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Optimization with
Tosca Structure
SIMULIA Tosca Structure Seminar
Day 1
► Introduction
► Workflow with TOSCA Structure
► Topology optimization I
► Workshop 1a
► Topology optimization II
► Workshop 1b
► Postprocessing
► Topology optimization III
► Workshop 1c
Slide 2 | 02/2014
1
Day 2
► Shape optimization I
► Workshop 2a
► Shape optimization II

► Workshop 2b
► Configuration and Troubleshooting
► Sizing optimization
► Workshop 3
► Bead optimization
► Workshop 4a
► Workshop 4b
► Solver Interfaces
► Final Discussion
Slide 3 | 02/2014
Legal Notices
The Software described in this documentation is available only under license from Dassault Systèmes
and its subsidiary and may be used or reproduced only in accordance with the terms of such license.
This documentation and the software described in this documentation are subject to change without prior
notice.
Dassault Systèmes and its subsidiaries shall not be responsible for the consequences of any errors or
omissions that may appear in this documentation.
No part of this documentation may be reproduced or distributed in any form without prior written
permission of Dassault Systèmes or its subsidiary.
© Dassault Systèmes, 2014.
Printed in the United States of America
The 3DS logo, SIMULIA and CATIA are trademarks or registered trademarks of Dassault Systèmes or its
subsidiaries in the US and/or other countries.
Other company, product, and service names may be trademarks or service marks of their respective
owners. For additional information concerning trademarks, copyrights, and licenses, see the notices at:
http://www.3ds.com/products/simulia/portfolio/product-os-commercial-programs.
Slide 4 | 02/2014
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Revision Status
Lesson 1 2/14 Updated for TOSCA 8 Workshop 1a 2/14 Updated for TOSCA 8
Lesson 2 2/14 Updated for TOSCA 8 Workshop 1b 2/14 Updated for TOSCA 8
Lesson 3 2/14 Updated for TOSCA 8 Workshop 1c 2/14 Updated for TOSCA 8

Lesson 6 2/14 Updated for TOSCA 8 Workshop 3 2/14 Updated for TOSCA 8
Lesson 9 2/14 Updated for TOSCA 8
Slide 5 | 02/2014
3
4
Notes
5
Notes
6

Optimization with
Tosca Structure
Introduction
Introduction
1. Motivation
2. Optimization definitions
3. Optimization strategies
Slide 2 | 02/2014
7

Motivation for
Optimization
Why optimization?
time
competition
costs law
man
power
environment
weight warranty
Slide 4 | 02/2014
8
Success factors for product development

Why optimization?
Costs Cost pressure

► Material

► Manpower
► Warranty issues
Quality Innovation pressure

► Legal requirements
► Customer requests
Time Time-to-market
Slide 5 | 02/2014
Optimization driven design development

Reducing costs and development time
Costs Decrease
in costs
Reduction of development time
Time
Optimized Design Development Conventional Design Development
Optimize Design Design
Design Analyze Build
Build Build Test
Validate Test
Slide 6 | 02/2014
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Costs and their influence in the development cycle
► The total costs are mainly defined in an early

stage of development

► The costs of a change of design increase
significantly during the development cycle
► Significant cost reduction with good design

proposal in the conceptual phase
Changes should be inserted as early as possible
Progress
Slide 7 | 02/2014
Optimization
Definitions
10
Mathematical description of an optimization task
Design variables Minimize f(x)

How can you modify your structure? considering gi(x) = 0, i=1..n,
gj(x)  0, j=n+1..m,

Changeable values x,y,z,…
x IRd
Objective function
What is to be maximized/minimized ?
Function dependent on the design variable: f(x)
Constraints
Which restrictions must be considered?
restrictions for variables: x2  x  x1 Fixed beam, from Discorsi e
dimostrazioni matematiche,
equality restrictions: g(x) = 0 intorno a due nuove scienze
inequality restrictions: g(x)  0 (Galileo Galilei, Leyden 1638)
Slide 9 | 02/2014
How can you modify a structure?

Number of design variables
Problem One DV = thickness

Increasing shape flexibility
Two DV = thickness, angle
Several DV = variable thickness
More design variables

 better solution
Best design obtained by free („non-parametric“) modification

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How can you modify a structure?

Design variables / area
CAD model
parametric
a
► Geometric parameters

(angle, radius, cross section,…)
discrete continuos
CAE model
► Material: parameters, orientation
► Structural layout (adding and wood steel concrete
removing of elements)
non-parametric
 Topology optimization
► Outer surface nodes of model
 Shape optimization
► Nodes on surface of sheet
metal structure
 Bead optimization
Slide 11 | 02/2014
What are your targets?

Objective
► The objective is maximized or minimized

► Maximize overall stiffness
► Minimize stresses
► Maximize eigenfrequencies
► Minimize mass Minimum
► Etc.
Maximum
► Modification of the design variables changes the
value of the objective
► Frequently, the objective consists of results from
a finite element analysis (e.g. for specific
loadcases and of certain component areas)
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What are your restrictions?

Constraints
► Frequently, the constraints are geometrical Constraint

manufacturing requirements… Feasible Infeasible
► Casting constraints

► Symmetry constraints
► Mass constraint
► ...
► … or design limitations on structural responses
from a FE analysis.
► Frequency constraints
Active constraint
► Nodal displacement restrictions
► Etc.
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Which sources provide you with inputs for the optimization?

Design responses
► Finite element analysis

► Stiffness, stresses, eigenfrequencies, Extract values
displacements, etc.
► For given loadcases and loadcase types
Combine loadcases
► For given areas in the model
► CAE model Combine (sum, max,...) for areas
► Weight, volume
► COG, inertia
Restrict value Optimize value
► Position of nodes
► Element layout
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Optimization definitions required

for an optimization workflow
Model: design variables

Generate new model
Inputs (responses): FE analysis
Objective
Constraints
Update design variables
Finish?
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Optimization
Strategies
14
Choice of optimization strategy

Influencing factors
Model: design variables Chosen design variables?

Typical number of optimization

Inputs (responses) FE analysis CPU time?
Objective Chosen objective?

iterations?
Constraints Chosen constraints?
Update design variables Number of design variables?
Finish?
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Optimization strategies
Heuristic algorithms
Genetic
Monte Carlo
algorithms
Mathematical programming Optimality criteria
Direct methods Structural Fully stressed design

- SQP, MMFD, MFD,
optimization
Penalty methods
Kuhn Tucker
- Newton, gradient based, ...
Approximation methods Other OC

- SLP, SCP, .. - Tosca
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Heuristic algorithms
► No guarantee of achieving an optimum solution

(but greater probability)
► Large number of numerical analysis necessary

► Often not a feasible optimization approach when
the number of design variables is high
► No derivatives required for all response types
► Examples:
► Genetic algorithms
(imitation of biological evolution)
► Monte Carlo methods
(random choice of values) Flowchart of a genetic algorithm
Source: “An introduction to genetic algorithms”, Kalyanmoy Deb
Slide 19 | 02/2014
Methods of mathematical programming
► Iterative changes of an initial design for improving the objective function and fulfilling
constraints in each optimization iteration
► Gradient information has to be calculated by sensitivity analysis:
► Finite differences (numerical approach)

► Analytical approaches (finite element formulations, Tosca)
► Semi-analytical approaches (finite element formulations, Tosca)
x0 s1
► Use of local attributes of the objective function and constraints
to determine direction and size of changes in design variables
► Large number of numerical solutions generators exist: Xq-1
(SQP, SLP, CONLIN, MMA, MMFD, Simplex, ...) sq
► Efficient when having a high number of design variables xq
and few constraints
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Optimality criteria
► Mathematical formulations of conditions that characterize the optimum

► The start design is changed based on a redesign rule

► Specific problem classes may be solved very efficiently. Often a low
number of optimization iterations is required
► Normally, the number of design variables do not influence the number of
optimization iterations
► Examples
► Kuhn Tucker conditions
► Fully stressed design
► Tosca Structure
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Characteristics of different optimization approaches
Mathematical + General applicability

programming - Convergence speed depends on the type
An optimized design is determined
of objective and the number of constraints
by an iterative algorithm which
+ Generally, the number of design variables

changes an initial design using
has no significant impact upon the
sensitivities
convergence speed
- Effort in numerical implementation
Optimality criteria + Convergence speed independent of the

number of design variables
+ Fast convergence Design variables are redesigned so
+ Solution independent of start value they fulfill the optimality criteria
- No general approaches (very specific)
Heuristic methods + Very general applicability A whole group of designs is derived

- Only for small number (<500) of design according to heuristic methods
variables (combination, arbitrarily,…)
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Thank you for your
attention
18
Notes
19
Notes
20
Optimization with

Tosca Structure
Workflow with
Tosca Structure
Workflow with Tosca Structure
1. Tosca Structure modules

2. Optimization workflow
3. Tosca ANSA environment

4. Tosca Extension for ANSYS/Workbench
5. Tosca Structure.gui
Slide 2 | 02/2014
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Structural

Optimization
Using Tosca
Structure Modules
Structural optimization using Tosca Structure
Tosca Structure.topology Tosca Structure.shape

Images courtesy of AUDI AG Images courtesy of Ford Werke AG
Find the design with maximum stiffness or minimum weight Reduce local stresses and increase durability
Tosca Structure.sizing Tosca Structure.bead
Optimize sheet thickness for best static and dynamic behavior Increase stiffness or eigenfrequency of sheet metal structures
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Structural optimization
Design process with your FEA solver and Tosca Structure
► Reduction of weight
► Enforcing desirable Optimized CAD Finite element
stiffness and dynamic reconstruction model of design space

process
► Minimize the maximum
stresses of several
loadcases
► Minimize damage
and increase durability
Shape
► Include manufacturing optimization Topology optimization
constraints
► Design for
displacements/forces/
eigenfrequences
Smoothing and generation
Validation run of validation file
Slide 5 | 02/2014
Optimization
Workflow
23
Optimization workflow with Tosca Structure

General procedure
Preprocessing ► Definition of optimization task (model, design area, objective, constraint)
► Check for completeness, correct syntax and boundary conditions

Check
Optimization ► Modification of model in iterative process between optimizer and solver
Postprocessing ► Visual evaluation of result
Validation ► Verification analysis of modified model
Transfer ► Preparation for further processing in CAD
Slide 7 | 02/2014

Integration of Tosca Structure in your CAE environment
FE- FE-
Interactive setup
preprocessing postprocessing
ABAQUS
ABAQUS/CAE ANSYS ABAQUS/Viewer
ANSYS MSC.Nastran ANSYS
ANSA mETA
FEMAP FEMAP
Hypermesh Hypermesh
MEDINA
CAD system
CAD system
MEDINA
MSC.Patran
MSC.Patran NX ….
NX …
Generation of FE model Fully automatic, Evaluation of finite element

with group information non parametric optimization and optimization results
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Optimization task
Workflow Preprocessing
Preprocessing ► Geometric model

► Created in a CAD system

Check
► Analysis model
Optimization ► Meshing of the CAD model (or directly defined design space)
► Entering the boundary conditions and loads
Postprocessing
► Optimization model
Validation ► Link to FE-model
► Definition of design variables, objective function and constraints
Transfer
 Definition of complete optimization task saved in a parameter file
Slide 9 | 02/2014
Definition of the optimization task

User interfaces
Tosca ANSA environment Tosca Extension for Tosca Structure.gui

ANSYS/Workbench
Graphical user interface Integration of topology Classical user interface
based on ANSA technology optimization into ANSYS/WB
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Check of optimization task
Preprocessing Automatic check of the optimization task

► Test for completeness and correct dependencies

Check ► Syntax check
► Visual check for correct definition of geometric restrictions (symmetries,
Optimization displacement constraints)
► Checks without time-consuming FE-analysis
Postprocessing
Virtual displacement for check
of symmetry restriction
Validation
Transfer
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Optimization
Preprocessing ► Iterative process between optimizer and solver

► Evaluation of actual design
► Modification according to optimization task
Check
Optimization
Postprocessing
ABAQUS
ANSYS
MSC.Nastran
Validation
Transfer
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Topology optimization using Tosca Structure.topology
► Topology optimization calculates an optimized

design in a given design space for all specified
loads and boundary conditions

► The result is a design proposal for the
following detailed design process
► Benefit:
► Significantly shorter development time
► The design process starts with a very good
design proposal
► Precondition for a final design with high
quality
► Increase stiffness, save material
Courtesy of
Slide 14 | 02/2014
Shape optimization using Tosca Structure.shape
► Shape optimization performs an improvement of

an existing design or component by a
modification of the surface
► Mesh adjustment and mesh smoothing in each

optimization iteration
► The objective is a homogenization of the
stresses for unlimited number of loadcases
► Benefit:
► Fast improvements of existing FE models
► Reducing stress concentrations
► Increasing of durability
► Manufacturing constraints
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Sizing optimization using Tosca Structure.sizing
► Sizing optimization determines optimum sheet

thicknesses
► The resulting design proposal combines

minimum weight with best static and dynamic
behavior
► Benefit
► Automatic calculation of directly producible
design proposals
► Material savings together with increased
comfort and eco-efficiency
► Reduced development time for your
performance goals.
Slide 16 | 02/2014
Bead optimization using Tosca Structure.bead
► Bead optimization determines an optimum

location and orientation of beads in sheet metal
structures
► Beads lead to an enhancement of the bending

stiffness or improvement of the dynamic
behavior of shell structures
► Benefit
► Time savings through fully automated bead
calculation in only 2-3 solver iterations
► Clear bead layouts for complex models
► Innovative, directly producible bead designs
through consideration of manufacturing
restrictions during optimization
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Postprocessing with Tosca Structure
Preprocessing Visual evaluation of result

Check ► 3D animation sequences of the optimization history
► results as fringe plots with filtering
Optimization ► x-y-plots of constraint and objective function values
► tables of relevant output values
Postprocessing
Validation
Transfer
► GLview Plugin not installed. Press here to install plugin

Slide 19 | 02/2014
Tosca Structure.smooth
Smoothing of optimization results
Preprocessing Discrete optimization result must be smoothed for further processing

Check
Optimization result
Optimization
Postprocessing
Validation
Result after smoothing

Transfer
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Verification run
Automated meshing and validation
Preprocessing Validation is of major importance when arguing for CAD changes
Validation model with

Check original loads and boundary
conditions
Optimization
Postprocessing
Validation
Validation result
Transfer
Slide 21 | 02/2014
CAD transfer
Slice or surface generation
Preprocessing CAD transfer required for further processing in the development process
Smoothed result
Check
Cutting splines
Optimization
Postprocessing
Validation
Smoothed result
Surfaces
Transfer
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Tosca ANSA

Environment
Setup of structural optimization problems with

Tosca ANSA environment
CAD model (Initial design or maximum design space)
FE model – complete setup for supported FE solver

(1) Optimization preprocessing
(2) Check optimization model
(3) Run optimization
(4) Generate postprocessing information
(5) Smoothing
(6) Automatic validation
Validation result IGES/STL IGES splines Tosca Structure.view ASCII results

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Interactive graphical user interface
► FUNCTION BASED setup of the optimization task

► INTERACTION with finite element model
► CONSISTENCY CHECK and update of all dependencies

► Simplified definition of SURFACE NODE GROUPS for shape optimization
► GRAPHICAL VISUALIZATION of manufacturing constraints
► Generation of VALIDATION RUNS after topology optimization
Slide 25 | 02/2014
General remarks
► Based on the preprocessing application ANSA from BETA

► Only part of the ANSA functionality is available for Tosca ANSA environment
► Finite element models
► can be imported
► contents may be browsed and visualized
► the original can not be changed
► Modification and export of finite element models only possible for the validation run
► Automatic generation of validation models only possible using Tosca ANSA environment
(use of ANSA meshing technology)
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Definition of Tosca Structure tasks in ANSA
► Preprocessing
► Definition of the complete Tosca Structure optimization
task (topology, shape and bead optimization)
► Link to finite element model

► Check Inputs
► Test runs / model check
► Start optimization
► Postprocessing
► Definition of postprocessing sequences
► Smooth
► Definition of Tosca Structure Smooth parameters
for smoothing results
► Generation of validation input files
Slide 27 | 02/2014
Live demonstration Tosca ANSA environment

Slide 28 | 02/2014
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Workshop Tosca ANSA environment

Abaqus
► Start a new Tosca Structure task

► Select your solver and load file
<solver>/topo/cranehook, update

► Navigate through model: change color of
properties, check for groups, show only one
group, e.g. FROZEN (using database manager,
sets, show only), lock view of this group, add
layers, return to locked view
► Change background color
► Measure distance between two nodes
Slide 29 | 02/2014
Workshop Tosca ANSA environment

Nastran
► Start a new Tosca Structure task

► Select your solver and load file
<solver>/topo/cranehook, update
► Navigate through model: change color of

properties, show only one property, lock view of
this property, add layers
► Change background color
► Measure distance between two nodes
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Tosca Extension

for
ANSYS/Workbench
Integration of Tosca Structure into ANSYS/Workbench

Tosca Extension for ANSYS/WB
► Tosca Optimizer is integrated as ► Tosca Structure is operated within the

system into the Project Schematic. Mechanical application.
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Structural optimization
Workflow using Tosca Extension for ANSYS/WB
Validation run Geometry creation or import

Meshing, loads,
Smoothing boundary conditions
Optimization FE Simulation
Slide 33 | 02/2014
General remarks
Tosca Extension for ANSYS Workbench
Entire workflow within ANSYS/WB

► Topology optimization with Tosca Structure fully integrated into ANSYS Workbench
► Results visualization within the mechanical application
► Semiautomatic validation run included

► IGES3-export for CAD-transfer available
Handling
► Easy graphical selection of bodies and surfaces
► Structured overview within one application including forces, boundary conditions,
optimization options, results, etc.
► Familiar functions available
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Definition of Tosca Structure tasks

Tosca Extension for ANSYS/WB
► Preprocessing
► Definition of the complete optimization task
► Overview of FE-analysis

► Start optimization
► Postprocessing
► Different result visualization possibilities
► Smooth
► Definition of Tosca Structure.smooth parameters
for smoothing results
► Validation
► Semi automatic validation run using the previously
smoothed model
Slide 35 | 02/2014
Live demonstration
Tosca Extension for ANSYS/Workbench
Slide 36 | 02/2014
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Tosca Structure.gui

Support of the optimization process

Tosca Structure.gui
Tosca Structure.pre Start Tosca Structure Tosca Structure.report Tosca Structure.smooth

Definition of the Topology, shape and Postprocessing and Preparation for result
optimization task bead optimization visualization transfer and validation
Slide 38 | 02/2014
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Defining the optimization task

Tosca Structure.pre
Graphical user interface to define optimization tasks (parameter files)
► Menu control

► Control of commands in the parameter file
► Overview of the defined parameters
► Using groups and coordinate systems given in the analysis file
► Integrating predefined macros
► Using predefined design response formulations
► Direct choice of predefined commands for referencing
► Integrated online help
Slide 39 | 02/2014
Tosca Structure.gui
Wizard
► Easy setup of
optimization tasks
► Definition of
standard tasks in a
few steps
Slide 40 | 02/2014
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Live demonstration Tosca Structure.gui

Slide 41 | 02/2014
Documentation
Pdf and Online-help:

► Start manual
► User manual
► Commands manual
► Examples manual
Access
► <tosca_install_dir>/docu
or online_docu
► ? Button in GUI
► Help menu in WB
► In TAE: Tooltips
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Thank you for your

attention
41
42
Notes
43
Notes
44
Optimization with

Tosca Structure
Topology
Optimization I
Topology optimization I
1. Topology optimization
2. Stiffness optimization
3. Preprocessing
4. Start optimization
5. Workshop
6. Postprocessing
Slide 2 | 02/2014
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Topology

Optimization
What is topology optimization?
Aim ► Calculation of an optimized material distribution in a specified design area

under consideration of boundary conditions (optimization constraints,
structural boundary conditions and loads).
► In this way: the creation of holes and breaches (the component is lighter)
Challenge ► Optimization problem with very many variables (up to 500 000 and more!)
► Resolution depends on discretization, fine mesh → larger computation time
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Topology optimization
► Given a predefined design domain in the 2D/3D space with structural boundary
conditions and load definitions.
► Distribute a given mass such that a global measure takes a minimum (maximum) value.

70 %
Slide 5 | 02/2014
Process and material groups
Process: hard, soft and trans Design: discrete material

Design area
elements distribution (hard, soft)
Slide 6 | 02/2014
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Theory of topology optimization

Material groups
1,0
Simple material model for isotropic material HARD
0,9
HARD elements (=0) 0,8

0,7
► Supporting elements
0,6
► Maximum Youngs modulus TRANS
E/Eo
0,5
TRANS elements (=f()) 0,4
0,3
► Intermediate elements
0,2
► No unique material allocation 0,1
SOFT
SOFT elements (0) 0,0
0,0 0,2 0,4 0,6 0,8 1,0
► Non-supporting elements /0
► Minimum Youngs modulus Source: inuTech GmbH
Slide 7 | 02/2014
Topology optimization of a transverse link at AUDI
Redesign Existing design

Design
Cutting splines space model
Image courtesy of
Slide 8 | 02/2014
48
Comparison
Existing design – new design
Result
100
► Speed-up of the development process

80 ► 45% stress reduction, 10% weight reduction
► The 1st prototype passed all mechanical tests !
Admissible
Stress
60
40
20
0
Weight Max. stress Max. displacement
Existing design New design (Image ATZ MTZ extra)
Slide 9 | 02/2014
Topology optimization of a gear oil line bracket
Original design Topology optimization result Constructional implementation

Tosca Structure
optimization result:
deflection: - 39 %
max. stress: - 60 %
Original design for comparison weight: - 21 %
Images courtesy BMW Motoren GmbH
Slide 10 | 02/2014
49
A Stiffness

Optimization
Stiffness optimization
Objective ► Minimize the sum of

► aiCi Compliance of different loadcases
Constraints ► Tosca Structure will use the sensitivity based algorithm

if instead an inequality constraint is defined !!!!!
► V = V* Volume (equality constraint !!!!)
Controller algorithm ► Compliance is objective (static loadcases)

► Objective can be minimized
► One constraint which is material weight
► Manufacturing and symmetry constraints
► Fast convergence
Slide 12 | 02/2014
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Example: brake booster
Maximize stiffness with 30% target volume

Slide 13 | 02/2014
Workflow topology optimization
Check ► Check for completeness, correct syntax and boundary conditions

Slide 14 | 02/2014
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Preprocessing

Design Area
Objective Function
Constraint
Preprocessing topology optimization
Model ► Definition of analysis model
Groups ► Node and element sets for further definitions

Design Area ► Area for modification with geometric restrictions
Objective ► Optimization target
Constraint ► Optimization restrictions
Stop ► Stop condition
Slide 16 | 02/2014
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Start
Tosca ANSA environment ► Start Topology optimization task

► Open folder preprocessing in task tree

Tosca Extension for ► Load Tosca Extension for ANSYS/Workbench
ANSYS/Workbench
► LinkTOSCA Structure.topology with your Analysis
Tosca Structure.gui ► Define new task

► Follow tree view of Tosca Structure.pre
Slide 17 | 02/2014

Model
Model ► Design space as FE model with relevant loads and boundary conditions
► Assign model to optimization task
Groups ► MODEL_LINK (Tosca ANSA environment)
► Import Geometry (Tosca Extension for ANSYS/WB)
Design Area ► FEM_INPUT (Tosca Structure.gui)
► Nodes, elements, materials, coordinate systems,

Objective
groups and properties are loaded
► Optional reading options
Constraint
► SETTINGS (Tosca ANSA environment)
► OPTIONS (Tosca Structure.gui)
Stop ► n/a (Tosca Extension for ANSYS/WB)
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Model considerations
► Do not spend too much time on geometrical Ω

details !!!!!!

