm
mm
N/mm^2
(MPa)
mm^3
50
100
60
20
5
20
0.1266
795.13
50
100
40
30
5
10
0.09366
547.45
60
100
50
30
7
15
0.05751
354.55
60
100
50
30
3
15
0.13427
821.57
60
100
50
20
3
15
0.14682
896.04
23429.20367
24607.30092
40762.99789
17469.85624
17469.85624
Units
Iteration28
Iteration29
Iteration30
Iteration31
Iteration32
40
100
50
20
3
15
0.21067
1368.8
40
100
50
20
7
15
0.09021
586.12
40
100
50
30
7
15
0.14147
1125.5
60
100
50
20
7
15
0.06288
382.64
40
100
50
30
3
15
0.33084
2715.3
Volume1
mm
mm
mm
mm
mm
mm
mm
N/mm^2
(MPa)
mm^3
11469.85624
26762.99789
26762.99789
40762.99789
11469.85624
Component
Units
Iteration33
Iteration34
Iteration35
Iteration36
Iteration37
Volume1
Component
name
DV1
DV2
DV3
DV4
DV5
DV6
Displacement1
Stress1
Volume1
Component
name
DV1
DV2
DV3
DV4
DV5
DV6
Displacement1
Stress1
Volume1
Component
name
DV1
DV2
DV3
DV4
DV5
DV6
Displacement1
Stress1
43
name
DV1
DV2
DV3
DV4
DV5
DV6
Displacement1
Stress1
Volume1
Component
name
DV1
DV2
DV3
DV4
DV5
DV6
Displacement1
Stress1
Volume1
Component
name
DV1
DV2
DV3
DV4
DV5
DV6
Displacement1
Stress1
Volume1
mm
mm
mm
mm
mm
mm
mm
N/mm^2
(MPa)
mm^3
50
110
50
25
7
20
0.08372
480.91
50
110
50
25
7
10
0.07168
399.61
50
110
50
25
3
10
0.16735
933.51
50
90
50
25
3
10
0.13827
942.7
50
90
50
25
3
20
0.16655
1159.1
36300.88514
37950.22129
16264.38055
13264.38055
12557.5222
Units
Iteration38
Iteration39
Iteration40
Iteration41
Iteration42
mm
mm
mm
mm
mm
mm
mm
N/mm^2
(MPa)
mm^3
50
90
50
25
7
20
0.07133
481.89
50
110
50
25
3
20
0.19545
1157.8
50
90
50
25
7
10
0.05921
403.68
60
100
60
25
5
20
0.09392
573.52
60
100
60
25
5
10
0.07733
448.27
29300.88514
15557.5222
30950.22129
28429.20367
29607.30092
Units
Iteration43
Iteration44
Iteration45
Iteration46
Iteration47
mm
mm
mm
mm
mm
mm
mm
N/mm^2
(MPa)
mm^3
60
100
40
25
5
10
0.07662
442.92
40
100
40
25
5
10
0.12207
733.82
40
100
40
25
5
20
0.19231
1353.1
40
100
60
25
5
20
0.20968
1358.2
60
100
40
25
5
20
0.09177
584.67
29607.30092
19607.30092
18429.20367
18429.20367
28429.20367
Component name
DV1
DV2
DV3
DV4
DV5
DV6
Displacement1
Stress1
Volume1
Units
mm
mm
mm
mm
mm
mm
mm
N/mm^2 (MPa)
mm^3
Iteration48
40
100
60
25
5
10
0.12346
734.24
19607.30092
44
Iteration49
50
100
50
25
5
15
0.09812
619.37
24116.42707
Tutorial Problem 3. A rectangular plate with a hole subjected to bending loading
Launching SolidWorks
Main menu
Help icon
Roll over to
display
File,
Tools and
other menus

45
Check
SolidWorks
Simulation boxes
1. Pre-Processing
Geometry creation
Mesh generation.
downloaded part.
Simulation package.
46
Figure 3
under the load
o Click OK

properties.
47

components.
48

Fixture menu
The next step is to load the beam with the applied bending force. The total force applied
is 320 N in the direction as shown in the figure 6.
49

1.4 Mesh Generation
clicked
50

2. Solution
3. Post-Processing
51

Optimization Study:
52

Designstudy1.
3. On the Designstudy1 tab, click Design Study Options .
(slower).
5. Click Ok.
53

7. In the Add Parameters dialog box, type DV1 for Name.
8. Set Filter to Model dimensions.
9. In the graphics area, click the D11 dimension shown in the figure.
10. Click OK to close the Add Parameters dialog box. DV1 appears in the
11. Click OK to close the Parameters dialog box.If needed, click to close the
Dimension PropertyManager. The parameters DV2 and DV3 are also defined in
Figure 12: Defining type of variable.
54
3. The program defines the parameter as a continuous variable for optimization. A

continuous variable is one which can take any value between the limits. For
example, 14.1567mm is a valid value between a minimum value of 45mm and a
4. The program varies the model dimension between 25mm and 35mm to find the
5. Repeat steps 1-3 to add the parameter named DV2 through DV6.
example, it runs the frequency study to track the resonant frequency values.We define a
sensor to track the value of the von Mises stress.
13. Similarly the sensor Displacement1 is also defined as like in the tutorial1.
Defining Constraints:
Figure 14: Defining the Maximum value of sensors for constraints.

55
select URES.
sensor's value.
Defining a goal:
the Volume1 sensor.
56

57
And we can plot the results into a word file or html file. And we can list all the iterations
as follows:
Figure 18: Figure showing the procedure to plot the results into a word file or html
file.
Study Results
Component
name
DV1
DV2
DV3
DV4
Stress1
Units
Current
Initial
Optimal
Iteration1
Iteration2
35.20752
251.24512
172.05811
19.99756
563.39
40
300
150
15
616.59
35.20752
251.24512
172.05811
19.99756
563.39
45
350
150
15
705.93
45
250
150
15
435.73
Displacement1
Volume1
mm
mm
mm
mm
N/mm^2
(MPa)
mm
mm^3
22.27108
42658.174
33.10184
59116.42707
22.27108
42658.174
46.46544
77866.42707
16.93068
55366.42707
Component
Units
Iteration3
Iteration4
58
Iteration5
Iteration6
Iteration7
name
DV1
DV2
DV3
DV4
Stress1
Displacement1
Volume1
Component
name
DV1
DV2
DV3
DV4
Stress1
Displacement1
Volume1
Component
name
DV1
DV2
DV3
DV4
Stress1
Displacement1
Volume1
Component
name
DV1
DV2
DV3
DV4
Stress1
Displacement1
Volume1
Component
name
DV1
DV2
DV3
DV4
Stress1
Displacement1
Volume1
mm
mm
mm
mm
N/mm^2
(MPa)
mm
mm^3
35
350
150
15
1018.1
35
250
150
15
560.01
40
300
175
20
594.91
40
300
175
10
591.27
40
300
125
20
833.93
59.87979
60366.42707
21.93951
42866.42707
33.39551
58429.20367
32.53606
59607.30092
34.44358
58429.20367
Units
Iteration8
Iteration9
Iteration10
Iteration11
Iteration12
mm
mm
mm
mm
N/mm^2
(MPa)
mm
mm^3
40
300
125
10
646.64
45
300
150
20
602.97
45
300
150
10
525.23
35
300
150
20
982.33
35
300
150
10
675.46
32.76191
59607.30092
29.90728
65929.20367
28.99068
67107.30092
39.13601
50929.20367
37.31989
52107.30092
Units
Iteration13
Iteration14
Iteration15
Iteration16
Iteration17
mm
mm
mm
mm
N/mm^2
(MPa)
mm
mm^3
40
350
175
15
709.96
40
350
125
15
915.71
40
250
175
15
495.65
40
250
125
15
512.72
45
300
175
15
530.29
52.00566
69116.42707
52.70332
69116.42707
18.95363
49116.42707
19.3154
49116.42707
29.15408
66616.42707
Units
Iteration18
Iteration19
Iteration20
Iteration21
Iteration22
mm
mm
mm
mm
N/mm^2
(MPa)
mm
mm^3
45
300
125
15
619.47
35
300
175
15
645.99
35
300
125
15
902.71
40
350
150
20
949.97
40
350
150
10
730.05
29.56717
66616.42707
37.63415
51616.42707
38.36122
51616.42707
53.6616
68429.20367
51.53545
69607.30092
Units
Iteration23
Iteration24
Iteration25
mm
mm
mm
mm
N/mm^2 (MPa)
mm
mm^3
40
250
150
20
495.13
19.46402
48429.20367
40
250
150
10
487.14
18.90288
49607.30092
40
300
150
15
616.59
33.10184
59116.42707
59
Attachment E. Post-test
1.
The internal force per unit area acting inside the body when a force is applied on
the body is called:
O
O
O
O
Stress
Strain
Displacement
Other
2. What is state variable?
3. Define basic and feasible design space
4. What is an Optimum Design?
5. Ranges and limits are set for which entity in an optimization study?
O
O
O
O
goals
Constraints
both the above
None of the above
6. Bending moment induces:

O
O
O
O
Tensile stress
Compressive stress
Both tensile and compressive stress
Shear stress
7. State variables can be directly controlled.

O True
O False
8. A point in the feasible design space represents one feasible design

60
O True
O False
9. What is Youngs modulus?
O
O
O
O
The ratio of the normal stress to the normal strain

The ratio of the shear stress to the normal stress
The ratio of the displacement to the normal stress
The ratio of shear stress to shear strain
10. The 2D space in which the horizontal dimension represents all feasible designs and
the vertical dimension represents the objective function is:
O
O
O
O
Feasible design space

Evaluation space
All the above
None of the above
61
Attachment F. Assessment
Do you feel it was bad to not have a teacher there to answer any questions you
might have?
O It didnt matter
O It would have been nice
O I really wanted to ask a question
How did the interactivity of the program affect your learning?

O
O
O
O
O
Improved it a lot
Improved it some
No difference
Hurt it some
Hurt it a lot
The six levels of Blooms Taxonomy are listed below. Rank how well this
learning module covers each level. 5 meaning exceptionally well and 1
meaning very poor.
1. Knowledge (remembering previously learned material)

O 5
O 4
O 3
O 2
O 1
2. Comprehension (the ability to grasp the meaning of the material and give
examples)
O 5
O 4
O 3
O 2
O 1
3. Application (the ability to use the material in new situations)
O 5
O 4
O 3
O 2
O 1
62
4. Analysis (the ability to break down material into its component parts so that
its organizational structure may be understood)
O 5
O 4
O 3
O 2
O 1
5. Synthesis (the ability to put parts together to form a new whole)
O 5
O 4
O 3
O 2
O 1
6. Evaluation (the ability to judge the value of the material for a given purpose)
O 5
O 4
O 3
O 2
O 1
Do you think the mixed text and video format works well?
O Yes
O Indifferent
O No
Do you think the module presents an affective method of learning FEA?

O Yes
O Indifferent
O No
Did you prefer this module over the traditional classroom learning
experience? Why or why not.
63
How accurate would it be to call this module self-contained and stand-alone?

O
O
O
O
O
Very accurate
Accurate
Indifferent
Inaccurate
Very inaccurate
What specifically did you like and/or dislike about the module.
How useful were the practice problems?