► Set the physical boundary conditions correct
because the boundary conditions are driving the
optimization
Slide 19 | 02/2014
Mesh considerations
Coarse mesh
► Not a good mesh for topology optimization
► The mesh indirectly enforces the level of details

in a topology optimization e.g. ribs, bars, beams,
holes, etc.
► As minimum 3~4 elements over the desired Mesh for optimization

minimum size
Slide 20 | 02/2014
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Analysis model: mesh – element types
► Add more elements in design domain which will allow more details when adding and
removing material (elements).
► Use more elements in the design domain with a lower order instead of a few elements

with a higher order.
► TETRA 4 node elements can be artificially too stiff. Therefore, if possible, use HEXA 8
node elements instead.
Slide 21 | 02/2014
Choose linear element

formulation
Choose hexahedral
formulation
Not always possible to mesh using hexahedral elements!
Slide 22 | 02/2014
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Groups
Model Use of groups

► Optimization areas
Groups ► Optimization restrictions

► User-specific output
Design Area Predefined groups
► ALL_NODES, ALL_ELEMENTS
Objective ► Groups of the analysis model
Defining groups
Constraint ► Select nodes or elements graphically
► Choose nodes or elements (SELECT) and assign to group (GROUP)
Stop ► Allocate a list of nodes or elements to a group (GROUP)
► Automatic group definition (GROUP_AUTO_DEF)
Slide 23 | 02/2014

Design area
Model Element group

► Elements can be modified
Groups ► Density is changed during optimization (design variable)

Assign group to design area

Design Area
► DESIGN_AREA (Tosca ANSA environment)
► EL_GROUP parameter in DV_TOPO (Tosca
Objective Structure.gui)
► Design Area (Tosca Extension)
Constraint
Additional definitions
► Design variable constraints
Stop
► Meshrefine (adaptive refinement of FE mesh)
Slide 24 | 02/2014
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Objective
Model Objective function

► function depending on the design variables
Groups ► functional value to be minimized or maximized

► produced from the results of the FEM analysis
Design Area ► specified via a design response
Objective Maximize the stiffness = Minimize the sum of compliance
Constraint
Stop
Slide 25 | 02/2014
Defining the objective function
Values to be optimized ► Scalar results from analysis, model geometry or combination of them
► OBJECTIVE_FUNCTION (Tosca ANSA environment)
► Combination as DRESP (design response) in Tosca Structure.gui
► Define Design Responses using available categories (Tosca Extension)
Optimization target ► Min, Max, Minmax

► Edit OBJECTIVE_FUNCTION definition (TAE)
► TARGET parameter in OBJ_FUNC, assign design response(s) (GUI)
► Call Design Response in Objective Function (Tosca Extension)
Slide 26 | 02/2014
57

Constraint
Model Constraint
► restricts certain values dependent upon the design variables
Groups (design responses)

► e.g. volume and displacement constraints are admitted for
topology optimization
Design Area
Target volume: V = V* (Equality constraint!)

Objective
Constraint
Manufacturing restrictions and other geometric constraints independent

Stop
of the optimization run can be defined as design variable constraints.
(later)
Slide 27 | 02/2014
Defining the constraint
Values to be restricted ► Scalar results from analysis, model geometry or combination of them
► Choice in CONSTRAINT folder (Tosca ANSA environment)
Constraint ► Target value (equality constraint), lower/upper value (inequality constraint)

► Edit CONSTRAINT definition
► EQ/LE/GE_VALUE parameter in CONSTRAINT, reference required design
response(s)
► Call Design Response and set target value with attribute “Equality”, “Less or
equal” or “Greater or equal” (Tosca Extension)
Slide 28 | 02/2014
58

Stop condition
Model Global stop criterion

► Number of iterations
Groups ► Standard tasks 15 iterations

Design Area Definition
► GLOBAL_STOP_CONDITION (TAE)
Objective ► STOP command (GUI)
► Set „Max Design Cycles“ to desired limit (Tosca extension)
Constraint
Stop
Slide 29 | 02/2014
Finish preprocessing
Save optimization task
Tosca ANSA environment ► Define jobname in OUTPUT folder

► Update your definitions
Tosca Extension for ► Save the entire ANSYS Workbench project

ANSYS /Workbench
Tosca Structure.gui ► Combine all required items in OPTIMIZE command

► Save parameter file (jobname.par)
Parameter file jobname.par with optimization task definitions created
Slide 30 | 02/2014
59
Block structure for topology optimization
Design variables Mesh refinement Design variable constraints

DV_TOPO MESH_REFINE
MESH_REFINE DVCON_TOPO

Link_rule
LINK_TOPO
Objective function
Optimize OBJ_FUNC
OPTIMIZE Design
response
Constraints DRESP
CONSTRAINT
Optimization parameters
OPT_PARAM
(STOP, LOGICAL)
Slide 31 | 02/2014
Command structure
Parameter file
► Each command is started with a keyword

► Each single allocated parameters are followed by a value or a character string with the
symbol ‚=‚
► The command must close with an END_ -statement

► Detailed information: commands manual
Command
parameter_1 = value_1 [, value_2, ...]

...
END_
Slide 32 | 02/2014
60
Parameterfile (I)
Analysis model FEM_INPUT

ID_NAME = MY_INPUT_FILES
FILE = boost.bdf

END_
Design area DV_TOPO

ID_NAME = DESIGN_AREA
EL_GROUP = ALL_ELEMENTS
END_
Slide 33 | 02/2014
Parameterfile (II)
Design response DRESP

strain energy
ID_NAME = SUM_ENERGY
TYPE = STRAIN_ENERGY
DEF_TYPE = SYSTEM
GROUP_OPER = Sum
END_
Objective function OBJ_FUNC

ID_NAME = MAXIMIZE_STIFFNESS
TARGET = MIN
DRESP = SUM_ENERGY, ,
END_
Slide 34 | 02/2014
61
Parameterfile (III)
Design response volume DRESP

ID_NAME = MY_VOLUME
TYPE = VOLUME

DEF_TYPE = SYSTEM
GROUP_OPER = Sum
END_
Constraint CONSTRAINT
ID_NAME = VOLUME_CONSTRAINT
MAGNITUDE = REL
EQ_VALUE = 0.3
DRESP = MY_VOLUME
END_
Slide 35 | 02/2014
Parameterfile (IV)
Optimization task OPTIMIZE

ID_NAME = MY_OPTIMIZATION_TASK
OBJ_FUNC = MAXIMIZE_STIFFNESS
DV = DESIGN_AREA
CONSTRAINT = VOLUME_CONSTRAINT
STRATEGY = TOPO_CONTROLLER
END_
Slide 36 | 02/2014
62
Start Optimization

Start optimization
Tosca ANSA environment ► Update RUN item in START_OPTIMIZATION folder

Tosca Extension for ► Select Optimization Result in the Tree Outline

ANSYS /Workbench
► Click Solve
Tosca Structure.gui ► Switch to start optimization screen

► Choose parameter file
► Start
Slide 38 | 02/2014
63
Optimization loop
Preprocessing (FE + optimization)
Analysis file Parameter file

Optimization
CAD/DMU system
Tosca Structure
Solver
Calculation results Diverse output files
Postprocessing (FE analysis + optimization)
Slide 39 | 02/2014
TOSCA.OUT (very important for checking !!!)
ERROR in Tosca Structure-module:

Checking for errors --------------------
| FE-solver : ansys |
--------------------
Solver license could not be found.
Checking for Number of DESIGN CYCLE : 5

optimization definitions
Value of OBJ_FUNC : 0.691592
----------------------------------------------------------------------
| Name of OBJ_FUNC_TERM Value Weight Reference |
----------------------------------------------------------------------
DRESP_VOL_TOPO 0.207478E-01 1.00000 0.000000E+00
----------------------------------------------------------------------
----------------------------------------------------------------------
| Name of CONSTRAINT act. Value TARGET VALUE NORM |
----------------------------------------------------------------------
CON_Y 286142. <= 400000. 0.72 TRUE
CON_Y_2 282124. <= 400000. 0.71 TRUE
CON_Y_3 286142. <= 400000. 0.72 TRUE
Slide 41 | 02/2014
64
optimization_report.csv
OBJ_FUNC_DRESP: OBJ_FUNC_TERM: VOLUME_CONSTRAINT:EQ:

ITERATION MAXIMIZE_STIFFNESS DRESP_SUM_ENERGY DRESP_SUM_ENERGY DRESP_VOL_TOPO
Norm-Values: 1.878.885 1.878.885 1.878.885 0.4500000
0 1.878.885 1.878.885 1.878.885 1.000.000
1 2.297.808 2.297.808 2.297.808 0.8025129

2 2.381.976 2.381.976 2.381.976 0.7501249
3 2.545.511 2.545.511 2.545.511 0.7070240
4 2.602.819 2.602.819 2.602.819 0.6676000
5 2.716.730 2.716.730 2.716.730 0.6293547
6 2.841.263 2.841.263 2.841.263 0.5948450
7 2.897.292 2.897.292 2.897.292 0.5641469
8 2.980.773 2.980.773 2.980.773 0.5356328
9 3.041.345 3.041.345 3.041.345 0.5138644
10 3.118.250 3.118.250 3.118.250 0.4938602
11 3.212.392 3.212.392 3.212.392 0.4775141
12 3.246.898 3.246.898 3.246.898 0.4652300
13 3.286.278 3.286.278 3.286.278 0.4563897
14 3.301.253 3.301.253 3.301.253 0.4517990
Slide 42 | 02/2014
Online
Presentation
Workshop
65
Stiffness optimization booster
Model ► Booster.ext
Groups

Design Area ► ALL_ELEMENTS
Objective ► Minimize  Compliance Controller
Constraint ► 30 % Target Volume
Stop
Slide 44 | 02/2014
Postprocessing
66
Visualization of standard optimization results using

Tosca Structure.view
► Standard report (jobname_report.vtfx):

► Animation of material distribution
► Convergence plots of optimization results

► Visualization using Tosca Structure.view
► Tosca ANSA Environment

► VTF_VISUALIZATION | View
► Tosca Structure.gui
► Tosca Structure.report  View Report
Slide 46 | 02/2014
Visualization of standard optimization results in

ANSYS/Workbench
► Show material
distribution
► Filter soft elements
Slide 47 | 02/2014
67
Postprocessing
CTRL Dynamic rotation

Animation

CTRL Rotation
CTRL Model translation
Dynamic model
CTRL zoom
Slide 49 | 02/2014
Optimization progress
Start model 8th iteration Result

Slide 50 | 02/2014
68
Optimization progress

Slide 51 | 02/2014
Smoothed result
Slide 52 | 02/2014
69
Thank you for your

attention
70
Notes
71
Notes
72
Optimization with

Tosca Structure
Topology
Optimization II
Design Variable Constraints
Topology Optimization II
1. Manufacturing restrictions
2. Symmetries
3. Workshop
Slide 2 | 02/2014
73
Manufacturing

Restrictions
Topology optimization with manufacturing restrictions
Model Restricting the removal of elements is required to...

► avoid the removal of border areas to other components.
Groups
► ensure the ability to manufacture the component.

► control the design and look of the part.
Design Area
Objective
Constraint
Stop
Slide 4 | 02/2014
74
Restrictions on design variables
► Fixation of elements (frozen areas)

► Minimum member size
► Maximum member size

► Casting restrictions
► Tightness
► Stamping restriction
► Symmetries
► Coupling
Slide 5 | 02/2014
Fixation of elements
Frozen elements
Keep Example pipe clamp
► Functional areas
frozen area
► Border areas to
other components Design space
Optimization result
Complete FE-model
Slide 6 | 02/2014
75
Requirements for casting

Der fertigungsgerechte Guss
Quelle: Dubbel 1990
Slide 7 | 02/2014
Casting restrictions (demold control)

Pull directions
► Avoidance of undercuts
Pull direction
Component
► Definition of a pull direction

► Three coordinates
► Coordinate system Mold
► Different pull directions for different areas
► Mesh independency
Slide 8 | 02/2014
76
Plate with slot
No demolding direction With demolding direction

Demolding
direction
F F F F
Slide 9 | 02/2014
Demolding directions: crane hook
No definition of a demolding direction With definition of a demolding direction

Demolding
direction
Max. displacement: Max. displacement:

2,676 mm 3,262 mm and +21%
Slide 10 | 02/2014
77

MID_PLANE
MID_PLANE = NONE ► One pull direction

MID_PLANE = NONE
MID_PLANE = AUTO ► Automatic midplane detection with two opposite

pull directions
MID_PLANE = NONE
MID_PLANE = POINT ► Midplane perpendicular to casting direction

through point (two pull directions)
Slide 11 | 02/2014

MID_PLANE
MID_PLANE = SURFACE ► Pull in direction of the nearest surface point

MID_PLANE = AUTO_TIGHT ► Tightness – midplane will not be removed

during optimization
MID_PLANE = STAMP ► Create a stampable optimization result
Slide 12 | 02/2014
78
Motor bearing
Maximize stiffness with a volume constraint of 60%
Optimization result
Start model
No restrictions

99784 elements
Maximum displacement: 0,18 mm
Slide 13 | 02/2014
Motor bearing
Demolding direction
Demolding to the top Demolding to the front and rear

MID_PLANE = NONE MID_PLANE = AUTO
Maximum displacement: 0,22 mm (+22 %) Maximum displacement: 0,24 mm (+33%)
Slide 14 | 02/2014
79
Casting restrictions (demold control):

Tightness (AUTO_TIGHT)
► Components filled
with liquid (gear
boxes filled with oil)

► Easier design of
casting mold
► At least one layer of
elements remains
„HARD“
► Similar to
MIDPLANE-Type
„AUTO“
► MIDPLANE thick-
ness = 2*RADIUS
Slide 16 | 02/2014
Casting restrictions (demold control):

Check group
► Demolding with adjacent parts possible Check group
► Must contain group of casting restriction

► Demolding checked against all elements of

x Demolding direction
check group
Design area
Slide 18 | 02/2014
80
Member size control: motivation
► Thin structures can not be produced

Source: Ref.:Michell: The limits of economy of material in frame structures.
Philosophical Magazine, Series 6, 8(1904) 589 - 597
► Thick structures are problematic for casting (cool down)

Definition of minimum and maximum thickness in the structure
Slide 19 | 02/2014
Member size control

Minimum member size: Original model without Maximum member size:

definition of a minimum restrictions definition of a maximum
structure thickness structure thickness
Slide 20 | 02/2014
81
Engine mount
Minimum member size
Without minimum member size filter With minimum member size filter

Max. displacement: 1,447mm Max. displacement: 1,590mm
Slide 21 | 02/2014
Maximum member size

High speed tool support
Optimization task: maximize the stiffness with a volume constraint of 60%
Acceleration
Single point constraints Without maximum member size

Slide 22 | 02/2014
82
Maximum member size

With casting constraint
Without maximum member size With maximum member size

Result contains one thick support Structure with thin supports
Images courtesy Heidenreich & Harbeck AG
Slide 23 | 02/2014
Member size control - comments
Maximum member size

► The given diameter can not be guaranteed. For
some models structures can be seen which have
a diameter which is less than the specified
value.
► Computation time increases by the power of Minimum
three with the diameter. Careful choice, limitation member size
on parts of design group.
► Distance between two supports normally is at
least maximum member size value if no distance
is defined.
► Maximum Member Size only supported by
sensitivity based optimizations!!
Slide 24 | 02/2014
83
Symmetries

Symmetry conditions: motivation
Old design (asymmetric)

► The loads in a model are often asymmetric but
symmetric results are required
► The influence of asymmetric meshes can be

suppressed
► The number of loadcases can be reduced New design (symmetric)

because symmetric loads can be omitted and
thereby, calculation time can be reduced
Slide 26 | 02/2014
84
Symmetries in topology optimization

Point symmetry TYPE=POINT_SYM Rotational symmetry TYPE=ROTATION_SYM
ANGLE=<angle>
CS_Master CS_Child
Cyclic symmetry TYPE=CYCLIC_SYM Link conditions
TRANSLATION=<dist>
Slide 27 | 02/2014
Rotational symmetry
Without rotational symmetry Rotational symmetry with a given angle of 60°

Irregular mesh
Slide 28 | 02/2014
85
Workshop

Stiffness optimization controlarm
Model ► control_arm.ext
Groups
Design Area ► All elements without fixations,

casting restriction
Objective ► Minimize  Compliance Controller
Constraint ► 70 % Target Volume
Stop
Slide 30 | 02/2014
86
Stiffness optimization control arm

Design area
► All elements in green

can be modified

► Define group
consisting of these
elements (remove
elements marked in
red from selection)
► Check using
highlighting
Slide 31 | 02/2014
Stiffness optimization control arm

Casting restrictions
Define a casting constraint with pull direction (0,0,1) (demolding in positive z-direction)
Slide 32 | 02/2014
87
Control arm
Results (gif)

Slide 34 | 02/2014
Control arm
Results
Slide 36 | 02/2014
88
Thank you for your

attention
89
90
Notes
91
Notes
92
Optimization with

Tosca Structure
Postprocessing
Validation
Result Transfer
Postprocessing
1. Postprocessing
2. Visualization with Tosca Structure.view
3. Report generation
4. Visualization with Tosca Extension for
ANSYS /Workbench
5. Smoothing
6. Result transfer
7. Validation run
8. Workshop
Slide 2 | 02/2014
93
Postprocessing

Directory and file structure after optimization
The directory 'jobname' with the following sub-directories and files:

► Standard directories
► DB_ERROR
created in case of errors

► TOSCA_POST optimization results for postprocessing
► Optional directories containing data of the single iterations:
► SAVE.ext FE solver files, „ext“= file extension
► Files
► TOSCA.OUT output protocol file
► optimization_report.csv comma separated list of optimization values
► jobname.ext FE model of the initial model
► jobname.par Tosca Structure input file
► jobname_report.vtfx file for visualization with Tosca Structure.view
Slide 4 | 02/2014
94
Visualization with

Tosca
Structure.view
Easy postprocessing of optimization results

COMBINE VISUALIZE TRANSFER

Tosca Structure.report Tosca Structure.view Report Generator
Slide 6 | 02/2014
95
Postprocessing of Tosca Structure optimization result

Combine: Tosca Structure.report
Combine Information about optimization history

► 3D animation sequences of model with fringe plots

► smoothed optimization result
► x-y-plots of constraint and objective function values
Export Combination into vtfx archives

► platform independent
► binary
► compact
Default reports automatically generated after optimization
Slide 7 | 02/2014
Postprocessing of Tosca Structure optimization results

Visualize: Tosca Structure.view
View Tosca Structure.view

► Free, high-performance 3D viewer
► Tosca Structure results in vtfx format

► Available for Windows and Linux
Integrate Plug-in on Windows for

► Office applications
► Internet Explorer
Export ► Current view as image

► Current animation as avi file
Slide 8 | 02/2014
96

Slide 9 | 02/2014
Handling
► Set draw styles in settings panel
► Move model with mouse buttons:
► Ctrl + right: rotate in space
► Ctrl + middle: translate

► Ctrl + left: rotate in plane
► Mouse wheel: zoom
► Switch cases in case panel
► Get information about objects in selection panel
► Modify result settings in results panel
► Start animation in toolbar
► Further details: help menu
Slide 10 | 02/2014
97
Application of Tosca Structure.view (gif)
► Visual check of optimization results (contour and

convergence plots) already during the optimization run
► Propagation of results with customers and colleagues as

base for discussions (free distribution of viewer)
► Professional demonstration of 3D results, interactive moving
and animation of models in presentations (plugin for Office
applications and html)
► Quick viewing of very large models for first checks without
time-consuming data import into postprocessors
► Small memory requirements for animation sequences due to
very compact format
Slide 12 | 02/2014
Report Generation
98
Report Generator
Result capturing (GIF)
Combination of views with integrated

Report Generator:
► Screenshots

► Fringe plots
► Animation sequences
► Interactive 3D data (vtfx plugin)
Iteration OBJ_FUNC
► Animated video (avi) 0 3.3873e+005
1 3.6847e+005
► Result plots ... ...
► Result tables ... ...
12 3.8646e+005
13 3.8676e+005
14 3.8711e+005
Slide 15 | 02/2014
Report Generator
Transfer
Automatic report
generation
User defined templates

for customized layout
MS Powerpoint MS Word Html documents

2007 and 2010 2007 and 2010
Slide 17 | 02/2014
99
Visualization with

Tosca Extension
for
ANSYS/Workbench
Post-processing in ANSYS Workbench

Slide 20 | 02/2014
100
Post-processing of Tosca Structure optimization result

Visualization in ANSYS Workbench
Result information ► TOSCA.OUT-file is integrated into the Solution section

► Contains constraint
and objective values

ANSYS Report Preview ► Standard ANSYS Report Preview available
Slide 21 | 02/2014

Result information ► Model with material distribution

► Different material distribution plots available

► Use toolbar:
Animation ► Within the graph window, single iteration steps

and an animation are available
Slide 22 | 02/2014
101

Smooth result ► Smoothed model, fineness depends on ISO value

Export ► Iges3, STL and slices (igs) export available
Slide 23 | 02/2014
Tosca
Structure.smooth
Result Preparation for
Further Processing
102
Transfer of optimization results

into the construction process
Motivation Topology optimization offers design suggestions for constructions

► Result validation required
► Analysis model of result must be derived

► Processing of optimization results in a CAD system necessary
► Transfer of data is required
Optimization result ► Complete detachment from the initial geometry

► Very rough looking “model of a building block“
► Large amount of data (especially with fine meshes)
► FE formats cannot usually be loaded directly in CAD
Slide 25 | 02/2014
Transfer of optimization results into the construction process
► Result validation:
► Iso surface calculation
► Smoothing
► Meshing and load transfer

► Output as analysis model
► Result transfer into CAD:

► Iso surface calculation
► Smoothing
► Data reduction
► Output in CAD readable formats as patched
surfaces or slices
Slide 26 | 02/2014
103
Iso surface
Principle
► Optimization result with discrete material

distribution (relative density)
/0 ≈ 1 /0 ≈ 0

► Filtering of soft elements
► Isosurface (isoline) calculation:

► Extrapolation of material values to points on
edges (continuous distribution)
0,5
► Connection of points with same material 0,25
value (isopoints)
► Cut on isosurface (isoline) Isovalue

larger
Isovalue
smaller
Slide 27 | 02/2014
Isovalue
► Isovalue = cut parameter for smoothing

Iso value 0.3 (default)

Iso value 0.7
► Iso value smaller → more material remains

► Target volume = relative volume of target structure compared to original model
Slide 28 | 02/2014
104
Reduction parameter
Reduction rate Default
► Reduce the number of nodes by this percentage

(0 = no reduction (def), 100 = maximum

reduction)
50 %
Angle
► Maximum angle (0-40, def 15) between „parallel
normals” (Combination of “parallel“ surfaces) 80 %
Note
► If no more “parallel“ normals are found, the Angle 30
reduction will be stopped
Slide 29 | 02/2014
Output parameter
Output format Use
IGES (surfaces) (igs1) ABAQUS/CAE, Pro/E
IGES (EXT) (igs2) Solid works (surfaces+points)

IGES3 ANSYS/Workbench
STL Rapid Prototyping, CATIA , FEMAP, I-DEAS, Medina, UG

STL: 17.300 elements
WRL VRML-Viewer
OUT (patran neutral file) MSC.Patran, other pre-/postprocessors
CDB ANSYS
INP ABAQUS
BDF NASTRAN
VTFX Tosca Structure.view
Slices Slices through 3D model or Border of 2D model for CAD transfer Cutting splines (x, y and z)
Slide 30 | 02/2014
105
Tosca Structure.smooth:
Smoothing of topology optimization results
Tosca ANSA environment ► SMOOTH_INSTANCE → RUN_SMOOTH | EDIT: set TASK to “iso”

► Set parameters
► Choose output format(s)

Tosca Extension for ► Add a Smooth result to the solution section
ANSYS /Workbench
► Set parameters
► Solve
Tosca Structure.gui ► Tosca Structure.smooth: set task to “Create Isosurface”

► Choose your parameter file
► Set parameters
Slide 31 | 02/2014
Result Transfer
106
Generation of new CAD model
► Generate slices from smoothed results and export as IGES splines to be imported in
CAD systems for the generation of new CAD design.
► Export smoothed surface model in CAD-readable format (see table of output formats).