O
O
O
O
O
Very helpful
Helpful
Indifferent
Unhelpful
Very unhelpful
Was there any part of the module that you felt was unnecessary of redundant?
Was there a need for any additional parts?
Please list any suggestions for improving this module.
Overall, how would you rate your experience taking this module?
O
O
O
O
O
Excellent
Fair
Average
Poor
Awful
64
Attachment G. Practice Problems
1. A rectangular alloy steel plate has one of its ends fixed to the wall. The plate has a
width w = 5 mm and a height h = 30 mm. The length of the plate is l = 150 mm. A
load of 26800 N force acts horizontally on the other end of the plate as shown in the
figure. Find the optimal dimensions of the plate ussssssing Shape optimization.
Problem 1
2. A cylindrical rod made up of alloy steel has one of its ends fixed to the wall. The rod
has a diameter d = 20 mm. The length of the rod is l = 200 mm. A bending load of
2550 N force acts vertically on the other end of the rod as shown in the figure. Find
the optimal dimensions of the rod using Shape optimization.
Problem 2
3. A cylindrical rod made up of alloy steel has one of its ends fixed to the wall. The rod
has an internal diameter d1 = 15 mm and an external diameter d2 = 20 mm. The length
65
of the rod is l = 200 mm. A tensile load of 80000 N force acts along the axis on the
other end of the rod as shown in the figure. Find the optimal dimensions of the rod
using Shape optimization.
Problem 3
4. Follow the tutorial 1 and reverse the direction of loading on the plate. Compare
the results obtained with the results obtained in tutorial 1. Explain the difference
in results if any.
66

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Learning Module 8

An objective in optimization is a parameter of the design that the designer seeks to

4. Tutorial Problem Statements

Figure 1. A Rectangular plate subjected to tensile loading.

Shape optimization may result in:

Usage of constraints is of not much importance in shape optimization

Which of the following are not useful in shape optimization.

Bending moment applied to a beam induces mostly

Von-Mises stress, Displacement as variables & mass or volume as goal.

The ratio of the axial displacement to the axial normal stress

What is feasible design space?

10. Explain state variables, design variables and constraints

Conceptual Analysis of Shape Optimization:

The above steps are explained in some detail as follows.

To define a Design Variable:

In the Design Variables column select Add parameter.

To define Constraints on state variables:

Tutorial Problem 1. A rectangular beam subjected to tensile loading

Frequently used command icons

Figure 1: general user interface of SolidWorks.

to accept and close the menu

Figure 3: The SolidWorks Study menu.

Figure 4: The Material window.

Figure 5: Applying an immovable restraint to the beam.

Figure 6: Applying the tensile force.

Figure 7: A completed mesh.

Figure 8: The von Mises stress plot.

Figure 9: The displacement plot.

Figure 10: Creating News Design Study.

Figure 12: Defining Design Variables.

In the Add Parameters dialog box, type DV1 for Name.

To define the variables:

2. For the DV1 variable, select Range.

Figure 14: Defining type of

3. For Min, type 25mm and for Max, type 35mm.

Figure 17: Defining the sensors for constraints.

8. Similarly the sensor Displacement1 is also defined.

3. For Max, type 620.4 N/mm^2.

Figure 19: Defining the Goal.

Figure 20: Figure showing the run command for iterations.

Figure 21: Figure showing the process of iterations.

Viewing the Results:

Figure 22: Figure showing the iterations.

Tutorial Problem 2. A rectangular plate with a hole subjected to tensile loading

Frequently used command icons

Figure 1: general user interface of SolidWorks.

to accept and close the menu

Figure 3: The SolidWorks Study menu.

Figure 4: The Material window.

Figure 5: Applying an immovable restraint to the beam.

Figure 6: Applying the tensile force.

o Click OK to close the menu and generate the mesh.

Figure 7: A completed mesh.

Figure 8: The von Mises stress plot.

Figure 9: The displacement plot.

Figure 10: Creating News Design Study.

Figure 11: Defining Design Variables.

Figure 12: Defining type of variable.

3. The program defines the parameter as a continuous variable for optimization. A

Figure 14: Defining the Maximum value of sensors for constraints.

Figure 15: Defining the Goal.

Figure 16: Figure showing the run command for iterations.