Slide 33 | 02/2014
Validation Run
107
Generation of new solid mesh

Smoothed surface generated by Import, feature lines for Reconstructed TET-
Tosca Structure.smooth reconstruct mesh for validation
Slide 36 | 02/2014
Preparation of validation run
► Apply all boundary conditions from the design

space model to the new mesh (using Tosca
ANSA environment, this is done automatically)
► Run finite element analysis to evaluate stresses

and displacements.
Slide 37 | 02/2014
108
Result of validation

Slide 38 | 02/2014
Validation run
Processing of topology optimization results
Tosca ANSA environment ► Reconstruct

► Solid mesh
► Validation output
► Validaton run
Tosca Extension for ► Click Validation  Run

ANSYS /Workbench
► Check the intermediate step model, then click Validation  Continue
► Reassign meshing options, loads and boundary conditions to the model
Tosca Structure.gui ► Transfer model to your preprocessor

► Apply loads and remesh manually
Slide 39 | 02/2014
109
Problems with automatic validation

Automatic generation of validation files does not work. Try:

► Activate automatic feature line recognition (often successful)
► Create solid mesh directly based on result of isosurface calculation

► Apply manual reconstruct restricted to certain areas
► Move (few) problematic nodes manually (module buttons → GRID → move…)
► Restart smoothing using another iso value
► Restart smoothing using a smaller smoothing parameter (2 often successful)
Slide 40 | 02/2014
Problems with automatic validation II

► Validation output analysis file does not run. Try:

► Disable automatic validation output generation (VALIDATION_OUTPUT)
► Create modification files (VALIDATE → MODIFICATION_FILES)
► Update  Tosca Structure will create a validation file in your solver format.
(recommended for ANSYS workbench models and files with specific solver settings
not supported by ANSA).
Slide 41 | 02/2014
110
Workshop

Postprocessing and
Validation Run
Post-processing control arm

Visualization
Visualize optimization result

Slide 43 | 02/2014
111

Smoothing
Smooth result using Tosca Structure.smooth

(2 smooth runs)

Slide 44 | 02/2014

:
Reconstruct
Perform batch reconstruct and solid mesh creation
Slide 45 | 02/2014
112

:
Validation run
► Perform validation
run
► View analysis result

Slide 46 | 02/2014
Thank you for your

attention
113
114
Notes
115
Notes
116
Optimization with

Tosca Structure
Topology
Optimization III
General Optimization
Topology optimization III
1. Terms for optimization

2. Load case settings
3. Controller based optimization

4. Sensitivity based optimization
5. Comparison of controller with
sensitivity based optimization
6. Workshop
Slide 2 | 02/2014
117

Slide 3 | 02/2014
Design Responses
Terms for
Optimization
118
Terms for optimization (design responses)
Design responses ► Functions (scalar values) dependent on design variables

► Results of FE analysis (compliance, displacement, eigenfrequency) or
model geometry (weight)

► Data for objective function or constraint
► Values changing when design variables are modified
Optimization ► Determine design variables such that design responses for the objective are
optimized and design responses for the constraints are feasible
Slide 5 | 02/2014
Definition of design responses
Type ► Form of result (e.g. volume, displacement,...) Extract

values
Combine
Loadcases ► Loads and boundary conditions influencing result loadcases
Combine
Target ► Group of nodes/elements for extraction of values for groups
Restrict /
Optimize
Slide 6 | 02/2014
119
Design responses in topology optimization

DRESP
Static analysis ► Compliance of different static loadcases

► Displacement functions of different loadcases
► Reaction forces for different loadcases

► Internal forces for different loadcases
► Von Mises stress
Modal analysis ► Eigenfrequencies
Frequency response and ► Sound pressure

acoustic analysis
► Amplitude and phases for displacements, velocities and accelerations
Loadcase independent ► Material weight / volume

► Center of gravity
Slide 7 | 02/2014 ► Moment of inertia
Compliance
TYPE = ► Compliance of different loadcases c = uTKu

STRAIN_ENERGY
► Overall flexibility or “softness” of a structure
► Given by the sum of elastic or strain energy in a structure
► Maximize the global stiffness = minimize compliance

(if forces are applied as loads)
Please note: Strain energy for all elements required!

(TARGET = ALL_ELEMENTS)
Slide 8 | 02/2014
120
Energy stiffness measure
TYPE = ENERGY_ ► Term for stiffness optimization for combined External forces
STIFF_MEASURE only
static loading and prescribed displacements
► Always leads to maximized stiffness!

prescribed displacements
Increasing influence of
► But the term itself has no physical meaning
𝑷∙𝒖 𝑹∙𝜹
𝒎𝒊𝒏 −
𝟐 𝟐
► No need to distinguish between force- and

path-controlled problems
► New energy stiffness measure
applicable in all cases
Forces + prescribed displacements
Slide 9 | 02/2014
Displacement and rotation
TYPE = DISP_X uz
DISP_Y
DISP_Z
} ui Translation displacement
+/- minus dependent
uy
ux
z
y
ROT_X
ROT_Y
ROT_Z
} i
Rotation
+/- minus dependent
|ux |
x
DISP_X_ABS
DISP_Y_ABS
DISP_Z_ABS
} ui2
Absolute displacement
in a direction
|uy |
|uz |
Total absolute
DISP_ABS }u 2
x  u 2y  u z2 displacement
► Always defined in global coordinates of the finite element model !!!

Slide 10 | 02/2014
121
Important note for displacements and reaction forces
Please, remember this ► It is always strongly recommended that the user defines design elements
important comment !!
attached to nodes used in displacement definitions (DRESP) or reaction
definitions (DRESP) as frozen elements. This stabilizes the optimization and

often leads to a significant lower number of optimization iterations.
1 The user should define this element as frozen !!!! 1 1
Slide 11 | 02/2014
Von Mises stress
s 
TYPE = ► Stress in topology optimization 2
SIG_TOPO_MISES
Max vonMises
s y
 f r s  i y
2
► Based on elemental centroidal von Mises stress svonMises

(applied for avoiding stress singularities)
► Used in the objective function definition sy is defined as reference stress
► Used in the constraint definition sy is defined as constraint value
► f(ri) is a factor for interpolating the stresses of the elements with
intermediate densities
► Can only be applied once in the objective function or constraint definition!
Slide 12 | 02/2014
122
Eigenfrequency
TYPE = DYN_FREQ ► Single eigenfrequency fk

► Of a modal loadcase
► Eventually mode tracking required)

 J k  f j
 
TYPE =
DYN_FREQ_KREISSEL
► Kreisselmaier-Steinhauser measure  ln   e 

► For a given set of eigenfrequencies k  j 1 
► Recommended when maximizing the first eigenfrequencies especially for
multiple eigenfrequencies (mode tracking is not needed).
Slide 13 | 02/2014
Volume / Weight
TYPE = VOLUME ► V = ∑ ve where ve is the element volume
TYPE = WEIGHT ► W = ∑ we where we is the element weight

Slide 14 | 02/2014
123
Other design responses
Reaction forces F = |∑ Ke ui |
Reaction moments
Internal forces F = |∑ Ke ui |

Internal moments
Center of gravity xG 
 rxdV , Mass  rdV
Mass z-direction
Moments of inertia I x   r ( y 2  z 2 )dV

y-rotation
Slide 15 | 02/2014
Other design responses
Combined terms using operators (SUB, MAX, NORM)
αu1 - βu2 or α f1 - β f2,

e.g. to restrict relative movements of two nodes (shift fork)
Slide 16 | 02/2014
124
Load Case Settings

Example load case dependency I
Problem definition
Slide 18 | 02/2014
125
Example load case dependency II
Scenario 1 : Maximize the stiffness of individual load cases subject to 70% volume reduction

1. Load case 2. Load case 3. Load case
Slide 19 | 02/2014
Example load case dependency III
Scenario 2 : Maximize the stiffness of multiple load cases using a weighted summation subject to 70%
volume reduction
3
1
Min  3 Comp
i 1
Lci
s.t.
Volume  0.3 Vinit
Slide 20 | 02/2014
126
Load case setting
LC_SEL ► Parameter for combination of loadcases

LC_SET ► Parameter for choice of loadcase in your design response defintion

Tosca ANSA environment ► Edit LC_SET parameter (type „?“) in your objective or constraint term
Tosca Extension for ► Choose Load Case = Manual, insert load case into tab
ANSYS /Workbench
Tosca Structure.gui ► Add Loadcases to your LC_SET definition
Slide 21 | 02/2014
Controller-Based
Topology
Optimization
127
Controller algorithm for stiffness optimization
Objective ► Minimize the sum of

iCi Compliance of different loadcases

Constraints ► Tosca Structure will use the sensitivity based algorithm if instead an inequality
constraint is defined !!!!!
V = V* Volume (Important that is an equality constraint !!!!)
Controller algorithm ► Compliance is objective (static loadcases)

► Objective can be minimized
► One constraint which is material weight
► Manufacturing and symmetry constraints can be enforced
► Fast convergence
Slide 23 | 02/2014
Sensitivity-Based
(“General”)
Optimization
128
General optimization tasks
► “Free” choice of objective.

► Objective can be minimized or maximized.
► Multiobjective Min-Max formulation.

► Several constraints (max: 10~20 constraints).
► The following responses can be used in objective and/or constraints:
► Static analyze: compliance, displacement, reaction forces, von Mises stress
► Modal analyze: eigenfrequencies
► Loadcase independent: material weight, center of gravity, moment of inertia
► Read solution from several FE input files.
► Manufacturing and symmetry constraints can be enforced.
→ (a lot of possibilities !!!!!) Requires more considerations of the user.
Slide 26 | 02/2014
Design domain for examples
y
z
x
1 Design domain
1
2 Frozen domain 2
3 Clamped supports
3
Loadcase 3
Loadcase 1
Loadcase 2
Slide 27 | 02/2014
129
Example (1): additional constraints

Introducing other constraint types, e.g. displacement constraints
Objective ► Maximize stiffness (=minimize compliance)
► Mass < Mass* = 30%

Constraints
► Additional constraints are now valid
 ux < u* = 7*10-4 (static loadcase 1)

uy < u* = 7*10-4 (static loadcase 2)
ux
uy
u*
Compliance Mass (percentage) Displacements
Slide 28 | 02/2014
Example (2): other objective function

and response types
Objective ► Minimize material amount (mass) → other objective function type is now
valid
Constraints ► Additional constraints and types are now valid

f1 < f1* = 95 Hz (lower !)

f2 < f2* = 100 Hz (lower !)
f3 > f3* = 200 Hz (upper !)
 f4 > f4* = 205 Hz (upper !)
f4
f3 f2
f1
Material amount (percentage) Frequencies
Slide 29 | 02/2014
130
Comparison of optimized topology
- Maximize stiffness
- Mass constraints
- Displacement constraints

- Minimize material amount

- Frequency constraints
Choice of objective function and constraints
considerably influence the optimized structure
Slide 30 | 02/2014
Objective for sensitivity-based optimization
Model Minimize (or maximize) the sum of:

αCi (Ci - Ci*) Compliance of different loadcases
Groups
+ αV (V - V*) Volume
+ αui (ui –ui*) Displacement of different loadcases
Design Area + αRi (Ri – Ri*) Reaction forces of different loadcases
+ αfi (fi – fi*) Eigenfrequencies
Objective + αi xi Center of gravity in x- y- and/or z- direction
+ αijIij Moments of inertia about xx-, yy-, zz-, xy-, xz- or/and yz
Constraint axis,
where each term can have individual weighting factors and reference values.
Stop
Slide 31 | 02/2014
131
Combining responses in the objective
► Add up responses (DRESP) fi for objective function
f = ∑i αfi (fi - fi*) ,

where ai denote weighting factors and fi* reference values
► The objective can be minimized or maximized
► Determine maximum of all responses fi with weight and reference value for the
objective:
f = Maxi ( αfi (fi - fi*) )
► The objective is minimized (Min-Max optimization)
► The weighting factors and reference values have the default values 1 and 0
Slide 32 | 02/2014
Defining the objective function
Values to be optimized ► Scalar results from analysis, model geometry or combination of them
► Choice in OBJECTIVE_FUNCTION folder (Tosca ANSA environment)
► Define Design Responses using available categories(TOSCA Extension)
Optimization target ► Min, Max, Minmax

► Edit OBJECTIVE_FUNCTION definition (TAE)
► Select Design Response in Objective Function (Tosca Extension)
► TARGET parameter in OBJ_FUNC, assign design response(s) (GUI)
Slide 33 | 02/2014
132
Pre-processing topology optimization

Constraint
Model Constraint

► e.g. volume and displacement constraints are admitted for
topology optimization
Design Area
Objective
Constraint
Stop (later)
Slide 34 | 02/2014
Defining the constraint
Values to be restricted ► Scalar results from analysis, model geometry or combination of them
► Choice in CONSTRAINT folder (Tosca ANSA environment)
Constraint ► Target value (equality constraint), lower/upper value (inequality constraint)

► Edit CONSTRAINT definition (TAE)
► Select Design Response and set Target value with attribute “Equality”, “Less
or equal” or “Greater or equal” (Tosca Extension)
► EQ/LE/GE_VALUE parameter in CONSTRAINT, reference required design
response(s) (GUI)
Slide 35 | 02/2014
133
Constraints for sensitivity-based optimization
Inequality constraints Ci < Ci* Compliance of different loadcases
V < V* Volume

ui < ui* Displacement of different loadcases
Ri < Ri* Reaction forces of different loadcases
fi > fi* (or fi <fi*) Eigenfrequencies
xi > xi* (or xi < xi*) Center of gravity in x- y- and/or z- direction
Iii > Iii* (or Iii < Iii*) Moments of inertia about xx-, yy-, zz-, xy-, xz or/and yz
axis
Absolute and relative constraints are allowed.
Slide 36 | 02/2014
CONSTRAINT: numbers and feasibility !!!!!!!!!!
► Do not define more than 10~20 constraints.

► Avoid big node groups for constraints → leading to many constraints
► The optimization formulation should be feasible (if one can test that before the
optimization !). E.g. if the design space is filled up with material and the displacement
constraints are still not fulfilled.
► Frequency constraints should never be alike!
f1 < f1* = 95 Hz
f2 < f2* = 100 Hz
f3 > f3* = 150 Hz
f4 > f4* = 155 Hz
} f1*  f 2*  f 3*  f 4*
► Frequency constraints should have the order f1 < f2 < f3 < f4 in the initial structure
(otherwise, use modetracking).
Slide 37 | 02/2014
134
Pre-processing topology optimization

Local stop condition
Model Local stop criterion  n   n 1

 STOP_CRITERION_OBJ
n
► Change in objective
Groups ► Change in element densities

Number of elements
r n  r n 1
► Default: both 1
 STOP_CRITERION_DENSITY
Number of elements
Design Area
Definition
Objective ► Settings (Tosca ANSA environment)
► Parameters within the Analysis Settings (Tosca extension)
Constraint ► OPT_PARAM command (Tosca Structure.gui)
Stop
Slide 38 | 02/2014
Finish pre-processing

Tosca Extension for ► Save the entire ANSYS Workbench project

ANSYS Workbench

Slide 39 | 02/2014
135
Comparison

Controller /
Sensitivity Based
Optimization
Differences
controller-based algorithm <-> sensitivity-based
► Analysis types:
► The sensitivity-based algorithm supports the responses of linear static and modal
eigenfrequency (not allowed to be prestressed) finite element analysis. Depending on the
solver, several non-linearities are allowed (see next slide).

► The controller-based algorithm supports non-linear static like contact even when the
contact zones are on the surfaces of the design space. However, the responses of
eigenfrequency analysis are not supported by the controller-based algorithm.
► Objective and constraint types:

► The sensitivity-based algorithm can have one or multi objectives and several constraints
where the constraints are all inequality constraints. For the objective function and the
constraints several options exist.
► The controller-based algorithm has always the compliance as objective function and the
material volume as an equality constraint.
Slide 41 | 02/2014
136
Non-linearities for sensitivity based algorithm
Abaqus ANSYS MSC Nastran NX Nastran
Geometrical NO
YES  YES  NO
non-linearities

Contact YES  YES  NO NO
Constitutive material ALL  Linear isotropic Linear isotropic Linear isotropic

laws in design area (few exceptions*) (some laminates*) (some laminates*)
Constitutive material
ALL  ALL  ALL  ALL 
laws out-side design area
Slide 42 | 02/2014
Differences
controller-based algorithm <-> sensitivity-based
► Elements with intermediate densities (grey elements):

► The sensitivity-based algorithm has some elements in the final design containing
intermediate densities (grey elements).
► The controller-based algorithm in the final design has all the elements being either
void (density very close to zero) or solid (density equal to one).
► Number of optimization iterations:

► The controller-based algorithm always uses 15 optimization iterations.
► The number optimization iterations for the sensitivity-based optimization algorithm is
unknown before the optimization starts: normally, the number of optimization
iterations is around 30~45.
Slide 43 | 02/2014
137
Workshop

Model
1 Loadcase 1
2 Loadcase 2
Slide 45 | 02/2014
138
Optimization cranehook
Model ► cranehook.ext
Groups

Design Area ► ALL_ELEMENTS
► frozen area
► casting constraint
Sensitivity based
Objective ► Minimize  Volume topology optimization
Constraint ► Displacement constraints:

absolute displacement in specific node
Stop <= 1.1 for each loadcase
Slide 46 | 02/2014
Optimization cranehook:
Design variable constraints
► Select elements depicted on the right as frozen

group (selection using property (Nastran) or
predefined group (Abaqus, ANSYS))
► Define casting restriction with pull direction

(0,0,1), midplane through (0,0,0)
Slide 47 | 02/2014
139
Postprocessing cranehook
Visualization
Visualize optimization result

TOSCA Structure.view

Slide 48 | 04/2013
Postprocessing cranehook:
Smoothing
Smooth result using TOSCA Structure.smooth

(2 smooth runs)
Slide 49 | 04/2013
140
Thank you for your

attention
141
142
Notes
143
Notes
144
Optimization with

Tosca Structure
Shape Optimization
Basics
Shape optimization I
1. Shape optimization
2. Workflow
3. Preprocessing
5. Postprocessing
6. Result transfer
7. Workshop
Slide 2 | 02/2014
145
Shape Optimization

Shape Optimization
Modification of the model surface
Moving the model surface without changing the model topology
Parametric
Decreasing setup complexity
Increasing shape flexibility
Morphing
Shape Basis Vectors
Non-parametric
Freeform
Slide 9 | 02/2014
146
Non-parametric shape optimization
► Determination of the optimum contour of a

component
► Consideration of all given boundary conditions

► Displacement of each surface node
Motivation:
► Easy setup (no parametrisation required)
► Flexible result (maximum degree of freedom)
Slide 10 | 02/2014
Example
Stabilizer bar link from Audi A8
Problem
► Coupling link no longer fulfilled stiffness

requirements due to changes to the front axle
(see test and simulation results)

► Stress reduction of 25 % required!
Possible solutions
► Non-parametric shape optimization using Tosca

Structure
► Change of the radius of the contour
Slide 11 | 02/2014
147
What is non-parametric shape optimization ?

Results: stabilizer bar link from Audi A8
Result
► Verification of result by recalculation with

Pro/Mechanica:

► TOSCA-result (freeform surface):
Stress reduction by 30 %
► Modified radius:
Initial geometry Optimized coupling link
Stress reduction only by 18 %
110% ► Transfer into CAD and reconstruction
90%
70%
► Assembly in the new A8
50%
30%
10%
-10% Weight Max. stress
Initial design Optimization result
Slide 12 | 02/2014
Workflow
Shape Optimization
148
Workflow shape optimization

Slide 14 | 02/2014
Preprocessing
Defining the
Optimization Task
149
Preprocessing shape optimization

Slide 16 | 02/2014
Start
► Start shape optimization controller task

► Open folder preprocessing in task tree
Tosca Structure.gui
► Define new task

► Follow tree view of Tosca Structure.pre
Slide 17 | 02/2014
150

Model
Model Assign model to optimization task

► MODEL_LINK (Tosca ANSA environment)
Groups ► FEM_INPUT (Tosca Structure.gui)

Design Area Nodes, elements, materials, coordinate systems,
groups and properties are loaded
Objective
Optional reading options
Constraint ► SETTINGS (Tosca ANSA environment)
► OPTIONS (Tosca Structure.gui)
Stop
Slide 18 | 02/2014
Analysis model for shape optimization
Important model considerations: Too coarse Too fine
► Realistic models
► geometric details
► exact boundary conditions
► exact materials (evtl. non linear)
► Mesh quality
► Not too fine, not too coarse Good mesh
► Quadratic vs linear elements
Slide 19 | 02/2014
151

Groups
Model Use of groups


Defining groups
Constraint ► Select nodes or elements graphically (Tosca ANSA environment)
Slide 20 | 02/2014

Design area
Model Node group of surface nodes (design nodes)

Displaced design
► Node position can be modified nodes Design
Groups ► Optimization displacement is nodes
calculated during optimization

Design Area
Design variables are the displacement values
of the design nodes
Objective
► Positive: Displacement
node “grows” out of the structure Optimization
Constraint ► Negative: displacement
direction
node “shrinks” into the structure
Stop
Slide 21 | 02/2014
152
Design area
Definition
► Assign node group to design area

► DESIGN_AREA (Tosca ANSA environment)
► ND_GROUP parameter in DV_SHAPE (Tosca Structure.gui)

► Design variable constraints: geometric restrictions on design variables (later)
► Mesh smoothing to ensure high quality mesh for analysis
Slide 22 | 02/2014

Terms for optimization (design responses)
Model Design responses

► Functions (scalar values) dependent on design variables
Groups ► Results of FE analysis (stress, frequency) or model geometry (volume)
► Data for objective or constraint
Design Area
Definition
► Target: group of nodes/elements for extraction of values (evtl. operator)
Objective
► Type: form of result
► Load cases: loads and boundary conditions influencing result
Constraint
Determine design variables such that design responses for the objective
Stop are optimized and design responses for the constraints are feasible !
Slide 23 | 02/2014
153

Objective
Model Objective function

► function depending on the design variables
Groups ► functional value to be minimized or maximized

► often produced from the results of the FEM analysis
Design Area ► specified via a design response
Objective
Constraint
Stop
Slide 24 | 02/2014
Objective function
Definition
► Values to be optimized
► Stress results from analysis
► Choice in OBJECTIVE_FUNCTION folder (Tosca ANSA environment)
► Optimization target
► Minmax
► Edit OBJECTIVE_FUNCTION definition
► TARGET parameter in OBJ_FUNC, assign required design response(s)
Slide 25 | 02/2014
154
Tosca Structure.shape
Functionality
► Shape optimization by homogenization of the 100% 100%
stresses
► Update rule:

► Node stress > reference value 0% 0%
→ Growth in order to reduce stress
► Node stress < reference value
→ Shrinkage in order to increase stress σ
► Result: homogeneous stress distribution to

the level of the reference value σref
► 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 s
Slide 26 | 02/2014
Example ‚holeplate‘
LC 1
LC 2
LC 2= 2*LC1
LC 1
Slide 27 | 02/2014
155
Example ‚holeplate‘
Initial design Optimized design

100% 100%

Path for stress
distribution 0% 0%
Initial design Optimized design

8 8
Von Mises Stress (mpa)
Von Mises Stress (mpa)

6 6
4 4
2 2
0 0
1 3 5 7 9 11 13 15 17 19 21 1 3 5 7 9 11 13 15 17 19
Node position (Theta=[0°,90°]) Node position (Theta=[0.90°])
Loadcase 1 Loadcase 2 Loadcase 1 Loadcase 2

Slide 28 | 02/2014
Possible objective functions
1. Minimization of the maximum stress

2. Minimization of the deviation from a fixed reference value
3. Minimization of the deviation from a variable reference value (adv)
4. Others
Slide 29 | 02/2014
156
1. Minimization of the maximum stress
► Automatic determination of the reference value

► Reference value is updated in each design cycle
► Automatic adaption of the controller strategy if

► The maximum stress is located in the design
domain
► The maximum stress is located outside the
design domain
→ Very good designs for standard optimization
tasks
Slide 30 | 02/2014
2. Minimization of the deviation from a fixed reference value
► Direct definition of the homogenization level

► For each node in the design domain, the
deviation of the local stress to the reference
stress value is reduced

► Standard process for the Tosca Structure
controller
REF_VALUE = 70 N/mm²
► The maximum stress must be located in the
design area
REF_VALUE = 120 N/mm²

Slide 31 | 02/2014
157
3. Minimization of the deviation from a variable reference value:

relieving notch
► The homogenization level is defined via a numerical
variable
► The reference stress value is updated in each design
cycle

► Used for the dimensioning of relieving notches
(advanced) Reference
nodes
► Setup not directly possible in Tosca ANSA environment
200
Von Mises (N/mm2)
180
Design nodes
160
140
120
0 2 4 6 8 10 12 14 16 18 20
Iteration
SIG_REFERENCE
SIG_DESIGN
Slide 32 | 02/2014
4. Other advanced objectives
Temp. [°C]
► Finite element solver: High
► Different stress criteria

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

reduced by 50 %
Slide 33 | 02/2014
158

Constraint
Model Constraint

Admitted for shape optimization
Design Area ► only volume constraint with equality value defined on element
groups
Objective
Constraint (later)
Stop
Slide 34 | 02/2014
Example volume constraint (gif)

95 % target volume 105 % target volume
Slide 35 | 02/2014
159

Stop condition

Groups ► Standard tasks 5-10

Constraint Local stop criterion

► Change in certain variables, e.g. change of optimization displacement is
Stop smaller than 1% of previous iteration (see manual)
► not required, just resume your optimization with some more iterations
Slide 36 | 02/2014


Slide 37 | 02/2014
160
Parameterfile for shape optimization

Command blocks
Design variables Mesh Smoothing Design variable constraints

DV_SHAPE MESH_SMOOTH DVCON_SHAPE

Link_rule
LINK_SHAPE
Objective function
Optimize OBJ_FUNC
OPTIMIZE Design
response
Constraints DRESP
CONSTRAINT
OPT_PARAM
(STOP, LOGICAL)
Slide 38 | 02/2014
Basic structure of Tosca Structure command

► Each parameter is followed by a value or a character string with the symbol ‚=‚
Command

...
END_
Slide 39 | 02/2014
161
OUTPUT
Parameterfile (I)
FEM_INPUT
ID_NAME = OPTIMIZATION_MODEL
Analysis model
FILE = holeplate.ext

END_
DV_SHAPE
ID_NAME = design_variables
Design area
ND_GROUP = design_nodes
END_
Slide 40 | 02/2014
OUTPUT
Parameterfile (II)
DRESP
ID_NAME = DRESP_MAX_MISES
DEF_TYPE = SYSTEM
TYPE = SIG_MISES
UPDATE = EVER
ND_GROUP = design_nodes
GROUP_OPER = MAX
Objective function
END_
OBJ_FUNC
ID_NAME = minimize_max_mises
DRESP = DRESP_MAX_MISES
TARGET = MIN
END_
Slide 41 | 02/2014
162
OUTPUT
Parameterfile (III)
OPTIMIZE
ID_NAME = shape_optimization
DV = design_variables

Optimization task
OBJ_FUNC = minimize_max_mises
STRATEGY = SHAPE_CONTROLLER
END_
STOP
ID_NAME = global_stop Stop condition
ITER_MAX =5
END_
Slide 42 | 02/2014
Start Optimization
163
Start optimization
► Update RUN item in START_OPTIMIZATION

folder

► Remember to check log files (TOSCA.OUT)
Tosca Structure.gui
► Switch to start optimization screen

► Start
Slide 44 | 02/2014
Optimization loop

Optimization
CAD/DMU system
Tosca Structure
Solver
Slide 45 | 02/2014
164
Postprocessing

Visualization and
Report Generation

► DB_ERROR

► Files
Slide 48 | 02/2014
165


► Animation of optimization displacement


Slide 49 | 02/2014
Slide 50 | 02/2014
166
Handling
► Set draw styles/choose groups in settings panel
► Move model with mouse buttons:
► Ctrl + right: rotate in space

► Ctrl + middle: translate
► Ctrl + left: rotate in plane
► Mouse wheel: zoom
► Get information in selection panel
► Modify result settings in results panel
► Start animation in toolbar
Slide 51 | 02/2014
Shape optimization results
Model with optimization displacement and controller input as fringe plot

Slide 53 | 02/2014
167
Postprocessing of Tosca Structure optimization results

Report Generator
Capture Combination of views with integrated Report Generator:

► Screenshots

► Fringe plots
► Animation sequences
► x-y-plots of constraint and objective function values
► Result tables
Transfer Automatic report generation
► MS Powerpoint 2007 and 2010
► MS Word 2007 and 2010
► Html documents for Internet Explorer
► User defined templates for customized layout
Slide 54 | 02/2014
Result Transfer
168

Motivation ► Shape optimization modifies surface of already detailed design


Optimization result ► Large amount of data (especially with fine meshes)
Slide 56 | 02/2014

Solution ► Surface calculation

► Data reduction (optional)
► Output as
► Triangular mesh in CAD readable format (STL, IGES)

► Set of slices (cutting splines) in IGES format
STL: 63.200 elements STL: 17.300 elements Cutting splines (x, y and z)
Slide 57 | 02/2014
169
Smooth: processing of shape optimization results
► SMOOTH_INSTANCE → RUN_SMOOTH |
EDIT: set TASK to “surface”

► Set reduction rate
Tosca Structure.gui
► Tosca Structure.smooth: set task to “Create
Surface + optimization displacements”
Slide 58 | 02/2014
Transfer of optimization results into the construction process

Integrated methods
► Use results of shape optimization to deform/modify the CAD geometry

► Easy processing using
► CATIA RSO module
CATIA
NX ► NX Global deformation
► Modification file is written by Tosca Structure on request
► macros uf_shape_catia_rso.mac and uf_shape_nx_deform.mac
► Example using NX Global deformation
Slide 59 | 02/2014
170
Workshop

Shape example holeplate
F1
F2 =2F1 LC 1
LC 1: 100 N
LC 2
LC 2: 200 N
Slide 61 | 02/2014
171
Holeplate optimization problem
► Objective function
► Minimize the maximum stress of the design
nodes

► Constraints
► None
► Restrictions
► Fixation of the free surface nodes
Design
nodes
Node fixations for the
optimization
Slide 62 | 02/2014

Results
Start design Optimized design

Slide 63 | 02/2014
172

Course of optimization

Slide 64 | 02/2014
Thank you for your

attention
173
174
Notes
175
Notes
176
Optimization with

Tosca Structure
Shape Optimization II
Mesh Smoothing
Design Variable
Constraints
Shape optimization II
1. Mesh smoothing
2. Design variable constraints
3. Displacement restrictions
4. Symmetry constraints
5. Coupling restrictions
6. Check inputs
7. Morphing
8. Workshop
Slide 2 | 02/2014
177
Model Additional definitions for the design area
Groups

Design area ► Area for modification
Design variable constraint ► Geometric restrictions on design variables
Mesh smooth ► Mesh smoothing to ensure result quality
Objective
Constraint
Stop
Slide 3 | 02/2014
Mesh Smoothing
178

Mesh smooth
Model
Groups

Design area ► Area for modification with geometric restrictions
Design var. constraint ► Geometric restrictions on design variables
Mesh smooth ► Mesh smoothing to ensure result quality
Objective
Constraint
Stop
Slide 5 | 02/2014
Why mesh smoothing ?
Modifications during ► Displacement of the surface nodes due to the local stresses
shape optimization
► Strongly distorted elements on the surface layer
► Quality of the finite element analysis is affected
Design
nodes
Mesh smoothing ► Smoothing of the mesh of the internal structure (MESH_SMOOTH):

the optimization displacement is passed to the inner nodes
Slide 6 | 02/2014
179
Mesh smoothing
► Performed on an user defined element group

► All design nodes have to be located at the
surface of this element group

► Outside the mesh smooth area no
modifications are performed
► Displacements at the design nodes are moved
to the inner nodes in the mesh smooth area
► Element qualities are considered during mesh
smoothing
Slide 7 | 02/2014
MESH_SMOOTH command
► Tosca ANSA environment: DESIGN_AREA → MESH_SMOOTH

► Tosca Structure.gui: MESH_SMOOTH command
► Definition of MESH_SMOOTH element group

► Assign existing group
► Select new element group graphically (Tosca ANSA environment)
► Automatic definition by layers around node group
► Fixation of free surface nodes
Slide 8 | 02/2014
180
MESH_SMOOTH
Layer
► Automatic definition of the mesh smooth area

► Starting on a surface node group
► All elements in the defined number of element Design_nodes

layers are grouped
► The MESH_SMOOTH area should contain at
least 5-6 element layers.
The mesh smooth element group should be as

large as necessary but as small as possible to Element layers
guarantee:
► The best possible mesh quality
► The lowest possible calculation time
Slide 11 | 02/2014
MESH_SMOOTH
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
Slide 12 | 02/2014
181
MESH_SMOOTH
Additional parameters
► Convergence: Stepsize of the meshsmooth algorithm
► Level DVCON: Defines how often the design variable constraints are checked

► Mesh quality: Check of the internal mesh quality criteria
► Definition of limits for the element qualities

► For some element types limits may be defined
► If the limits are exceeded, the quality improvement is executed
These parameters have reasonable default settings – do not change at random!
Slide 13 | 02/2014
Manufacturing,
Coupling and
Symmetry
Constraints
182
Shape optimization with manufacturing restrictions

Motivation
► Result of a non-parametric shape optimization is the optimum concerning the

mechanical behavior of the component
► Algorithm generates freeform surfaces: processing in CAD systems may take some time

► Complex surfaces are not always producible
► External restrictions often require additional restrictions
Slide 15 | 02/2014
Shape optimization with manufacturing restrictions
Restrict the movement of ► avoid the change of border areas to other components
nodes to
► ensure the ability to manufacture the component
► control the design and look of the part
Implement restrictions by ► specification of displacement restrictions

► definition of casting restrictions
► definition of coupling conditions
► definition of symmetries …
Slide 16 | 02/2014
183
Displacement ► Restricting the absolute displacement amount

restrictions
► Minimum/Maximum member size
► Variation and restriction areas

► Element groups
► Restricting the displacement direction
Coupling conditions ► Stamping

► Drilling
► Turning
► Demolding
► Symmetry
Slide 17 | 02/2014

Design variable constraint
Model ► Restrictions on design variables
Groups
► DVCON_SHAPE command for displacement restrictions
Design area ► Defined for node groups

var. constraint
Design variable constraint ► For design nodes and nodes in the MESH_SMOOTH area
Mesh smooth
► LINK_SHAPE command for coupling conditions
Objective
► Referenced in DVCON_SHAPE command (hidden in TAE)
Constraint
Stop
Slide 18 | 02/2014
184
Displacement

Restrictions
Restrictions on
Movements of Design
Nodes
CHECK_BC
► Design nodes where the finite elements nodes Without consideration of

node fixations
are fixed in finite element model are also fixed in
the optimization
► The boundary conditions must be read in with

the analysis model (OPTIONS or Settings)
Node fixations for the

optimization
only part of symmetric model
is used for analysis
Slide 20 | 02/2014
185
DOF_CONTROL (CHECK_DOF)
► Enforces the design nodes not to move in an unwanted direction

► Restricts the displacement direction in an arbitrary coordinate system for a single node
group

► The degrees of freedom are fixed via the FIX parameter or set free via the FREE
parameter
my_cs
FIX
FREE
Slide 21 | 02/2014
Definition of coordinate systems
new_cs Z new_cs
f r 100
45
10 z
101
20
Y 10 Y
CS_0 X
Z X
Local: definition with reference to Nodes: definition by 3 nodes
existing coordinate system
Slide 22 | 02/2014
186
GROW/SHRINK_CONTROL
CHECK_GROW / CHECK_SHRINK
► Specification of maximum growth or shrinkage amounts

► The limits are always referring to the start model

Ar ea wh ere th e surfa ce no des
must lie a fte r th e op ti mizatio n
ma x_ gr ow_ va lue
max_sh rin k_valu e
Slide 23 | 02/2014
CHECK_SOLID
Solid as variation area

► Check for penetration against geometric
primitives
► Definition of variation and restriction solids via
SOLID command in Tosca Structure
Solids as restricted areas

Y Quad
6
CS_0 X
Slide 24 | 02/2014
187
PENETRATION_CHECK
CHECK_ELGR
Upper constraint area elem_top
► Check for penetration against beam and shell
elements that represent complex adjoining design_nodes
components

► Read elements from additional CAE model using
ADD_FILE (CREATE_FROM_INCLUDE)
Lower constraint area elem_bot
Slide 25 | 02/2014
CHECK_SLIDE
► Nodes generate the slide surface.

► Surfaces can be defined as slide surfaces in
order to force the design nodes onto this
contour.
Slide 26 | 02/2014
188
MEMBERSIZE_CONTROL
CHECK_MIN_MEM / CHECK_MAX_MEM
► Specification of minimum or maximum member

size r=3

► The sphere with radius r normal to the surface
defines an area of minimum or maximum
material accumulation
r=3
r=3
Slide 27 | 02/2014
Symmetry
Constraints
189
Example plane symmetry (gif)
Design area Without symmetry link

Symmetrical
meshing
Slide 29 | 02/2014
Example plane symmetry (gif)
With symmetry link
Symmetry
plane
Z X
Slide 30 | 02/2014
190
Plane symmetry: definition

PLANE_SYM
► Point on plane
► Origin (Tosca ANSA environment, F1 + Click
or direct entry of coordinates)

► Coordinate system (Tosca Structure.gui,
origin of CS = point on plane)
► Direction (normal vector)
Point
► Criterion for master node
Direction
► MAX:
Maximum growth and minimum shrinkage Master node
► MIN:
Maximum shrinkage and minimum growth. Displaced Displaced node
symmetrically
Please note: mesh in area of symmetry
restriction must be symmetric
Slide 31 | 02/2014
Example:
Rotational symmetry (gif)
Without rotational symmetry With rotational symmetry

Slide 32 | 02/2014
191
Rotational symmetry: definition

ROTATION_SYM
► Point on symmetry axis Direction

► Origin (Tosca ANSA environment, F1 + Click
or direct entry of coordinates)

Point
► Coordinate system (Tosca Structure.gui,
origin of CS = point on axis)
Master node
► Direction (of axis)
Displaced
► MAX: maximum growth and minimum symmetrically Displaced node
shrinkage
► MIN: maximum shrinkage and minimum
growth.
Please note: mesh in area of symmetry
restriction must be symmetric
Slide 33 | 02/2014
Plane symmetry for unsymmetric meshes

SURF_PLANE_SYM
Symmetry parameters:
► Point on plane
► Direction (normal vector)

► Tolerance
Point
Reference
Optimization displacement displacement Direction
► Reference displacement interpolated on Master node

„symmetric“ counterpart (mirrored point) CRIT = MAX
► Optimization displacement = Maximum
(minimum) of reference and original Displaced Displaced node
symmetrically CRIT = MAX
displacement according to criterion.
Slide 34 | 02/2014
192
Rotational cyclic symmetry for unsymmetric meshes

SURF_CYCLIC_SYM
► Surface consists of identical segments rotated Direction

around an axis with a certain rotational angle
► Symmetry parameters:

Point
► Point on axis Start point
for segments
► Direction (axis direction)
► Criterion for master node Angle
Master node
► Tolerance Displaced
symmetrically (by Displaced node
► Start point
segment rotation)
► Angle (for repeating segments)
Slide 35 | 02/2014
Mesh independent symmetry conditions

Comparison
Plane symmetry Rotational cyclic symmetry Combination of both

Slide 36 | 02/2014
193
Coupling

Restrictions
Stamping / Turning
► Preserving a stamping
/ turning surface
during the
optimization
► Definition of a
restriction area by a
group of surface
nodes
► Automatic
segmentation and
creation of a cutting
edge
► The cutting edge
moves through the
component and the
nodes are adapted
Slide 38 | 02/2014
194
Demolding
► Find and eliminate undercuts in terms of the

given demold direction
► Prove the ability to demold the design nodes

► Move nodes in undercuts to a geometric
acceptable position
Part
Mold
Slide 39 | 02/2014
Drilling
► Combination of turning and demolding

► Symmetry of rotation in terms of a drilling axis
► Steps of proceeding according to the turning
restriction but at the same time preserving the

ability to demold the surface
► Profiled drilling possible
► Drilling with previous coupling not yet possible
Slide 40 | 02/2014
195
Example:
Design area
Mesh smooth area

Slide 41 | 02/2014
Example:
Model with tet mesh
► No special requirements on the finite element

meshing
► Enormous reduction of the modeling time
► Easy definition of the optimization task
Slide 42 | 02/2014
196
Example:
Manufactured design
Existing design Optimized design

Slide 43 | 02/2014
Check Inputs
197
TEST_SHAPE
► Visual control of the optimization task (geometric restrictions, mesh_smooth area)

► Checks without time-consuming FE-analysis
► Nodes in design domain get virtual displacement (growth, shrinkage or random)

► Mesh modification is tested in the preprocessor of the optimization system
► Visual postprocessing of modified design using Tosca Structure.view
(VTF_VISUALIZATION)
Virtual random displacement for

check of symmetry restriction
Slide 46 | 02/2014
TEST_SHAPE Results
► The displacements of the surface nodes and the effects on the finite element mesh are
simulated
► As no finite element results are used, no fringe plots are available
► GLview Plugin not installed. Press here to install plugin ► GLview Plugin not installed. Press here to install plugin
DIRECTION = SHRINK DIRECTION = GROW
Slide 47 | 02/2014
198
SET UP of a TEST RUN
Tosca ANSA environment ► CHECK_INPUTS → TEST_SHAPE_CHECK → TEST_SHAPE:

Define virtual displacement and output format (vtf)
► Update

► VTF_VISUALIZATION
Tosca Structure.gui ► Define TEST_SHAPE command in parameter file (Tosca Structure.pre)

► Start Tosca with type „test1“
► Generate vtf sequence using Tosca Structure.post (choose parameter file,
enter result name of test shape files)
► View vtf
Slide 48 | 02/2014
Morphing
199
SIMULIA Tosca Structure.morph
► Add-on to shape optimization

► Highly flexible mesh geometry manipulation tool
► Quick and easy geometry changes

► Directly applied by CAE engineer based on simulation results
► Complex production requirements applicable
► Mesh distortions kept at minimum
CAE simulation and calculation
CAD FEM FEM design final CAD

geometry geometry analysis decisions realization

shortened design loop
Application Example: Manifold
Tosca Structure.morph – quickly create design variants

Automatically run simulations – in parallel environment
Easily evalutate design responses
200
Workshop

Workshop connecting rod

Manufacturing restrictions
Model ► Autogenerated tetrahedron mesh

► Symmetric to the xz and yz plane
Material properties ► E = 210 000 N/mm²

► Poisson‘s ratio: 0.3
z
y
x
Slide 53 | 02/2014
201
Workshop connecting rod

Loadcases
Loadcase 1 ► Centrifugal force (in a):

a b
15000 N applied in +z
Screw fixation

Loadcase 2 ► Gas pressure (in b), 2
5000 N applied in –z
Fixation in nodes of big eye z
Loadcase 3 ► Bending about the x-axis

Fixation in nodes of big eye y
x
Loadcase 4 ► Bending moment about y
Fixation in nodes of big eye
Loadcase 5 ► Torsion about the z-axis
Fixation in nodes of big eye
Slide 54 | 02/2014
Optimization task
Analysis model ► Complete FE model in conrod.ext

Design variables ► See figure
► Minimize the maximal von Mises stress
Objective function
(maximal stress from all load cases)
Mesh smoothing area ► See figure
Constraints ► Initial volume must remain unchanged
Restrictions ► Maximal thickness 5.5 mm in the design area
► Casting restrictions in both directions
y
x
Slide 55 | 02/2014
202
Optimization results (gif)
Optimization displacements Controller input

Slide 56 | 02/2014
Thank you for your

attention
203
204
Notes
205
Notes
206
Optimization with

Tosca Structure
Configuration and
Troubleshooting
Configuration and troubleshooting
1. Optimization control
2. Troubleshooting
Slide 2 | 02/2014
207
Optimization

Control
Tosca Structure workflow in detail
model.par
model1.<input>,
model2.<input>,
...
TOSCA_PREP
fem2onf
model_req.onf
model_fem.onf
model_grp.onf
FEM_MODIF
SAVE.<input>
model1.<input>,
model2.<input>, ... model1_<iter>.<input>,
model2_<iter>.<input>,
...
SOLVER
SAVE.<output>
model1.<output>,
model2.<output>, ... model1_<iter>.<output >,
model2_<iter>.<output>, ...
RES2VTM
tosca_memory.idx
tosca_memory.vtm
TOSCA_OPT
model_mod.onf
Slide 4 | 02/2014
208
Control shell
► The control shell

► Generates the working directory and all save directories
► Searches and copies all necessary files for the optimization (parameter file, input file(s) and

all include files)
► Starts the optimization modules, the finite element solvers and other simulation software
► Saves the results for each design cycle
► The Tosca Structure configuration file is called tosca_ctrl.cfg

► Configures settings for the Tosca modules, FE solver settings, life solver settings, Settings
for saving the results, ...
► Created by installer and will in most cases need no changes
Slide 5 | 02/2014
Configuration files hierarchy
► The global Tosca Structure configuration settings may be overwritten by a user

configuration and a job configuration
► Global configuration: $tosca/bin/tosca_ctrl.cfg
► User configuration: $HOME/tosca_ctrl.cfg

► Job configuration: Definition via CONFIG command in the parameter file
► The configuration files are read in the following order

1. Tosca Structure global configuration
Priority
2. User configuration
3. Job configuration
Slide 6 | 02/2014
209
Start Tosca Structure
Command line ► tosca <jobname>

► Parameter file: <jobname>.par
► FE input file is read from the parameter file (FEM_INPUT, ...)

► Standard solver (defined in the configuration file)
► Parameter file and analysis deck(s) must exist in the start directory
Tosca Extension for ► Select Optimization Result in the Tree Outline  Click Solve
ANSYS/Workbench

► Start
Slide 7 | 02/2014
Tosca Structure start options
► ALL
Complete Tosca Structure optimization
► TEST1
tosca_prep
► TEST2
tosca_prep – copy an existing FE result file –
tosca_opt
► TEST3
tosca_prep – FE analysis – tosca_opt
► TEST4
copy the result file for the 1st iteration (test2)
and execute complete optimization
Slide 8 | 02/2014
210
Tosca Structure additional parameters

Tosca Structure.gui
Activate „additional parameters for additional start options“

Slide 9 | 02/2014
Tosca Structure logging

TOSCA.OUT
► Logging to the command shell and to the file <jobname>/TOSCA.OUT

can be set to the following levels:
►NOTICE
Default output to STDOUT. Only the most important logging

►INFO
Default output to logfile TOSCA.OUT
►DEBUG
Very verbose output, mostly for support.
Can be switched on in start screen for Tosca Structure
Slide 10 | 02/2014
211
TOSCA.OUT
► Main logfile of Tosca Structure

► At best viewed in a text editor that uses a fixed width font, e.g. Courier New
► Structure: (<log tag>) [<time stamp> | <executable>] <message>

► <log tag> = CRITICAL | ERROR | WARNING | NOTICE | DEBUG | TRACE
► <time stamp> Current time in format HH:MM:SS (hours, minutes, seconds)
► <executable> Name of the executable that wrote the logging message
► In case of an ERROR the previous WARNINGs or following error list have to be checked
Slide 11 | 02/2014
Example: TOSCA.OUT
(NOTICE ) [10:58:03|tosca_perl] | Starting: OPTIMIZATION CONTROL Tosca Structure.control |

(NOTICE ) [10:58:03|tosca_perl] | Tosca Structure by FE-DESIGN GmbH |
(NOTICE ) [10:58:03|tosca_perl] | Version 7.1.0 |
(NOTICE ) [10:58:03|tosca_perl] ---------------------------------------------------
(INFO ) [10:58:03|tosca_perl] Logging to STDOUT at loglevel NOTICE
(INFO ) [10:58:03|tosca_perl] Logging appended to log-file "Output\TOSCA.OUT" at loglevel

DEBUG
(DEBUG ) [10:58:03|tosca_perl] ---------------------------------------------------
(DEBUG ) [10:58:03|tosca_perl] Current Directory : C:/EXAMPLES
(DEBUG ) [10:58:03|tosca_perl] Workdir : C:/EXAMPLES/Output
(NOTICE ) [10:58:03|tosca_perl] Logfile: Output\TOSCA.OUT
(INFO ) [10:58:03|tosca_perl] | READING Tosca Structure CONFIGURATION |
(NOTICE ) [10:58:03|tosca_perl] ---------------------------------------------------
(NOTICE ) [10:58:03|tosca_perl] | Starting jobname: "Output" |
(NOTICE ) [10:58:03|tosca_perl] ----------------------------------------------------
...
(ERROR ) [10:48:41|tosca_prep] **** Tosca Structure ERROR ****
(ERROR ) [10:48:41|tosca_prep] Definition of the optimization task was not
(ERROR ) [10:48:41|tosca_prep] successful because there are/is a command defintion
(ERROR ) [10:48:41|tosca_prep] which returned an error or a serious warning.
Slide 12 | 02/2014
212
Tosca Structure restart
► Restart
► Standard restart for aborted Tosca Structure
optimizations

► Tosca Structure starts with the finite element analysis in the corresponding design
cycle
► Restart 2
► Possibility to save the computation time of a finite element analysis if the analysis
finished correctly and Tosca Structure stopped in the optimization module
► Restart in tosca_opt
IMPORTANT:
The restart is only possible in case of license or I/O problems. In case of abortions caused
by the formulation of the optimization problem or mesh problems the restart is not possible.
Slide 13 | 02/2014
Tosca Structure.report
► Possibility to generate postprocessing

information in vtfx format for Tosca
Structure.view directly after the optimization has
finished animation sequences of contour plots

► Data plots for all optimization relevant values
(converted from <plot>.conf and <plot>.tab
files)
► For each report generation a parameter file with tosca_report
REPORT and eventually several --input_file tosca_report.par
--add_user_data plot.conf,plot.tab
CONTOURPLOT commands is generated
Slide 14 | 02/2014
213
Tosca Structure control shell
► Numbering of working directories (-ow (overwrite) )

► If Tosca Structure is started, the existing working directory will not be deleted but moved to
<jobname>_counter
► Existing Tosca Structure result directories will not be deleted if a new variant with the same

parameter file is executed
► The Commandline option ‘-ow’ forces Tosca Structure to overwrite the existing directory
► With Tosca Extension for ANSYS/WB existing directories are always overwritten!
► Include files
► For Abaqus and Nastran the include structure is kept during modification of the input files. ANSYS
files with include files are modified by Tosca Structure and combined into two new files.
► If optimization with include files is started, all Input filenames are kept and moved into a common
save directory. The Save directory is generated in the SAVE.$inp_ext directory and the folder name
<jobname>_<iteration_counter> is assigned
► This feature always keeps consistency of the filenames
Slide 16 | 02/2014
Troubleshooting in
Detail
214
Important locations for troubleshooting
► Screen output
► On command line or GUI window
► DB_ERROR directory:

► Created when optimization is cancelled
► Contains all files necessary to find the error
► TOSCA.OUT
► Tosca Structure protocol file
► In case of an error the file is located in the DB_ERROR directory
► Solver dependent message or log files
► Are located in the DB_ERROR directory
Slide 18 | 02/2014
Solver-specific message and log files
► If an ERROR occurs in the finite element analysis, all existing files are moved to the
DB_ERROR directory
► All existing solver specific files may be found in this directory
► ABAQUS : *.dat, *.msg, *_log.onf (TOSCA-ABAQUS interface log file)

► ANSYS : *.err, *.log
► MARC : *.out
► Msc.Nastran : *.f06, *.f04, *.log
► Permas : *.pro, *.res
Slide 19 | 02/2014
215
Troubleshooting with Tosca Extension

for ANSYS/Workbench
The DB_ERROR directory can be found by using

the right mouse button click on Solution – Open
Solver Files Directory

The current working directory opens up and within
the tosca-folder the DB_ERROR directory can be
found
Slide 20 | 02/2014
When does the error occur ?
1. Error on program startup

2. Error while saving the optimization model
3. Error during the finite element analysis
4. Error during the optimization loop
→ Check screen output, TOSCA.OUT or solver log files to localize error
Slide 21 | 02/2014
216
1. Error on program startup
Cause Action
► Files not found ► Copy the files to local directory

(analysis deck, include files, ...)

► Wrong name or extension ► Specify correct names
► Wrong path settings ► Check the configuration (tosca_ctrl.cfg)
► Missing license or license not found ► Install license (check file authorization.log)
(ERROR ) --------------------------------------------------------------------
(ERROR ) | ERROR in Tosca Structure-module "Tosca Structure.control" |
(ERROR ) --------------------------------------------------------------------
(ERROR ) Error while copying necessary files for optimization into working
(ERROR ) directory
(ERROR ) File could not be found:
(ERROR ) myjob.ext
Slide 22 | 02/2014
2. Error in Tosca Structure preprocessor
Cause Action
► Wrong syntax in parameter file ► Look up the commands in the error table and
correct the parameter file definitions
► Missing objects
► Check errors in TOSCA.OUT
► Unsupported objective function or constraints

► Wrong solver interface selected
(ERROR ) **** Tosca Structure ERROR ****

(ERROR ) Definition of the optimization task was not successful because there is
(ERROR ) a command defintion which returned an error or a serious warning.
…
(ERROR ) Table of failed commands:
(ERROR ) ---------------------------------------------------------------
(ERROR ) | Command with the error ID_NAME of command |
(ERROR ) ---------------------------------------------------------------
(ERROR ) OPT_PARAM SETTINGS
(ERROR ) [12:06:37|tosca_prep] Table of failed commands:

(ERROR ) [12:06:37|tosca_prep] ---------------------------------------------
(ERROR ) [12:06:37|tosca_prep] | Command with the error ID_NAME of command |
(ERROR ) [12:06:37|tosca_prep] ----------------------------------------------
(ERROR ) [12:06:37|tosca_prep] OPT_PARAM SETTINGS
Slide 23 | 02/2014
217
2. Error in Tosca Structure preprocessor

Typical mistakes
► Loadcase for design responses not specified correctly (special attention needed when
static and modal analysis are combined - please take care of correct numbering)
► Inequality constraint used for controller based topology optimization (not allowed)

► Equality constraint used for sensitivity based topology optimization (not possible)
► Mesh smooth area does not contain design variables
► Design nodes for shape optimization contain line parts (for 3D models) where no normal
can be found or inner nodes
Slide 24 | 02/2014
3. Error in the finite element analysis
Cause Action
► Error in analysis model ► Correct analysis input file

► All solver licenses in use ► Wait until licenses are available and restart
optimization job
► No free space on disk ► Generate free disk space or modify the MOVE
settings and restart job
(NOTICE ) Starting MSC.Nastran analysis - design cycle x

(ERROR ) ------------------------------------------------------
(ERROR ) | ERROR in Tosca Structure-module "FE-solver : mscnastran“|
(ERROR ) ------------------------------------------------------
(ERROR ) Error occured during Analysis.
(ERROR ) The following string was found in the solver output file
(ERROR ) String : "FATAL MESSAGE"
(ERROR ) File : "holeplate.f06"
(ERROR ) Please check the ERROR log files of the solver
(ERROR ) for further information.
Slide 25 | 02/2014
218
4. Error in the optimization module
Cause Action
► Missing results due to bad elements ► Check the mesh quality / Restart job
► Errors in the optimization module ► Find ERROR message in TOSCA.OUT

Slide 26 | 02/2014
Thank you for your

attention
219
220
Notes
221
Notes
222
Optimization with

Tosca Structure
Sizing
Optimization
Sizing optimization I
1. Sizing optimization
2. Preprocessing
4. Workshop
5. Postprocessing
Slide 2 | 02/2014
223
Sizing Optimization

Sizing optimization
1. Introduction
2. Workflow
4. Postprocessing
5. Result transfer
6. Workshop
Slide 4 | 02/2014
224
Introduction to

Sizing Optimization
What is sizing optimization?
Calculation of optimized sheet metal

thicknesses
► in a specified design area
► under consideration of boundary conditions

(optimization constraints, structural boundary
conditions and loads).
General target: mass reduction considering static
and dynamic requirements
► Parametric approach: up to approx. 50 variables

► Non-parametric approach (Tosca Structure):
handle several millions of design variables
Slide 6 | 02/2014
225
Modification of sheet thicknesses

Example Car body

Slide 7 | 02/2014
Sizing optimization in door development
Minimize the weight of a car front door

► Using typical loadcases in door development
(sagging, eigenfrequency)
► Keeping the stiffness

► –z displacement door lock nd ≤ actual value
► First modal eigenfrequency ≥ actual value z
► Considering manufacturing and design driven

constraints
► One thickness for each metal sheet
► Same parts for two hinge brackets
► Hinges, outside door panel unchanged "This model has been developed by The National Crash Analysis
Center (NCAC) of The George Washington University under a contract
► Reasonable range for sheet metal thickness with the FHWA and NHTSA of the US DOT"
Slide 8 | 02/2014
226
Result: Thickness distribution
Clustered thickness optimization Free thickness optimization

Thickness
Delta
thickness 17 % weight 42 % weight
reduction reduction
Slide 9 | 02/2014
Sizing Optimization
Workflow
227
Workflow sizing optimization

Slide 11 | 02/2014
Preprocessing
Design Area
Objective Function
Constraint
228
Preprocessing sizing optimization

Slide 13 | 02/2014

Model
Model ► FE model with relevant loads and boundary conditions

► Linear static, modal and frequency response analysis
Groups ► Shell or plate elements must be present
Design Area
Objective
Constraint
Stop
Slide 14 | 02/2014
229
The thicknesses of the most typical modeling shell elements are supported as design
variables:
► Abaqus

► Lower order shell elements:
S3, S3R, S4 and S4R
► Higher order shell elements:
STRI65, S8R
► ANSYS
► Shell 181, Shell 281
► Nastran
► Not supported
► Single layered shells
Slide 15 | 02/2014
Analysis model
► Contact is supported also for design elements

► Outside design area all sorts of constitutive non-linear modeling is allowed,
e.g. a non-linear spring
► Constitutive non-linear material in design area is not supported
► Geometrical non-linearities are not supported
► “Constant” temperature loading

► Prescribed displacements for static analysis, not allowed for modal and frequency
response analysis.
Slide 16 | 02/2014
230
Loading Types
Static Modal eigenfrequencies Frequency response

Slide 17 | 02/2014

Groups
Model Use of groups

Defining groups
Constraint ► Select nodes or elements graphically (Tosca ANSA environment)
Slide 18 | 02/2014
231

Design area
Model Element group

► Elements can be modified
Groups ► Elemental thickness of shell elements as design

variables (other options are open…..)
Design variable constraints
Design Area ► Different lower and upper bounds on the thicknesses
can be defined for different element groups.
► Initially, the thickness of each individual shell element
Objective
can be a design variable  thousands to millions of
design variable thicknesses !!
Constraint ► Additionally, the individual shell element thickness can
be clustered  e.g. thousands of shell thicknesses are
clustered to 50 design variable thicknesses.
Stop
Slide 19 | 02/2014
Thickness Design variables
► 331578 S4 shell elements

► 17443 S3R shell elements
► ~ 2 MDOF
► 198 shell sections

► Thickness of each shell section is
chosen as design variable
► 198 design variable thicknesses
► Or free thickness variables
► Upper and lower bound on design variable thicknesses: -20 (-40) % and +20 (+40) % of initial thickness,
e.g. *SHELL SECTION... *SHELL SECTION...
2.48, tinitial = 2.48 0.86, tinitial = 0.86
tlower = 1.98 tlower = 0.69
tupper= 3.00 tupper= 1.03
Slide 20 | 02/2014
232

Design variable constraints (DVCON_SIZING)
Model Geometric restrictions on design variables:

► FROZEN: Fixation of elements (not to be affected by optimization)
Groups ► THICKNESS_BOUNDS: Upper and lower bounds for shell thicknesses

► CLUSTER: Clustering of element areas with the same shell thickness
Design Area ► LINK_SIZING: Area linking and symmetry restrictions
► MIN_MEMBER: minimum member size control
Objective
Constraint
Stop
Slide 21 | 02/2014
Frozen areas
Areas which remain fixed during optimization,

i.e. where the shell thickness is not changed
Slide 22 | 02/2014
233
Thickness bounds
► Lower and upper bound for variation of shell thicknesses

► Relative or absolute value (MAGNITUDE)
► Relative lower (upper) value x initial shell thickness value = absolute lower (upper) value

► Default value: +/- 20%
UPPER_BOUND shell
LOWER_BOUND thickness
Slide 23 | 02/2014
Clustering
Clustering of shell thicknesses to remain the same during optimization

► reduces the number of design variables
► No influence on calculation time
Free sizing
shell
thickness
Clustering
shell
thickness
cluster area
Slide 24 | 02/2014
234
Clustering
Example

Free sizing Clustering
All shell elements are modified Clustering combines elements to
individually (shell thicknesses) areas with the same shell
 Good start for definition thicknesses
of clustering areas
Slide 26 | 02/2014
Width Control (minimum cluster width)
Define minimum width (WIDTH) of substructures of the same thickness

► Small sheet parts undesirable
► Avoids high oscillations in the thickness distribution

► Avoids checkerboard effects
► Creates mesh (size) independent results
► Provides automatic clustering
MIN_WIDTH shell
thickness
Slide 27 | 02/2014
235
Symmetry restrictions
No symmetry Planar symmetry

Rotational symmetry Cyclic translational symmetry
Point symmetry Link condition (coupling of arbitrary areas)

Slide 28 | 02/2014
Plane symmetry
► Point on plane:
Origin of coordinate system
► Direction:
Normal vector of symmetry plane

symmetric shell
shell thickness thickness
Point Normal
direction
Symmetry
plane
Slide 29 | 02/2014
236
Cyclic translational symmetry
► Replication of an area with a given distance

► Point:
Origin of coordinate system

► Direction:
shell symmetric
Translation direction
thickness shell thickness
► Translation:
Translation distance
Point Direction Translation
Slide 30 | 02/2014
Rotational symmetry
► Point on symmetry axis

► Origin (TOSCA ANSA environment, F1 +
Click or direct entry of coordinates) Direction
Symmetric
► Coordinate system (TOSCA Structure.gui, shell Point
origin of CS = point on axis) thickness
► Direction (of axis)

► Angle: Angle for rotational symmetric segments
Slide 31 | 02/2014
237

Design responses
Model
Extract values
Groups

Combine loadcases
Design Area
Objective
Combine (sum, max,...) for areas
Constraint
Restrict / optimize value

Stop
Slide 32 | 02/2014
TOSCA Structure.sizing
Supported structural design responses
Free choice of objective function and multiple constraints:

► Static load cases:
► Stiffness (= compliance)
► Displacements
► Forces
► Modal eigenfrequency load cases:
► Eigenfrequencies
► Frequency response
► Also vibroacoustic
► Mass
► At the present stresses are not supported
Slide 33 | 02/2014
238

Objective function
Model ► Defines target for design responses (minimize / maximize)

► Combines static loadcases/design responses with weights /
Groups reference values

Design Area
Objective
Constraint
Stop
Slide 34 | 02/2014

Constraint
Model ► restricts certain values dependent upon the design variables (design
responses)
Groups
Design Area
Objective
Constraint Manufacturing restrictions and other geometric constraints independent

of the optimization run are defined as design variable constraints.
Stop
Slide 36 | 02/2014
239

Stop condition

Groups ► Standard tasks 15 iterations

► Set „Max Design Cycles“ to desired limit (Tosca extension)
Constraint
Stop
Slide 38 | 02/2014
Block structure for sizing optimization
Design variables Design variable constraints

DV_SIZING DVCON_SIZING
Link_rule
LINK_SIZING
Objective function
Optimize OBJ_FUNC
OPTIMIZE Design
response
Constraints DRESP
CONSTRAINT
OPT_PARAM
(STOP, LOGICAL)
Slide 40 | 02/2014
240
Command structure
Parameter file

symbol ‚=‚

Command

...
END_
Slide 41 | 02/2014
Example: Minimize mass having stiffness restrictions
Bending stiffness Torsional stiffness Axial stiffness

uz,2  uz,1 uz,2  uz,1 ux,2  ux,1

 ubending
target
 utarget
torsional  uaxial
target
2 2 2
► Minimize Mass
► Bending stiffness requirement constraint
► Torsional stiffness requirement constraint
Slide 42 | 02/2014
► Axial stiffness requirement constraint
241
Optimization iteration history - Clustered thickness

optimization (20% upper and lower bound)
Objective: Minimize mass Constraints: Stiffness
Mass (normalized) Displacement (normalized)

Axial Bending
15% less mass
for same
stiffness 
Torsional
Optimization iteration Optimization iteration
Slide 43 | 02/2014
Optimization iteration history - Free thickness optimization

(20% upper and lower bound)
Objective: Minimize mass Constraints: Stiffness
Mass (normalized) Displacement (normalized)

Axial Bending
19% less mass
for same
stiffness 
Torisional
Slide 44 | 02/2014
242
Optimization comparison
Sizing for Stiffness of Static loading
Bending Torisional Axial
stiffness stiffness stiffness
Mass
reduction

Clustered thickness
15 %
20% upper and lower bound
Clustered thickness
40% upper and lower bound 17 %
Free thickness
Free thickness
Slide 45 | 02/2014
Example: Maximize the lowest modal eigenfrequncies
Optimization formulations
f1 = 20.4 Hz f2 = 22.1 Hz f3 = 25.8 Hz
► Maximize the lowest

modal eigenfrequncies f4 = 26.4 Hz f5 = 30.6 Hz f6 = 35.0 Hz
► The mass is not allowed
to exceed the original mass
Slide 46 | 02/2014
243
Optimization iteration history - Clustered thickness optimization

Objective: Maximize lowest eigenfrequncies Constraints: Mass

Modal eigenfrequencies Mass (normalized)

16% higher
eigenfrequeny

Slide 47 | 02/2014
Optimization iteration history - Free thickness optimization

Objective: Maximize lowest eigenfrequncies Constraints: Mass
Modal eigenfrequencies Mass (normalized)

26% higher
eigenfrequeny
for lower mass

Slide 48 | 02/2014 Optimization iteration Optimization iteration

244
Optimization comparison
TOSCA Sizing for Maximum Modal Eigenfrequencies
Increased

Eigenfrequency Mass constraint
Clustered thickness
16 %
20% upper and lower bound
Clustered thickness
Free thickness
20% upper and lower bound 26 % Not active
Free thickness 54 %
40% upper and lower bound Not active
Slide 49 | 02/2014
Start Optimization
245
Start optimization
► Select Optimization Result in the Tree Outline

Tosca Extension for
ANSYS /Workbench
► Click Solve

► Start
Slide 51 | 02/2014
Optimization loop

Optimization
CAD/DMU system
Tosca Structure
Solver
Slide 52 | 02/2014
246
Online

Presentation
Workshop
Stiffness optimization holder
Model ► Holder.ext
Groups
Design Area ► Design Area, several clustering groups
Objective ► Minimize  Compliance
Constraint ► 100 % Volume Constraint
Stop
Slide 54 | 02/2014
247
Clustering
► Free sizing
► Horizontal clustering
► Vertical clustering groups

► Cicular clustering groups (from left to right)
Slide 55 | 02/2014
Postprocessing
248


► Animation of material distribution


Slide 57 | 02/2014
Postprocessing

Animation
CTRL Rotation
Dynamic model
CTRL zoom
Slide 58 | 02/2014
249
Optimization result
Clustering

without horizontal vertical circular
Slide 59 | 02/2014
Result discussion
► Original design (original shell thicknesses)
► free sizing optimization without additional

restrictions leads to the best results:

reduction of the maximum displacement by 45%
► optimization with circular clustering required by

manufacturing:
improvement of 30%
Slide 60 | 02/2014
250
Thank you for your

attention
251
252
Notes
253
Notes
254
Optimization with

Tosca Structure
Bead Optimization
Bead optimization
1. Introduction
2. Workflow
4. Postprocessing
5. Result transfer
6. Workshop
Slide 2 | 02/2014
255
Introduction to

Bead Optimization
What are bead stiffeners ?
► Bead stiffeners are pits and elevations in planar

or arched sheet metal structures where the Round beads
depth is small corresponding to the length
Form beads
► Bead stiffeners may be stamped without the
requirement of additional material
Rectangular beads
► Bead stiffeners can have different geometries of
the cross section
Trapezium Triangle
beads beads
Slide 6 | 02/2014
256
Functionality of bead stiffeners
► Deflection of a bending beam
F  l3 l
d = -----------------

3 E I
d : deflection d
l : length
E : Young‟s modulus
b  h3 Cross section F
I : moment of inertia I = -------------
12 b
► The maximum deflection may be reduced by h
► Increase of the Young's modulus (defined by
the selected material)
► Increase of the moment of inertia (variable)
Slide 7 | 02/2014
Functionality of bead stiffeners
► Eigenfrequency of a bending beam:
ωj : Eigenfrequency
EI 1
j   2 λj : Constant, depending on boundary conditions

A  2
j A : Cross section area
ρ : Density
► The eigenfrequency may also be increased by increasing the moment of inertia
Slide 8 | 02/2014
257
Inspection of the rectangular bead

b
3
2 2 SH
e 1 1
t

1
Mb
 1 – b  t3  t  SH
3
---------
Ix = ------------------------- + e 2   1 – b  t + 2   ---------------- + e 2  t  SH + b t-3- + e 2  b  t 
12 12 12
1 2 3
► The implementation of bead stiffeners results in Steiner terms when determining the
moment of inertia. These terms lead to an increase of the moment of inertia.
► The moment of inertia has a cubed dependency upon the bead height (SH).
Slide 9 | 02/2014
Comparison of the initial structure

and the bead stamped design
► Beam with bead stiffener ► Beam with bead stiffener

► Maximum deflection 100 % ► Maximum deflection 10 %
Slide 10 | 02/2014
258
Bead pattern design up to now
► Use of bead-design catalogues Increasing bending stiffness

► Proposals for
► Standard shell/plate geometries
► Standard loading
► The determination of the optimum bead

configuration is very difficult for a complex
components geometry and for complex loading
Source: Oehler, „Steife Blech- und Kunstoffkonstruktion“
Slide 11 | 02/2014
Bead pattern design
► For the bead pattern design in shell structures, several basic parameters have to be
considered
► Bead height : Height of the stiffeners

► Bead width : Width of the single stiffeners
► Bead location : Where in the design domain must the stiffeners be located
► Bead orientation : How have the single stiffeners to be oriented ?
Slide 12 | 02/2014
259
Bead optimization with Tosca Structure.bead
► The bead optimization module in Tosca Structure enables the automatic determination of
the bead pattern design
► The following parameters are determined

► Bead location
► Bead orientation
► Under the following demands
► Bead height
► Bead width
► The Tosca Structure.bead optimization module is based on algorithms that were
developed at the Institute for Product development (IPEK formerly mkl) at the University
of Karlsruhe.
Slide 13 | 02/2014
Bead location and orientation
► The determination of the bead location and

orientation is the basic problem in bead pattern
design.
► Beads have a stiffening effect in areas of high

bending stresses, i.e. bead stiffeners should only
be used in areas of high bending stresses.
► A special bending hypothesis was developed for
Tosca Structure, which is used for the
determination of the bead location and
orientation.
Slide 14 | 02/2014
260
Bead height
► The moment of inertia depends cubic upon the

bead height and therefore the bead height is the
most important parameter.

► The maximum possible bead height results in
the maximum possible stiffness. Bead height
► The bead height also has a strong influence on

the manufacturing (deep drawing).
► The bead height is formulated as constraint in

the optimization problem.
Slide 15 | 02/2014
Bead width
► The bead width is automatically determined

according to the medium element size
► The bead width may be defined in the

OPT_PARAM command using the
BEAD_WIDTH parameter
► Bead optimization is an ill-posed optimization Bead width

problem, therefore it is advised to try more than
one BEAD_WIDTH
Slide 16 | 02/2014
261
Model plate
Displacement plots
Initial design 22.

SPCs
Pressure
0.0
Bead stamped design 2.2
0.0
Slide 17 | 02/2014
Bead optimization strategies
► DST (Differential Stress Tensor) strategy

► Based on the bending stress tensors.
Greatest generality. Default.
► Sensitivity-based bead optimization

► More general optimization tasks, in particular
strong for dynamic optimization
► Computationally more expensive
(>20 iterations)
► Advanced topic
DST
Slide 18 | 02/2014
262
Bead Optimization

Workflow
Preprocessing bead optimization

Slide 20 | 02/2014
263

Finite element models for bead optimization
Model ► Linear static or modal analysis

► Shell or plate elements must be present
Groups

Design Area
Objective
Constraint
Stop Simply supported plate optimized with Simply supported plate optimized with
respect to a static force respect to 1st eigenfrequency
Slide 21 | 02/2014
Model ► All nodes at shell / plate elements may be used as design nodes
► The optimization displacement vector is determined in positive direction of the
element normals (element orientation !!)
Groups
► The direction may be inverted using the SCALE parameter in the

OPT_PARAM command
Design Area ► Displacement direction may be checked via the TEST_BEAD command
► Design variable is the absolute displacement amount for each design node in the
Objective optimization displacement direction.
Constraint
Stop
Slide 22 | 02/2014
264

Design responses
Model
Extract values
Groups

Combine loadcases
Design Area
Objective
Combine (sum, max,...) for areas
Constraint
Restrict / optimize value

Stop
Slide 23 | 02/2014
Design response
Compliance
► Design response for minimization of compliance equivalent to “Maximization of stiffness”

► Defined by sum of strain energy of all elements
Remember to reference a specific loadcase for each design response
Slide 24 | 02/2014
265
Design response
Frequency
► Design response for maximization of the lowest natural frequency

Remember to reference a specific eigenvalue
Slide 25 | 02/2014
Design response
Bead height
► Design response for bead height constraint

► Maximum optimization displacement amount of the design nodes Bead
► Necessary constraint definition in the design domain height
Slide 26 | 02/2014
266

Objective function
Model ► Defines target for design responses (minimize / maximize)

► Combines static loadcases/design responses with weights /
Groups reference values

Design Area
Objective
Constraint
Stop
Slide 27 | 02/2014
Objective function
Definition
Slide 28 | 02/2014
267
Model ► Bead height
Groups

Design Area
Must be referenced in the OPTIMIZE command
Objective
Constraint
Stop
Slide 29 | 02/2014

Design variable constraints (DVCON_BEAD)
Model Geometric restrictions on design variables:

► CHECK_BC: Fixations of the nodes that are fixed in the analysis model
Groups ► CHECK_DOF: Restriction of single dof„s
► CHECK_GROW: Restriction of the displacement amount

Design Area ► CHECK_SOLID: Check for penetration against geometric primitives
► CHECK_ELGR: Check for penetration against element groups
Objective ► CHECK_LINK: Check symmetry conditions
Constraint
Stop
Slide 30 | 02/2014
268
Symmetry restrictions
Plane symmetry

Point Direction
Master node
Displaced node
Displaced
symmetrically
Slide 31 | 02/2014
Optimization task
► Typical OPTIMIZE command for bead

optimization
► Note the references to DVCON‟s and

CONSTRAINT‟s
OPTIMIZE command is automatically generated

by Tosca ANSA environment
Slide 32 | 02/2014
269
Bead controller
► SCALE = <value>
► Direction of the optimization displacement
vectors

► Only the sign is interpreted
► Inversion of the displacement direction
► BEAD_WIDTH = <value>
► Definition of the bead width (approximation)
Slide 33 | 02/2014


Slide 34 | 02/2014
270
Block structure for bead optimization
Design variables Design variable constraints

DV_BEAD DVCON_BEAD

Objective function
Optimize OBJ_FUNC Design
OPTIMIZE response
DRESP
Constraints
CONSTRAINT
OPT_PARAM
(STOP, LOGICAL)
Slide 35 | 02/2014
Basic structure of the single commands

symbol ‚=‚

Command

...
END_
Slide 36 | 02/2014
271
Start Optimization

Start optimization
Tosca ANSA ► START_OPTIMIZATION > RUN

environment
► Check TOSCA.OUT and/or Tosca_report.csv
Tosca Structure.gui ► Start optimization screen

► Start
Slide 38 | 02/2014
272
Optimization loop

Optimization
CAD/DMU system
Tosca Structure
Solver
Slide 39 | 02/2014
Postprocessing
273

► DB_ERROR

► Files
Slide 41 | 02/2014
Postprocessing with Tosca Structure.view
Bead model with optimization displacement and bead height as contour plot
Animation
CTRL Rotation
CTRL Dynamic model

zoom
Slide 42 | 02/2014
274
Handling

► Set draw styles and choose groups in settings
panel

► Get information about objects in selection panel
► Modify result settings in result panel
Slide 43 | 02/2014
Visualization of optimization results using

Tosca ANSA ► GENERATE_REPORT_FILE | New | CONTOUR_PLOT in folder POST-

Environment
PROCESSING: TYPE_PROPERTY = NODAL_DISPLACEMENT (BEAD)
► Update VTF_VISUALIZATION →Tosca Structure.view opens
► Navigate through result sequence
Tosca Structure.gui ► Generate vtf sequence file using Tosca Structure.report: choose parameter
file and results
► Generate Report
► View Report
Slide 44 | 02/2014
275
Result Transfer

Smooth
Result Transfer
Transfer of optimization results into the design process
Motivation ► Bead optimization modifies surface of already detailed design

Optimization Result ► Large amount of data (especially with fine meshes)

Slide 46 | 02/2014
276
Transfer of optimization results into the design process
Solution ► Surface calculation

► Data reduction (optional)
► Output as

► Triangular mesh in CAD-readable format (STL, IGES)
► Slices in iges format
20.000 Trias 4.114 Trias
Data
reduction
Slide 47 | 02/2014
Smooth: processing of bead optimization results
Tosca ANSA ► SMOOTH_INSTANCE → RUN_SMOOTH | EDIT: set TASK to “surface”

Environment
Tosca Structure.gui ► Tosca Structure.smooth: set task to “Create Surface + optimization

displacements”
Slide 48 | 02/2014
277
Online

Presentation
Workshop
Model hood
► Shell model 20
► Shell thickness: 1,0
► Two loadcases:
► F1 = [ 0.0, -0.2, 0.0]

15
► F2 = [ -0.6, 0.0, 0.0]
► Irregular, triangular mesh
y 15
F2
x
z F1
Slide 50 | 02/2014
278
Optimization results hood

One loadcase

Slide 51 | 02/2014
Optimization results hood

Two loadcases and symmetry
Slide 52 | 02/2014
279
Workshop example: oil pan

Initial design
► Frequencies of the start design

► Freq 1: 177 Hz
► Freq 2: 301 Hz

► Freq 3: 336 Hz
► Freq 4: 392 Hz
► Freq 5: 474 Hz
► Target of optimization
► Introduction of bead stiffeners
► Maximize the lowest natural frequency
Slide 53 | 02/2014
Workshop example: oil pan

Optimized design
► Frequencies of the optimized design

► Freq 1: 395 Hz
► Freq 2: 536 Hz
► Freq 3: 700 Hz
► Freq 4: 736 Hz
► Freq 5: 933 Hz
Slide 54 | 02/2014
280
Workshop example: solution

Slide 55 | 04/2013
Thank you for your

attention
281
282
Notes
283
Notes
284
Optimization with

Tosca Structure
Solver Interfaces
Optimization procedure with Tosca Structure
model.fem
FEM preprocessing
Opt preprocessing model.par Tosca Structure PREP
ABAQUS/CAE
ANSA model_xxx.fem
ANSYS
FEMAP
HYPERMESH
Abaqus
CAD
I-DEAS
Ansys
MEDINA
Marc
MSC.PATRAN
MSC.Nastran
MENTAT
Permas
FEM postprocessing
Opt postprocessing model_xxx.res
VRML viewer
OPT results Tosca Structure OPT
Slide 2 | 02/2014
285
Optimization preprocessing
FE preprocessor
► Definition of the analysis model
► Definition of the element and node sets for
the optimization

model.fem model_add.fem
► Definition of coordinate systems
OPT preprocessor ► Import of all sets and BC„s

► Definition of the optimization task
model.par
► Tosca Structure.pre, Tosca Structure.wizard,

Tosca Structure editor, integrated solutions
Slide 3 | 02/2014
Import of sets
► Node and element sets included in the analysis model are imported by Tosca Structure
and can be used for further definitions in the parameter file.
► Available for following solvers: ABAQUS, ANSYS, Marc and PERMAS*
model.inp: model.par:
... ...
*ELSET, ELSET=design, DV_TOPO
GENERATE
ID_NAME = design_variable
1, 1000, 1,
EL_GROUP = design
*ELSET, ELSET=frozen
...
500, 520, 521, 550, 890,
...
*no longer supported (available with functionality of Tosca Structure 6.2)

Slide 4 | 02/2014
286
Import of coordinate systems
► Coordinate systems in Tosca Structure can be used to define restrictions or

to apply selections.

► Import of coordinate systems from the analysis model:
► ABAQUS: *SYSTEM, *TRANSFORM
► ANSYS: LOCAL
► Marc: CYLINDRICAL, TRANSFORMATION
► MSC.Nastran: CORD1C, CORD1R, CORD1S, CORD2C, CORD2R, CORD2S
► PERMAS: $RSYS; definition via ID, import as “CS_<ID>”
Slide 5 | 02/2014
Optimizable element types

2D solid / shell elements
► PLANE_TRIANG_3 ► PLA NE_QUAD_4
► SHELL_TRIANG_3 ► SHELL_QUAD_4
► PLANE_TRIANG_6 ► PLANE_QUAD_8
► SHELL_TRIANG_6 ► SHELL_QUAD_8
Slide 6 | 02/2014
287
Optimizable element types

3D Elements
► SOLID_BRICK_8 ► SOLID_PENTA_6 ► SOLID_TETRA_4 ► SOLID_PYRAM_5*

► SOLID_BRICK_20 ► SOLID_PENTA_15 ► SOLID_TETRA_10 ► SOLID_PYRAM_13*
Slide 7 | 02/2014 *supported with Tosca Structure 7.3 for controller based optimization for ANSYS
General
► Following is allowed in FE model but not within the design area

► Other element and MPC types (i.e. BEAMs, Rods, RBEs, Contacts, etc)
► Super elements and submodelling
► Linear and Modal analysis is allowed with standard Tosca Structure license
► Non-linear, frequency response and other advanced analysis types call for advanced
licenses
► Note:
► ANSYS: Some contact definitions may make a „linear“ model „non-linear“, see documentation
► Abaqus: *STEP, perturbation is necessary. If perturbation is not set Tosca Structure assumes
non-linear analysis
Slide 8 | 02/2014
288
Solver versions
► Tosca Structure versions usually support the concurrent solver versions at release date
► Tosca Structure 8.0 supports:
► Abaqus 6.13

► Ansys 14.5.7
► Msc.Nastran 2013
► MD Nastran 2013
Slide 9 | 02/2014
Short comment on life solvers
► Tosca Structure.shape can utilize results from durability solvers

► The only "out of the box" supported durability solver is:
► Femfat
► Using some customizing the following durability solvers will work with Tosca Structure:
► fe-safe
► ncode Designlife
► MSC.fatigue
► LMS Virtual.Lab Durability
► FE-fatigue
► FEMSite
Slide 10 | 02/2014
289
Thank you for your

attention
290
Notes
291
Notes
292
W0.1
Workshop Tosca Structure

General Remarks
W0.2
General Remarks
Directory set-up
The FE models used for the optimization examples are grouped with respect to solver type and if
topology, shape or bead optimization is chosen:
/Tosca_STRUCTURE/<solvername>/topo
/Tosca_STRUCTURE/<solvername>/shape
/Tosca_STRUCTURE/<solvername>/sizing
/Tosca_STRUCTURE/<solvername>/bead
Additionally, a directory with the name /Tosca_STRUCTURE/include contains predefined group files
that can be loaded for the definitions. These groups can be used for all solvers. Nevertheless, for
certain solvers these groups are already included in the solver input file and are imported to the
graphical interface when the input file is read (Check the workshop description).
Help files and Manuals

A link to the Tosca Structure documentation can be found on the desktop or in the start menu. The pdf
document can also be opened by clicking on "Help" in Tosca Structure.gui. The Command Manual lists
all possible settings for all Tosca Structure commands. Detailed information and descriptions regarding
the use of Tosca Structure can be found in the User Manual.
293
W0.3
Tosca ANSA Environment

W0.4
Pull dow n menus Task Manager Toolbars
Start Tosca ANSA environment. The
complete optimization task including a
validation run can be executed with
Tosca ANSA environment.
TOSCA ANSA environment Info General buttons
294
W0.5
Toolbar and main menu (1/4)
All buttons in the toolbar can also be found in the

pull-down menu Windows:
Task Manager: Turn on/off the Optimization Task

manager window. Define and navigate optimization
task.
Info: Turn on/off the Information for logging,

warnings and error messages. Shows output of
feedback on actions.
Modules Buttons: Detailed Tosca Structure

commands. Allows access to all Tosca Structure
commands.
W0.6
Materials: Manage the model material definitions:

• Browse model materials.
• Change colors for material visualization.
Properties: Manage the model property definitions:

• Browse model properties.

• Change colors for property visualization.
Sets: Manage the model set definitions.
295
W0.7
Measure: Measure distances and angles:

• Select the corresponding entity.
• Select the measurement points by clicking in
the model.
• Select the corresponding result at Results in

Measure window.
• The values are shown in the model.
Database: Turn on/off the Database window.

• Control visibility of database contents.
Checkboxes are used to turn the corresponding
entity on/off in the model view.
• Doubleclick on item opens detailed information
dialog for selected entity in a separate window
which can be closed by ESC.
W0.8
Modules Buttons: Detailed Tosca Structure commands. Allows access to all Tosca Structure
commands.
Basic functions of task manager
Update of current item.
Execution of complete task (updating all items in the task manager).
Expand or collapse the complete task manager and all sub items.
Highlighting of active item in the model view.
296
W0.9
General buttons (1/2)
Focus:
INVERT: shows hidden objects while
OR: select the elements that remain
hiding shown objects.
visible (hide the remaining ones).
LOCK: saves the current view so
AND: select the elements, then their
that ALL command returns to this
neighbors will become visible.
view.
NEIGHB: makes one layer of
NOT: select the elements to be hidden.
neighbor elements visible.
!NOT: select entities that will remain NEAR: Logical operation that turns
visible. The selected entities are all the nearby items of selected
temporary (during selection) excluded entities visible, according to a
from the visible area and as soon as the specified tolerance value.
middle mouse button is pressed
(selections' termination) they -and only PEEL: hides one layer of outer
them- remain visible (invert operation). elements.
ALL: makes all geometric objects visible. ENT: Define the entity pick mode that
is used for above commands.
W0.10
General buttons (2/2)
WIRE: defines if the grid is shown. Draw Mode: defines how the model
is colored: according to the type of
SHADOW: defines if the shaded faces are geometric object (ENT), property ID
shown. of elements (PID), material ID of
elements (MID) or another element
related value.
HIDDEN: hidden line plot.
FE-Mod.: makes the elements visible or

hidden.
GRIDs: makes the nodes visible or Turn on/off the visibility of all
hidden. measurement objects in the model
view.
297
W0.11
Dynamic model control
To move the model press Ctrl and

left mouse button
for dynamic rotation: Rotation center is
the node entity closest to the actual
cursor position.
right mouse button

for rotation around normal axis to screen
plane.
middle mouse button

for model translation.
left and middle mouse button

for dynamic model zoom.
W0.12
Function keys
F1 TOP View Keys for dialog windows

ESC Close active dialog window (CANCEL)
F2 FRONT View
? Select from database list
F3 LEFT View
F1 Select from model area
F4 BOTTOM View
F5 BACK View
F6 RIGHT View
F7 Zoom In (Center: actual cursor position)
F8 Zoom Out (Center: actual cursor position)
F9 Fit View
F10 Default Iso View
F11 Presentation Parameters

F12 Open Database Browser
298
W0.13
Starting a new task
1. Start a new Tosca Structure task.
1
2
2. Type of optimization is selected as task
manager commands are dependent on the
selected type of optimization.
3. Select solver interface in MODEL LINK.

3
4
4. Select file.
5
5. Update the optimization task to import model.
W0.14
Group definition
1. To see predefined groups or to define a new

group enter ’?’ in GROUP_DEF text field or open
SET Help window by the corresponding button
1
2. Select a predefined group by doubleclick or
select New at the Action Button. If the New
group definition is selected, the DATABASE 2

browser is opened and the entity type for the
groups selection can be defined.
3. Select the corresponding entities to the group

using your mouse (described in next
subsection). Confirm with middle mouse button. 3
4. Specify group name in SET dialog and confirm

with OK. The group is now added to the
database. Select the group from database by 4
doubleclick.
299
W0.15
Selection and deselection of items
left mouse button

The selection of geometric objects
(elements, nodes, etc.) is done using the
left mouse button.
middle mouse button

A click with the middle mouse button

confirms the selection or terminates the
current action.
right mouse button

Using the right mouse button, the selected
objects are deselected.
W0.16
Tosca Extension for ANSYS Workbench

300
W0.17
Tosca Extension for ANSYS/WB (1/3)
In order to load the extension, open the Extension Manager by clicking

Extensions | Manage Extensions.
Check the box for the actual Tosca Extension for ANSYS Workbench. The extension is loaded
immediately; close the Extensions Manager and wait for the Busy icon in the down left corner of
the screen to disappear.
Use the Extension Manager to

load Tosca Extension for
ANSYS/Workbench
W0.18
If you save a project and the extension is used, it is

loaded automatically the next time the project will
be opened.
The entire optimization from model creating to the
last step of the optimization takes place in three
main windows / applications.
The main window of ANSYS Workbench with its

Project Schematic collects all parts of a
project in a graphically clear manner. Every
subsystem or template is listed and connections
between the single systems are visible.
ANSYS Workbench overview. The Project

Schematic shows the used systems / templates
301
W0.19
Tree Outline (left) and

Details View (right)
W0.20
Buttons (1/2)
The relevant buttons for the use of the Tosca Extension for ANSYS Workbench can be found in the
upper toolbar of the Mechanical application. All optimization options, controls and conditions will be
inserted with these buttons.
Set a design area or define different manufacturing restrictions.

Defines the part of the geometry that has to be optimized.
Defines parts that have to be left out of the optimization.
Inserts direction for pulling out the model of a casting mold.
Is able to avoid material accumulation in certain areas or to set a minimum size /

circumference for bars.
Adds different kinds of symmetry for the topology optimization.
302
W0.21
Buttons (2/2)
Constraints and Objective Functions for the optimization can be chosen.
Defines the kind of system output.
Minimizes or maximizes a certain design response.

Inserts values for a design response to converge to.
Here you can add the two result options.
Shows the actual result of the topology optimization.
Adds a smoothed surface model of the optimization.
After an optimization run an optional validation run can be performed.
Starts the validation run.
Continues the validation run.
W0.22
Hints for model generation with Tosca Extension for ANSYS/WB (1/3)
1. Do not spend too much time on geometrical

details for the design domain in topology
optimization.
2. It is more important to set the physical boundary

conditions correct because the boundary
conditions are manipulating the optimization:

2
3. The mesh indirectly affects the level of details in

topology optimization. Choose the element size
considering the minimum thickness (e.g. ribs,
bars, beams, etc.) of the part (approximately 3-4
elements in thickness)
303
W0.23
4. The mesh properties can be changed at Mesh in

Tree Outline:
4
- Geometry names the design domain
- Element size is chosen according to the
optimization task
- For topology optimization it’s more suitable to

select Hard at Behavior as a homogeneous
mesh is generated inside the volumetric parts.
5. Drop mid size nodes for elements in design

domain:
5
6. Lower order hexahedral elements are preferred

compared to lower order tetrahedral elements.
(It is not always possible to mesh using 6
hexahedral elements.)
W0.24
7. For group definition, select point, line, area or

volume and rightclick. Select Create Name
Selection and enter a name:
7
8. Before generating a finite element input deck,

verify that the FE-model is running. Then mark
one loadcase and click Write Input File.
Add .cdb as appendix at file name and select 8
“All Files (*.*)” as file type.
304
W0.25
Tosca Structue.gui
W0.26
Tosca Structure.gui
Tosca Structure.gui can be started either using the start menu or by clicking on the relevant symbol on
the desktop. The complete optimization task can be executed with Tosca Structure.gui.
305
W0.27
Tosca Structure.gui: basic layout
Main Pull Down Menu Toolbar
Main Window
W0.28
Task view
Different views of the optimization task are shown

in the left frame:
In Text view the text of the parameter file is shown.

In Tree view the structure and the entries of the

optimization task are shown. This view suits well for
navigation through the task. By clicking on the
folder icon, a subfolder opens with currently created
entries.
306
W0.29
Creating a new task (1/2)
For creating or modifying a task select the Tree view in task manager. Click at the corresponding
entity: A command entry like FEM_INPUT (folder icon) for creating a new one or a currently created
entry like MY_INPUT_FILES (document icon) in submenu for modifying.
For modifying select the currently created command in the subfolder (MY_INPUT_FILES for
example). Change the entries in the main window and click Modify. The definition of the
corresponding command in the parameter file changes.
Click at a command entry or a currently created entry. Enter or change the entries in the main
window and click Create. A second entry with modified or new parameters will be added.
With Close button the main window will be closed.
With Delete button the command entry will be deleted.
By clicking the question mark button the web help of the corresponding command opens.
The help button in the toolbar opens the pdf documentation.
W0.30
Creating a new task (2/2)
Additional to the existing commands in the task

manager, other specific commands can be created
by clicking at the dropdown menu Commands and
selecting the corresponding command.
307
W0.31
Modules (1/2)
In dropdown menu Module in the toolbar different

modules can be selected:
• At Tosca Structure.pre the optimization task is
defined.
• At Start Tosca Structure the optimization is
started.
• At Tosca Structure.report the optimization
results can be visualized
• At Tosca Structure.smooth the optimization
result can be smoothed and visualized.
In Start Tosca Structure select the corresponding

JobName if necessary by clicking at the button with
the three dots. The directory will be entered
automatically. Select your solver and start Tosca
Structure with the Start button.
W0.32
Modules (2/2)
In Tosca Structure.report select the corresponding

Jobname if necessary by clicking at the button with
the three dots. The directory will be entered
automatically. For visualizing the optimization result
use the buttons Generate and View Report.
In Tosca Structure.smooth click Select Job if

necessary and choose the Task. Smoothing starts
with the corresponding button and can be
visualized with View Result.
308
W0.33
Tosca Structure wizard
Tosca Structure.gui contains an integrated wizard

which enables you quickly to define standard
definitions in optimization tasks. The parameter file
created by the wizard is loaded into Tosca
Structure.pre and can be extended using more
advanced optimization definitions.
Tosca Structure wizard
309
310
Notes
311
Notes
312
W1.1
Topology Optimization
Procedure for topology optimization

The procedures used to define the optimization model are described briefly below. These procedures
are supported by Task Manager in Tosca ANSA environment (TAE) as well as the command tree in
Tosca Structure.pre screen of Tosca Structure.gui (GUI). The CAE analysis model must previously be
completely defined. Alternatively the entire optimization setup including the CAE analysis model can be
completed within ANSYS Workbench using the Tosca Extension for ANSYS Workbench (TExtWB).
Analysis Model
1. Question: Which file(s) contains the FE- model for the optimization?
Procedure: Link file(s) to optimization task.
TAE: MODEL_LINK | FILE item, choose Edit, then choose your model file.
GUI: Choose your model file in FEM_INPUT.
TExtWB: Right click the Geometry cell of the static or modal system and select Import
Geometry. Add the mesh and load cases later in the Mechanical application.
W1.2
Design Area
2. Question: Which part of the FE model should be selected as the design space?
Procedure: Assign an element group to the design area.
TAE: DESIGN_AREA item, choose Edit, then choose a predefined group or select a new group.
GUI: Choose or define the element group for the selected design area (GROUP_DEF) and define the
design variables (DV_TOPO).
TExtWB: Add a Topology | Design Area and assign a part of the geometry graphically or by
Named Selection.
3. Question: Are there elements in the design space which have to have certain restrictions? How can
these restrictions be described?
Procedure: Define design variable constraints for element group.
TAE: DESIGN_AREA | DV_CONSTRAINTS item, choose New | <type of restriction>,
choose predefined group or select new group for this restriction. If needed, define link conditions
using Modules Buttons toolbar.
GUI: Choose or define element groups with restrictions (GROUP_DEF). Define the restrictions using
DVCON_TOPO command.
TExtWB: Click Topology and choose a desired restriction. Then assign a part of the geometry.
313
W1.3
Design Area and Objective function
4. Question: Are there certain symmetry conditions that should be fulfilled?

Procedure: Create a symmetry coupling condition.
TAE: DESIGN_AREA | DV_CONSTRAINTS item, choose New | SYMMETRY_CONTROL.
GUI: Create a LINK_TOPO condition and reference it in the restriction command (DVCON_TOPO).
TExtWB: Select Topology | Symmetry and fill out the corresponding input boxes.
5. Question: Which terms describe the values to be optimized? Should these values be minimized or
maximized or otherwise combined using the minmax formulation (only available for sensitivity based
algorithm)? Are any special weighting factors or target values required?
Procedure: Choose the terms for optimization (design responses) and the target type.
TAE: OBJ_FUNC_ITEM_1 item, choose New | <term for optimization>; choose Edit for
choice of target type (min, max, minmax).
GUI: Define the design response (DRESP) and assign it to the objective function (OBJ_FUNC).
TExtWB: Select Optimization | Design Response and select the corresponding options.
Then add an Optimization | Objective Function and assign the predefined design
response.
W1.4
Constraint
6. Question: Which terms describe the constraint? What value should the constraint have?
Procedure: Choose the term for the constraint and set the target value or upper/lower boundary.
TAE: CONSTRAINTS item, choose New | <term for constraint>.
GUI: Define the design response (DRESP) and assign it to the constraint (CONSTRAINT).
TExtWB: Select Optimization | Design Response and select the corresponding options.
Then add an Optimization | Constraint and assign the predefined design response.
314
W1.5
Optimization Task
7. Question: Are all of the command definitions listed above complete and ready for the optimization
job?
Procedure: If necessary, make additional definitions and prepare the optimization job.
TAE: Automatically prepared by task manager.
GUI: Reference all definitions above in OPTIMIZE.
TExtWB: All active (not Suppressed) definitions will be used automatically in the Optimize
command and the following optimization.
8. Question: Are you using controller or sensitivity based optimization strategy?

Procedure: Choose the corresponding strategy.
TAE: Chosen in the beginning when the task is created (TOPO_CONTROLLER or
TOPO_SENSITIVITY).
GUI: Set the correct value to either TOPO_CONTROLLER or TOPO_SENSITIVITY in OPTIMIZE
subcommand STRATEGY.
TExtWB: Choose the desired Strategy in the Analysis Settings in the Tree Outline.
W1.6
Stop Condition
9. Question: Should the stop condition be modified?

Procedure: Modify stop condition.
TAE: GLOBAL_STOP_CONDITION, choose Edit and change the number of iterations.
GUI: STOP.
TExtWB: An iteration based stop condition can be defined as Max design cycles in Analysis
Settings in the Tree Outline.
10.Question: Is all required data specified?

Procedure: If yes, finish the definition of the optimization problem and save your definition.
TAE: Click twice OUTPUT item, then enter the jobname and click Update to save the .par file.
GUI: Save as <jobname>.par
TExtWB: Save the current workbench project.
315
316
Notes
317
Notes
318
W1a.1
Workshop Example Topology Optimization – Brake Booster
Task Maximize stiffness with volume constraint

Keywords Design area, objective function, constraint
The aim of this section is to introduce into optimization with Tosca Structure.topology. The basic
components of an objective task, design area, objective function and constraints, will be introduced.
They can be defined using Tosca ANSA environment, Tosca Structure.gui with or without the wizard or
the Tosca Extension for ANSYS Workbench.
Please note: this workshop could also be omitted.
30 min
W1a.2
Task description
The idea of this workshop model is to find a design proposal for a good brake booster of a mountain
bike. Such brake boosters are necessary to ensure the stiffness of the brake system, because the
brake is pressing against the bicycle rim from both sides. If the brake force is high, the bicycle frame
will be deformed. This can be limited with the application of a brake booster. This booster has to be stiff
and the weight has to be low. The optimization task is realized as a maximization of the stiffness
(minimization of the sum of the strain energy) with a volume constraint.
319
W1a.3
Model
The present model describes one half of a two

dimensional brake booster fixed on the upper left
side for symmetry reasons. A single force is applied
to node 2345 simulating the load under braking.
node
The design space is defined as a 2D model to save 2345
runtime and quickly get the desired result.
Workflow using Tosca ANSA environment
1 2
Model import Define Design area
boost.<ext> ALL_ELEMENTS
3
Objective function
4
Volume constraint
5
Save optimization
task
6 7
Start optimization Post-processing
run
320
W1a.5
Model import (1/2)
1. Select File | New to open a new file. In the

Confirmation window press Discard.
1
2. In Task Manager, select TASKS | Tosca

Structure Task | TOPO_CONTROLLER.
Click Expand-button to show the whole tree of
2
the optimization task.
3. Select PRE-PROCESSING | MODEL_LINK |

FILE | Edit and load the model boost.ext
(ext=inp, bdf, dat, ...) from the subdirectory
<solvername>/topo/booster.
3
W1a.6
Model import (2/2)
4. Right click the item named after the file you

have just chosen and select Update to show
the model in the main window.
4
321
W1a.7
Design Area
The design area contains all elements:
6. Choose the design variables for the topology

optimization (PRE-PROCESSING |
TOPOLOGY_OPTIMIZATION_CONTROLLER |
DESIGN_AREA | Edit). All elements of the FE
model are used as design variables in the

optimization.
W1a.8
Objective function
7. The objective function is chosen by

PRE-PROCESSING |
OBJ_FUNC_ITEM_1 | COMPLIANCE | Edit. 7
The compliance is equivalent to the total strain
energy of the structure. The relevant group is
ALL_ELEMENTS.
8. After defining the compliance as a design

response for the objective function, you must
now choose its target. In this case the 8
compliance should be minimized corresponding
to maximizing the stiffness. Choose
PRE-PROCESSING |
OBJ_FUNC_ITEM_1 | Edit. The target is set
to MIN.
322
W1a.9
Volume constraint
9. Define a volume constraint (PRE-PROCESSING

| TOPOLOGY_OPTIMIZATION_CONTROLLER
| CONSTRAINTS | VOLUME_CONSTRAINT |
Edit). Define a relative target volume of 30%. 9
10.The optimization task is now completed and the

parameter file can now be saved. Click twice at
Output under PRE-PROCESSING and enter the
new name booster for the optimization job (and
thus the parameter file). To save the parameter
file choose PRE-PROCESSING | booster | 10
Update.
11.Save the optimization database including all

optimization definitions using
File | Save as in the main menu (use a 11
meaningful filename).
W1a.10
Starting optimization task
12.The optimization can be started from Tosca

ANSA environment using
START_OPTIMIZATION | RUN | Update.
During the optimization please check the files

TOSCA.OUT or optimization_report.csv (in the
Output directory (evtl. changed name) or

subdirectory TOSCA_POST):
• Check correctness of optimization definitions
• Monitor the results during the optimization
• Examine the optimization iteration history.
Alternatively, the optimization can be executed
from a Tosca command shell writing
tosca <name>.par
-solver <solver type>.
323
W1a.11
Post-processing
13.Check the results visually after optimization.

Choose POST-PROCESSING |
GENERATE_REPORT_FILE | TOPO_MAT |
Update. The generation of material distribution
output file is set automatically. Navigate the
results by clicking the start, stop, forward and
backward button.
Workflow using Tosca extension for ANSYS Workbench
1 2
Start extension and Define Design area
load model ALL_ELEMENTS
3
Design responses
Dresp_Vol
4 Dresp_Stren
Objective function
minimize strain energy
5
Save optimization
task
6 7
run results in
Mechanical
324
W1a.13
Load Tosca Extension
1. Open the Workbench archive

brake_booster.wbpz
(File | Restore Archive) and save the
project in your working directory.
Click Extensions | Manage Extensions
and select Tosca Extension for ANSYS
Workbench in the pop up window to add the

extension to the project. Close the pop up
window. After a few seconds of loading, the
loaded extension appears in the toolbar.
2. Add a Tosca Structure.topology system

to the Project Schematic. Therefore drag
and drop Tosca Structure.topology onto the
Model cell of the existing Static
Structural system.
W1a.14
Define a Tosca Structure.topology system
3. Double click the Setup cell of the Tosca

Structure.topology system in order to open the
prepared model in the Mechanical application.
3
4. If you use the extension for the very first time,

the Tosca bin folder has to be defined. If the
path is already defined, you can skip this step.
Click on the Analysis Settings of the
Tosca Structure.topology in Tree Outline. In 4
the corresponding Details View window, set
your Tosca bin folder ("...\bin").
Within this menu, you can set the Auto
Frozen option, too. Load is the default setting
and suitable for this case.
325
W1a.15
Design area and design response
5. Click Topology | Design Area and assign

the model as Geometry in the design area’s
Details View window for design area 5
definition.
Choose the body of the entire model as design
area.
6. Click Optimization | Design Response

to add a design response for the volume
constraint used at the definition of the objective
function. 6
Select Base as Category and Volume as
Response Type. Assign the whole body as
Geometry.
Rename the design response to something
nonambiguous, for example Dresp_Vol using
the F2-button while Design Response is
selected in Tree Outline.
W1a.16
Volume constraint
7. To define a volume constraint, first click

Optimization | Constraint.
7
Then, within the corresponding Details View,
assign the previously defined design response
Dresp_Vol. For a target volume of 30% set
Value to 0.3 and Relative as Type.
8. Add a second design response to the project

(Optimization | Design Response).
8
Set Stress/Strain as Category, Strain
Energy as Response Type and All in the
Load Case Selection. Assign the entire
body as Geometry.
Rename the design response, for example to
Dresp_Stren by using F2-button.
326
W1a.17
Objective function and solution
9. Click Optimization | Objective

9
Function to define an objective function.
As Target choose Minimize sum in order to
minimize the strain energy (corresponding to
maximizing the stiffness).
Click on Tabular Data
10.Create a new tab within the appearing pop up

10
window and choose the strain energy design
response. Click Apply.
11.The optimization is now set up.

Click Result | Optimization Result and 11
Result | Smooth Result in order to add
results to the Solution category in Tree
Outline.
Then click Solve to start the optimization run.
W1a.18
Post-processing
12.The optimization result appears in Mechanical

application. The fringe colors show the
elements’ relative densities.
327
W1a.19
Post-processing
13.To filter the result according to the densities, use

the Geometry button and set it to Capped
IsoSurfaces. Either the ’soft’ elements (very
low relative density), which can be removed
from your structure, or the ’hard’ elements (high
relative density), which have to be kept in the
structure, are displayed. To see the ’hard’

elements, select Bottom Capped
IsoSurface.
W1a.20
Post-processing
14.Final optimization result.

328
W1a.21
Smoothing
15.Smooth Result (with Geometry button |

Exterior to view the initial design area).
Workflow using Tosca Structure.gui
1 2
boost.<ext> ALL_ELEMENTS
3
Design responses
volume and sum of
5 4 strain energy
Volume constraint Objective function
value: 0.3 min SUM_ENERGY
6 7 8
Save optimization Start optimization Post-processing
task run
329
W1a.23
Load model
1. Create a new topology optimization task

(File | New File).
2. Choose the FE input file for the topology

optimization task. This will be read using the
command FEM_INPUT. The corresponding form
to define the parameters can be found in the

menu COMMAND and in the tree view of Tosca
Structure.pre. Using the file dialog choose the
FE-input file ”boost.ext“ (ext=inp, bdf, dat, ...)
in the subdirectory <solvername>/topo/booster.
This file contains the complete analysis file for
the FE analysis. With the button Create the
definition is completed and will be added to the
tree and the text view of the parameter file.
W1a.24
Design area and design responses
3. Choose the design variables (DV_TOPO) for the

topology optimization. All elements of the FE
model are defined as design variables.
3
Choose DESIGN_AREA as ID_NAME.
4. Define the two required design responses

(DRESP) for the definition of the objective
function (sum of strain energy) and the 4
constraint (relative volume). Both design
responses are generated by selecting from the
predefined Standard Design Responses (Apply
Template). The relevant element group (in this
case ALL_ELEMENTS) has to be selected. The
ID names of the design responses are allocated
automatically (MY_VOLUME, SUM_ENERGY).
330
W1a.25
Objective function and volume constraint
5. The objective function is chosen in the menu

OBJ_FUNC. The total strain energy of the
structure, i.e. the design response 5
SUM_ENERGY, is minimized. Choose a well
suited ID_NAME like MAXIMIZE_STIFFNESS.
6. Define the constraint (CONSTRAINT). Define a

relative target volume of 30% by choosing the
design response MY_VOLUME and set the value
6
of the relative volume constraint via the sliding
control (30%). The ID_NAME
VOLUME_CONSTRAINT should be entered. Note,
that one should apply an equality constraint.
W1a.26
Assembly and saving of optimization task
7. The optimization task is assembled using the

command OPTIMIZE. Here, the individual
definitions are activated. In the text view on the
left hand side you can easily check which 7
definitions are activated. Additionally, the
optimization strategy is set to
TOPO_CONTROLLER.
8. Save the parameter file with the name

booster.par. Now you could change settings
(for example modify the target volume): Open
the appropriate command (by choosing it in the
text or tree view), make the desired 8
modifications and save them pushing the button
Modify. Now save the parameter file using
another name.
331
W1a.27
Start optimization task
9. Start the optimization task in the module Start

Tosca Structure of Tosca Structure.gui. If
jobname and start directory are not set correctly
9
in the mask then choose the correct parameter
file using the file dialog next to the field
JobName. Select your solver.
10.Check the results after optimization: Create vtfx-

sequences of the material distribution and the
controller input during the optimization using the
module Tosca Structure.report. Calculate a 10
sequence of the types Controller Input
and Material Distribution for all
iterations (select All from the Iter dropdown
menu).
W1a.28
Post-processing
11.Open the created sequence with Tosca

Structure.view using the button View Report
in the mask Tosca Structure.report and by
choosing the file booster_report.vtfx.
Compare the result with the results of the other
workshop participants. Switch between the
cases, start the animation for the several steps

and move the model in the viewer.
332
W1a.29
Result stiffness optimization of a brake booster
Optimization results for several steps: start model, 7th iteration, optimization result
W1a.30
Result
Smoothed optimization result

333
W1a.31
Solution (1/2)
! PARAMETER FILE FOR TOSCA STRUCTURE ! VOLUME AS DESIGN RESPONSE

OPTIMIZATION TASK DRESP
ID_NAME = MY_VOLUME
! INPUT OF THE FEM FILE TYPE = VOLUME
FEM_INPUT DEF_TYPE = SYSTEM
ID_NAME = MY_INPUT_FILES GROUP_OPER = Sum
FILE = boost.<ext> EL_GROUP = ALL_ELEMENTS

END_ END_
! DESIGN AREA ! SUM OF STRAIN ENERGY AS DESIGN RESPONSE

DV_TOPO DRESP
ID_NAME = DESIGN_AREA ID_NAME = SUM_ENERGY
EL_GROUP = ALL_ELEMENTS TYPE = STRAIN_ENERGY
END_
DEF_TYPE = SYSTEM
GROUP_OPER = Sum
END_
W1a.32
Solution (2/2)
! OBJECTIVE FUNCTION IN COMBINATION WITH A ! COMBINATION OF OBJECTIVE FUNCTION,

DESIGN RESPONSE DESIGN AREA AND CONSTRAINT
OBJ_FUNC OPTIMIZE
ID_NAME = MAXIMIZE_STIFFNESS ID_NAME = MY_OPTIMIZATION_TASK
TARGET = MIN OBJ_FUNC = MAXIMIZE_STIFFNESS
DRESP = SUM_ENERGY,, DV = DESIGN_AREA
END_ CONSTRAINT = VOLUME_CONSTRAINT

STRATEGY = TOPO_CONTROLLER
! RELATIVE VOLUME CONSTRAINT END_
CONSTRAINT
ID_NAME = VOLUME_CONSTRAINT ! STOP CONDITION
MAGNITUDE = REL STOP
EQ_VALUE = 0.3 ID_NAME = GLOBAL_STOP_CONDITION
DRESP = MY_VOLUME ITER_MAX = 15
END_ END_
334
Notes
335
Notes
336
W1b.1
Workshop Example Topology Optimization – Control Arm
Task Maximize stiffness, smooth optimization result

Keywords Design variable constraints (casting), smoothing
45 min
W1b.2
Control Arm
For existing components of mass products it is often possible to reduce the material amount necessary
or to increase specific properties for having a better component which offers more comfort, more safety
or which allows the usage of cheaper production methods.
For the workshop example an existing control arm of a car is used as initial geometry. Target of the
optimization is the reduction of material used for the component. The existing component represents a
classical way to de sign the control arm. It consists of a frame structure with a plate inside which is very
stiff. For a new car and higher loads (maybe due to higher engine power, higher mass of the car, ...) the
existing component does not fulfill the mechanical requirements. In such a case it makes sense to use
the existing geometry and to available space as design space. Then the topology optimization will be
able to find a design proposal.
The aim of this section is to apply manufacturing restrictions to a topology optimization task. A control
arm is optimized such that for a given target volume maximum stiffness is achieved. In the end, the
discrete result of the optimization is smoothed.
337
W1b.3
Model (1/2)
The component to be used within the tutorial is

found in the directory <solver>/topo/.
The model is loaded with one load case consisting

of two fixtures in the upper left and right areas and
is loaded with one load in the lower bearing area
(red areas). There also is a mounting of a sensor

for the headlight range adjustment. These are not
free for the optimization. Design Area
The component has to be manufactured by forging

and consists of aluminum.
Fig. 1
Existing design of a control arm
with the design area
W1b.4
Model (2/2)
The fixture is realized with spring elements on the

right upper side. The springs represent a rubber
bearing. The left bearing is fixed in all three
translation degrees of freedom, but is able to rotate
about the x-axis. A force is applied in the center of
the lower bearing.
Due to symmetry reasons only one half of the

model is meshed so the symmetry plane is fixed in
z-direction for ensuring the symmetry condition.
Fig. 2 Loads of the model
338
W1b.5
Optimization Task
The optimization task is to find a structure with the maximum stiffness for the component with a volume
or weight restriction. This represents the most common standard optimization task for the topology
optimization.
The value to be optimized is the compliance which is in reciprocal relation to the stiffness. The
compliance is represented as the sum of the strain energy of the complete model. This value has to be
minimized.
The constraint is the weight or volume constraint which is defined to be 70% of the initial volume/weight
of the structure.
A casting/forging constraint has to be defined. The idea of the constraint is to ensure that the created
structure of the topology optimization has no undercuts and can be demolded (or removed from the
forging die).

1 2 3
Optimization task Model import Design area
TOPO_CONTROLLE control_arm.<ext> exclude fixed areas
R
6 5 4
Start optimization Constraints Objective function
demold control minimize compliance
volume constraint
7 8 9
Post-processing Smoothing Validation
material distribution RUN_SMOOTH reconstruct, remesh &
view vtfx file run validation
339
W1b.7
Procedure using Tosca ANSA environment (1/2)
Preprocessing
Choice of the optimization type
1. If Task Manager panel is hidden, click the

button to make it appear in the left side of ANSA 1
window.
2. Select File | New to open a new file.
W1b.8
3. In the Confirmation window press Discard.

3
4. In Task Manager, select Tasks |

Tosca Structure TASK |

TOPO_CONTROLLER. 4
5. In Task Manager, press expand-button.

5
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W1b.9
Loading the input model file (1/2)
1. Right click the item MODEL_LINK in Task

Manager and select Edit or double click the
item MODEL_LINK. 1
2. In the window titled MODEL LINK, choose as

WORKING DECK the solver that matches your
input file (MSC Nastran in this example) and
click OK. 2
Note that the steps 1 and 2 are not needed if the
correct solver is already chosen in
MODEL_LINK.
3. Right click FILE item in Task Manager and

select Edit or double click the item FILE.
3
W1b.10
Loading the input model file (2/2)
4. In the Open dialog, choose the input file and

click Open. The items FILE and PRE-
PROCESSING in Task Manager get renamed:
the file name is used as the name of FILE item, 4
while the directory of the file is appended to
PRE_PROCESSING item name.
5. Right click the item named after the file you

have just chosen and select Update. The input
file is loaded and the model is shown in the main 5
window.
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W1b.11
Design area (1/5)
In topology optimization, the design area denotes

the set of elements that may be removed during the
optimization.
1. Right click the item DESIGN_AREA in Task

Manager and select Edit or double click the 1
item DESIGN_AREA.
2. In the appeared DV_TOPO window, choose

GROUP_DEF from the dropdown list below
EL_GROUP. 2
W1b.12
Design area (2/5)
3. Activate the text field with the title GROUP_DEF

and press "?" key.
3
4. The SET HELP window opens.

Click the "Actions"-button in the toolbar or right
click in the empty space and select New. 4
The window titled Modifying SET:
Untitled (Id:1) appears in the right part of
the screen.
342
W1b.13
Design area (3/5)
5. In this window, click ELEMENT item once in order

to highlight it. Now, the elements of the model
can be chosen using the mouse.
5
6. First, select the whole model by enclosing it in a

frame made with the left mouse button pressed.
Note that you may move, rotate in plane, rotate
in space or zoom the model using CTRL +
middle mouse button, CRTL + right mouse 6
button, CTRL + left mouse button and CTRL +
mouse wheel resp.
W1b.14
Design area (4/5)
7. Deselect the 4 parts shown in the figure by

moving the mouse with the right mouse button
pressed. It is recommended to rotate the model
in plane and zoom in and out to make the
selection more accurately. Click with the middle 7
mouse button to confirm the selection and to
proceed to SET window.
8. Enter the desired group name

(my_design_group in this example) in Name
window. You may also proceed with the default
group name and click OK. 8
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W1b.15
Design area (5/5)
9. In SET HELP window, double click the name of

the group you have just created. The window will
then close. 9
10.Click OK in DV_TOPO window.

10
11.If you want to check your group selection switch

on the highlight button in Task Manager and
click Design Area under
TOPOLOGY_OPTIMIZATION. 11
Your group definition will be marked in color in
the model.
W1b.16
Design variable constraints (1/3)
Design constraints introduce restrictions on the

shape of the optimized model. Besides the
demolding constraint discussed below, other types
of design constraints such as symmetry and
member size restrictions are supported by Tosca
Structure.
1. Right click DV_CONSTRAINTS item under

DESIGN_AREA and Select New |
DEMOLD_CONTROL.
1
2. In DEMOLD_CONTROL window, choose 2

GROUP_DEF from the dropdown list below
EL_GROUP
344
W1b.17
3. Activate the text field with the title GROUP_DEF

and press "?" key.
3
4. In the SET HELP window, double click

my_design_group item. The window will then
4
close.
5. Repeat the last 3 steps for CHECK_GROUP. Now,

the same element set my_design_group is
used in both EL_GROUP and CHECK_GROUP
fields 5
W1b.18
6. In DEMOLD_CONTROL window, enter the values

0, 0, 1 in the fields PULL_DIR_1,
PULL_DIR_2 and PULL_DIR_3. These values
are the components of the pull direction needed 6
for the definition of the demolding constraint.
Click OK.
7. Check the demold direction by clicking

DEMOLD_CONTROL and switching on highlight
button. The arrow shows the demold direction
and the coloured area shows that part of the 7
model for which the restriction is applied
(my_design_group in this case).
345
W1b.19
Objective function (1/2)
The objective function will be minimized or

maximized by Tosca Structure, depending on the
settings.
1. Right click COMPLIANCE item under

OBJ_FUNC_ITEM_1 and select Edit or double
1
click the item COMPLIANCE.
2. Click OK.
W1b.20
3. Right click OBJ_FUNC_ITEM_1 item and select

Edit or double click the item
3
BJ_FUNC_ITEM_1.
4. Set TARGET field to the correct value MIN and

click OK.
Note that although no changes are needed since

TARGET field has already set to the correct value 4
MIN, this step is required in order to proceed.
346
W1b.21
Constraints
Constraints are equations or inequations that are

maintained by Tosca Structure during the
optimization.
1. Right click VOLUME_CONSTRAINT item under

CONSTRAINTS and select Edit or double click 1
the item VOLUME_CONSTRAINT.
2. Enter 0.70 in the field VALUE and click OK.
W1b.22
Saving Tosca Structure parameter file
The Tosca Structure parameter file contains

commands which define all settings for the
optimization task.
1. Right click Output item. Select Update.

The parameter file Output.par for Tosca
Structure is written at this point. The file is saved

in the same directory where the input model is
located. The optimization with Tosca Structure
will also start in this directory.
347
W1b.23
Start Optimization
1. Right click RUN item under

START_OPTIMIZATION. Select Update.
Tosca Structure will start in background. Wait
until it finishes. Then close the Tosca Job and 1
the OPTIMIZATION_RUN window to continue.
2. Click Start_Optimization | Update.

2
Logging and monitoring
To see the optimization history (the values of
objective function and constraints for each
iteration), open the file toptimization_report.csv with
Microsoft Excel or a text editor. Tosca Structure log
file TOSCA.OUT from TOSCA_POST directory
contains this information too, along with the
warnings and errors if available.
W1b.24
Post-processing (1/2)
Using Tosca Structure.report, the intermediate

results of topology optimization, namely the
densities of individual elements, can be visualized.
This subsection is optional.
1. Right click TOPO_MAT item under

GENERATE_REPORT_FILE. Select Update.

The generated VTFX file containing the original 1
(non-smoothed) optimization result will open in
Tosca Structure.view.
2. If you’ve just generated the report file and want

to view the VTFX file again right click
VTF_VISUALIZATION item under 2
GENERATE_POST_FILE and select View.
348
W1b.25
3. The animation starts and stops by clicking on

the start forward/backward, pause and stop
symbol in the task menu.
Close the Tosca Structure.view, the
TOSCA_POST and the Tosca Job window in
order to proceed. 3
4. Click POST-PROCESSING | Update.

4
W1b.26
Smoothing (1/2)
Generating smooth surface
Tosca Structure.smooth generates the surface of

the material remaining after the topology
optimization and improves the surface quality
1. Right click RUN_SMOOTH item under

SMOOTH_INSTANCE and select Edit or double
1
click the item RUN_SMOOTH.
2. In SMOOTH RUN PARAMETERS window, choose

the output formats for the result transfer (e.g.
STL or IGES) if needed; click OK.
2
349
W1b.27
Smoothing (2/2)
3. Right click RUN_SMOOTH item under SMOOTH

and select Update.
Tosca Structure.smooth will start in background.
When finished, the generated triangular surface
is loaded and shown in place of the initial model.
W1b.28
Result Transfer and Validation Run (Smooth) (1/2)
The following steps are not yet explained in the

seminar. Therefore they should be skipped in the
beginning.
Modifying the surface using RECONSTRUCT
1. Right click BATCH_RECONSTRUCT item under

VALIDATE and select Edit or double click the
item BATCH_RECONSTRUCT. 1
2. Check the check button Preview and the

check button Freeze SPC Nodes, uncheck the
check button Automatic feature line 2
recognition at SMOOTH_CUT_ELEMENTS
area and click OK.
350
W1b.29
Result Transfer and Validation Run (Smooth) (2/2)
3. Right click BATCH_RECONSTRUCT item and

select Update.
BATCH_RECONSTRUCT generates a new, more
regular triangular surface that can be used for
the remeshing of the volume with tetrahedra
elements.
W1b.30
Remeshing the model
1. Right click SOLID_MESH under VALIDATE and

select Update.
1
2. Some time after SOLID_MESH starts, the

window PROPERTIES will appear. Double click
the first (and only) line in the list, then it will 2
close and SOLID_MESH will resume. When it
finishes, a new tetrahedral mesh will appear in
addition to the triangular surface mesh.
351
W1b.31
Saving the resulting model in solver format (1/2)
Please note, in some cases (ANSYS Workbench

models) the standard way may not work, as ANSA
does not support some specific solver settings. In
this case continue with saving the resulting model
in solver format (alternative).
1. Right click VALIDATION_OUTPUT item and

select Edit or double click the item
1
VALIDATION_OUTPUT.
2. In the Output Parameters window click

Browse.... Depending on your solver format,
several additional settings can be made.
2
W1b.32
Saving the resulting model in solver format (2/2)
3. Choose the file name for the output model to be

saved in the format of the solver you use and
click Save. In the Output Parameters
3
window click Ok.
4. Right click the item with the chosen file name

under VALIDATE and select Update.
4
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W1b.33
Running the solver with the new model
1. Right click VALIDATION_RUN and select

Update.
Then, the solver will start in the same folder
where the output file has been saved.
W1b.34
Saving the resulting model in solver format (alternative) (1/2)
1. Right click VALIDATION_OUTPUT and select

Disable.
1
2. Right click VALIDATE and select New |

MODIFICATION_FILES.
2
3. Choose the file name for the output model to be

saved in .onf format and click Save.
3
353
W1b.35
Saving the resulting model in solver format (alternative) (2/2)
4. Right click the item with the chosen file name

under VALIDATE and select Update.
4
5. Tosca Structure modification will start in

background. After finishing, the new verification
file in the format of the solver you use can be

found in the location specified in the previous
step. The file name will be the same as the one
of the .onf file defined in the previous step.
Running the solver with the new model

(alternative)
1. After creating a verification file using the
MODIFICATION_FILE option, the execution of
the solver job from Tosca ANSA environment is
not possible. Please use your solver specific
environment for starting and post-processing the
verification job.
W1b.36
Topology Optimization with Tosca Extension for ANSYS Workbench
This little instruction should help to get in touch with

the Tosca Extension for ANSYS Workbench. Some
guided clicks should provide a first overview, setting
up an optimization example.
The model
A car’s control arm is used as an example. A control
arm is a part of a car’s independent wheel
suspension and supports against occurring cross
forces. That means on the one hand that it is a
mass-produced component, so any material and
cost reduction pays off. On the other hand every
weight reduction in cars is welcome in general,
because dynamic characteristics increase and less
mass has to be accelerated and slowed. Fig. 3
This model shall show an example of a
topology optimization with Tosca Extension for
ANSYS Workbench
354
Workflow using Tosca Extension for ANSYS Workbench
1 2 3
Load extension Load model Model preparation
Extension control_arm.<ext> fixed areas, symmetry,
Manager loads & fixations
6 5 4
Design area, Start Tosca Run simulation &
Design responses & structure.topology save
Objective function extension
7 8 9
Constraints & Post-processing Validation run
Result options adjust view: Capped reassign load and bc
IsoSurfaces areas & run validation
W1b.38
Loading the Extension
In order to load the extension, open the

Extension Manager by clicking
Extensions | Manage Extensions.
Check the box for the current Tosca Extension for
ANSYS Workbench. The extension is loaded
immediately; close the Extensions Manager
and wait for the Busy icon in the down left corner
of the screen to disappear.
Use the Extension Manager to load Tosca

Extension for ANSYS/Workbench
If you save a project and the extension is used, it is

loaded automatically the next time the project will
be opened.
355
W1b.39
Example files
Dependent on where you want to start the

procedure, you can choose one of the following
files. You find all necessary files in the directory
<tosca_install>\ansys\TS_Ext_for_WB\examples\.
1. Start from scratch using the provided
control_arm.stp geometry file. Continue at
chapter 0.1.4 Preparing the model.
2. Start the project with an imported geometry file.

Use the ANSYS Workbench project archive
control_arm.wbpz. Continue at chapter
0.1.4 Preparing the model, step 15.
3. Start the project with an imported geometry file

and defined boundary conditions. Use the
ANSYS Workbench project archive
control_arm_bc.wbpz. Continue at chapter
0.1.5 Optimization preprocessing.
W1b.40
Preparing the model (1/12)
At first, the task has to be set up. Then the model is

loaded into ANSYS Workbench and loads and
boundary conditions are added, using the different
applications in ANSYS Workbench.
Make sure the extension is loaded (See chapter
Loading the Extension).
1. Add a Static Structural system to the

Project Schematic by dragging the 1
corresponding template onto the Project
Schematic surface.
2. Right click on the Geometry cell in order to

import the provided model "control_arm.stp".
2
356
W1b.41
3. Double-click Geometry in order to open the

application Design Modeler. 3
Select mm as unit and confirm.
4. The imported geometry is listed in the Tree

Outline. The yellow lightning symbolizes that
the import is not finished yet. 4

Click on Generate to execute the import of the
control arm model.
5. In order to create an isolated part of the

geometry that can be used as Design Area to be
optimized later, slice the geometry. Activate the
XYPlane in the Tree Outline and click New 5
Sketch.
W1b.42
6. The button Look at Face/Plane/Sketch 6

will turn the activated plane if necessary.
7. Click the tab Sketching to open the sketching

toolbar. Add geometry to mark the areas of the
model that are not to be changed during the 7

optimization. Be careful with overlapping
geometry which causes an error. Trim
(Modify | Trim) if necessary.
8. Make sure that the marked areas are defined

correctly.
357
W1b.43
9. Click Extrude. 9
10.If Extrude is clicked immediately after having

sketched, the correct sketch will be highlighted
as Geometry. If not, choose the correct sketch.
Click Apply.
10
11.Choose Slice Material as Operation.
W1b.44
12.Click Generate. Different body colors mark the

different parts; the transparency indicates the
parts as Frozen. Unfrozen geometries in
contact would be combined to a single body
automatically. 12
13.Close DesignModeler.
14.It is recommended in general to save the project 14

from time to time. Therefore use the button
Save or Save as in the upper toolbar of
ANSYS Workbench.
15.Double-click the Model cell in order to open the
Mechanical application.
15
358
W1b.45
16.Check if units are defined correctly

(Metric - mm, kg, N).
16
17.Activate Mesh in the Tree Outline by

clicking on it once. That makes appear the
concerned buttons in the upper toolbar. Mesh
control | Sizing adds a mesh sizing
17
operation.
18.Assign the entire geometry (5 Bodies). Enter 5

(mm) as Element Size. A click on Update 18
creates a tetrahedral (automatic) mesh.
W1b.46
19.It is possible to display the generated mesh of 19

the model. Either use the Show Mesh button in
the upper toolbar or click on the Mesh folder in
the Tree Outline.
20.Activate Model in the Tree Outline. Click on

20
the Symmetry button.
21.Right click the inserted Symmetry unit in the

Tree Outline, choose
Insert | Symmetry Region. 21
359
W1b.47
22.Apply the control arm’s mid plane as Geometry

by holding CTRL while selecting the different
faces (make sure Face Selection is
activated, see chapter "Handling Tips"). 22
23.Select Z Axis as Symmetry Normal.
23
24.Activate the Static Structural in the Tree

Outline.
25.Add a load to the Tree Outline with the 24 25
button Loads | Force. Make sure the
selection option Face is activated.
W1b.48
26.As Geometry choose the inner face of the lower

drill-hole; click Apply.
26
27.In the definition, change Define By from

Vector to Components and enter 7071 N as
X Component and -7071 N as Y Component 27
magnitude.
28.Add an Elastic Support by clicking

Supports | Elastic Support on the outer 28
face of the upper anchor.
360
W1b.49
29.Select the outer face with the face selection tool.
29
30.Enter 10 N/mm³ as Foundation

Stiffness.
30
31.Select the upper bearing’s inner face.

31
W1b.50
32.Add a Remote Displacement.

32
33.In the corresponding Details View, set the X

Coordinate to 25.65 mm, and the Y and Z
Coordinate to 0 mm. Within the Definition-

Group, change all Components from Free to 0,
except for the Rotation X. 33
361
W1b.51
34.Activate Solution in the Tree Outline.

Click Stress | Equivalent (von-Mises)
to add a stress analysis as result output. Make
sure all five bodies are selected for the analysis. 34
A stress analysis is set up. Click Solve to
execute the analysis.
35.Save the project.
35
W1b.52
Optimization preprocessing (1/8)
It is not mandatory to solve any stresses or strains before the optimization. Loads and boundary
conditions are enough. It is recommended though, since it can be checked whether the analysis is
correctly set up or not.
1. Close the Mechanical application and continue
working in the Project Schematic. Now use 1
a Tosca Structure.topology system.

2. Drag a Tosca Structure.topology
template onto the Model cell of the existing
Static Structural in the Project 2
Schematic. This way Tosca
Structure.topology draws on the
generated data of the Static Structural
system.
Important: If you connect the systems
otherwise, Tosca Structure.topology is
not able to operate correctly.
Mechanical needs to be closed when you
connect the systems.
362
W1b.53
3. Double-click the Setup cell on Tosca

Structure.topology in order to open the 3
Mechanical application.
4. For Tosca Structure.topology |

Analysis settings in the Tree Outline,
choose Controller as Strategy in the

Details View. Auto Frozen is not needed,
set it to Off.
4
If you use Tosca Extension for ANSYS/WB for

the first time, you have to define the Tosca bin
folder ("...\Tosca80\bin"). Otherwise the solver
does not start. After you set a path, and solved
the first project, your future projects will use this
path by default.
W1b.54
5. Add the options for the optimization run. The

area to be optimized is defined with a 5
Topology | Design Area.
6. Insert the Design Area in Tosca

Structure.topology in the Tree Outline. 6
7. Apply the main area as Geometry (1 Body).
363
W1b.55
8. Add a Demold Control.

8
9. Select the Global Coordinate System as

Coordinate System and Z as direction.
Therefore make sure the resulting vector equals

(0, 0, 1).
9
Remark:
Use the Show all Coordinate Systems
button (upper ANSYS toolbar) to facilitate the
definition of the Demold Direction.
The displayed disc shows the Demold Direction.
W1b.56
10.Select the main part of the geometry as

Geometry and CheckGroup.
10
11.Add the first of two Design Responses via

Optimization | Design Response. 11
12.In the corresponding Details View select

Volume as Response Type and choose the
same geometry as in Design Area as 12
Geometry (1 Body).
364
W1b.57
13.Rename the Design Response to

"Dresp_Vol"; click on it once in the Tree 13
Outline and then use the F2 button.
14.Add the second of the two Design

Responses.
15.Select Stress/Strain as Category. Again,

select the main area as Geometry and choose
All as Load Case. Rename the design 14
response to "Dresp_Stren".
16.Add an Objective Function by clicking

Optimization | Objective Function. 15
W1b.58
17.Choose Minimize sum as Target.

17
18.Click on Tabular Data in the Details View

window, create a new table; select 18
Dresp_Stren as Design Response.

Click Apply.
19.Add a Constraint to the optimization task by

clicking on Optimization | Constraint. 19
20.Select Dresp_Vol as Design Response and

0,7 as Value. 20
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21.Click the toolbar button Results and add an

Optimization Result and a Smooth
Result.
21
22.For the Smooth Result, choose 0,1 as Iso

Value.
For more information about the smooth options, 22

see the Tosca Structure Documentation.
23
23.Click Solve to start the optimization.
Save the project.
W1b.60
Postprocessing
The Tosca Extension for ANSYS/Workbench offers Geometry view option leads to
some visualization options in the Mechanical
application. The optimization result can be
displayed in different ways, single iterations can be
showed, too.
Optimization result view options
To display a topology optimization result correctly in

the Mechanical application, make sure that the
correct Geometry option in the upper toolbar is
activated.
With the option Capped IsoSurfaces it depends
on the elements’ relative density whether they are
displayed or not. This limit density (elements above
or below are displayed) is adjustable.
With IsoSurfaces activated, no result will be
displayed.
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Iteration Animation
The Graph window in the Mechanical application

provides an overview of the optimization steps. It’s
possible to have a look at each single iteration or to
show even a little animation from the beginning until
the end of the optimization run.
To display a single iteration step, select it with the

left mouse button, then right click |
Retrieve this result. For a little animation it
is possible to use a Play and Stop button or
regulate animation speed. All the needed buttons
can be found in the Graph window
W1b.62
Validation Run (1/3)
The smoothed model describes the surface of the

optimization result. Based on this resulting model, a
solid three dimensional model is reconstructed
which can be loaded with the original forces and
supported with the original boundary conditions.
The validation run can only be executed after a
smoothing run. 1
1. Click Validation | Run to start the

Validation. The procedure might take a few
minutes and is finished as soon as the new
Validation System is opened automatically.
2
The Project Schematic after the Validation looks
like shown on the left.
2. Forces, boundary conditions and other options

have to be reassigned.
367
W1b.63
3. Begin with the Symmetry Condition. Reselect

the mid plane faces and apply it as Geometry
of the Symmetry Region.
3
4. As Geometry of the Force, reassign the inner

face of the lower drill-hole.
4
5. Select the Elastic Support in the Tree
Outline and choose the corresponding face(s)
as Geometry.
5
Remark:
It’s possible, that the initial face is split into
several small pieces. Select all of them to
recreate this boundary condition.
W1b.64
6. Reassign the face of the Remote

Displacement.
6
7. When all options are reassigned to the model,

click Solve.
368
1 2 3
Model import Design area Design variable
control_arm.<ext> DESIGN_ELEMENTS constraints
DVCON_CAST
6 5 4
Start optimization Constraints Objective functions
volume at 70% minimize strain energy
7 8 9
Post-processing Smoothing Reconstruct
Tosca Structure.report Tosca Structure.smooth manually with ext.
CAE Program
W1b.66
Procedure using Tosca Structure.gui
Preprocessing
Starting Tosca Structure Preprocessor
1. Tosca Structure.gui starts and the Tosca

Structure.pre module is displayed. Left click on

the Tree button to change the view of the
optimization task structure on the left side to tree
mode.
369
W1b.67
Model input
1. Select the item FEM_INPUT from the

optimization task tree. The FEM_INPUT menu
appears on the right. 1
2. In the Input Files area, click Add to select

the model for the optimization. The Open dialog
appears. 2
3. In the Open dialog, choose the FE model for

your solver (control_arm.<ext> where <ext>
is the extension your FE-solver uses.) and press
Open. The model name with its full path appears 3
in the The finite element input files
field.
4. Left click on Create to add the item

4
MY_INPUT_FILES to the optimization task tree.
W1b.68
Group for topology optimization (NASTRAN users only) (1/2)
The following part is important only for Nastran users. If your input file matches any other solver
supported by Tosca Structure please skip this chapter and continue with the definition of the design
area. For any other solver the groups for topology optimization are included in the solver input files
and transferred in Tosca Structure via the FEM_INPUT command.
1. Select the item GROUP_DEF from the

optimization task tree. The GROUP_DEF menu

appears to the right. 1
2. Type a proper name for the group in the field

ID_NAME, DESIGN_ELEMENTS for example,
and activate the radio button Element next to 2
Type to specify the group type.
3. Click Read Nastran Set to select the existing

group. The Open dialog appears. 3
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Group for topology optimization (NASTRAN users only) (2/2)
4. In the Open dialog, choose the file

control_arm_groups.bdf which contains
the element set needed for the topology
optimization and press Open. The Select 4
Nastran Set dialog appears where the
content of the file control_arm_groups.bdf
is listed.
5. In the Select Nastran Set dialog, select 1

from the Set Number dropdown list if not
already selected and press Ok. The selected
Nastran set transferred to the Data field in the 5
GROUP_DEF menu.
6. Click Create to add the item

DESIGN_ELEMENTS to the optimization task
tree. 6
W1b.70
Design area
In topology optimization, the design area denotes

the set of elements that may be removed during the
optimization.
1. Select the item DV_TOPO from the optimization

task tree. The DV_TOPO menu appears on the
1
right.
2. Select DESIGN_AREA as ID_NAME, choose the

group DESIGN_ELEMENTS from the dropdown
list next to EL_GROUP and click Create to add 2
the item MY_DV_TOPO to the optimization task
tree.
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W1b.71
Design variable constraints introduce restrictions on the shape of the optimized model. Besides the
demolding constraint discussed below, other types of design constraints such as symmetry and
member size restrictions are supported by Tosca Structure.
1. Select the item DVCON_TOPO from the
optimization task tree. The DVCON_TOPO menu 1
appears on the right.
2. Type a proper name in the field ID_NAME, for

example DVCON_CAST, and select
DESIGN_ELEMENTS from the dropdown list next 2
to Element Group. The constraint will now be
applied to all elements of the selected group.
Please note that the ID_NAME is a special mark of any component of the optimization task. The
ID_NAME must be unique for each component. Using the ID_NAME you can select between different
components of the same type during the optimization setup. If no other component of the same type
appear in the optimization task, the change of the ID_NAME is optional and the Tosca Structure default
ID_NAME can be used.
W1b.72
3. For defining a cast restriction for the selected

element group activate the radio button Cast
and define the pull direction vector by typing in
the values 0,0,1 in the fields next to Pull 3
Direction. Make sure the global coordinate
system CS_0 is selected in the field next to
Pull_CS.
4. Choose DESIGN_ELEMENTS from the Check

Group dropdown list to define the check group
for the cast restriction and click Create to add 4
the item DVCON_CAST to the optimization task
tree.
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Definition of design responses (1/2)
1. Select the item DRESP from the optimization

task tree. The DRESP menu appears on the
right. 1
2. Type a name in the field ID_NAME, for example

DRESP_VOLUME, and choose the type VOLUME
in the field Type of the Base category.

2
3. Choose ALL_ELEMENTS from the
Element/Elementgroup dropdown list and
set the Group Operator to Sum to build the
sum of the volumes of each element in the
model. Thus the whole volume of the structure is
determined. 3
Click Create to add the design response
DRESP_VOLUME to the optimization task tree.
W1b.74
Definition of design responses (2/2)
4. Repeat step 1 to define another design

response.
5. Type an ID_NAME for the new design response,

for example DRESP_STRAIN_ENERGY, in the
corresponding field and choose

Stress/Strain from the Category dropdown 5
list and in the Type field choose the type
STRAIN_ENERGY.
6. Activate the Element/Elementgroup radio

button and select ALL_ELEMENTS from the 6
Element/Elementgroup dropdown list.
7. Set the Group Operator to Sum and click

Create to add the design response
7
DRESP_STRAIN_ENERGY to the optimization
task tree.
373
W1b.75

settings.
1. Select the item OBJ_FUNC from the optimization

task tree. The OBJ_FUNC menu appears on the
right. 1
2. Click Add Dresp to select a design response

for the objective function. The Select Design
Responses dialog appears. 2
W1b.76
3. In the Select Design Responses dialog,

activate the design response
DRESP_STRAIN_ENERGY and press Ok. The 3
window closes and the selected design
response appears in the field.
4. Select the radio button Minimize next to

Target and click Create to add the item 4
MY_OBJ_FUNC to the optimization task tree.
374
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Constraints (1/2)

optimization.
1. Select the item CONSTRAINT from the

optimization task tree. The CONSTRAINT menu

example VOLUME_CONSTRAINT, and choose
2
the design response DRESP_VOLUME from the
Design Response dropdown list.
W1b.78
Constraints (2/2)
3. Select the radio button Relative next to Type

to set the constraint type and push the slider to 3
70 or type the value in the field manually.
4. Select the equality radio button next to

Constraint Type, thus the target volume for 4
the optimization is set to exactly 70 percent of

the original volume, and click Create to add the
item VOLUME_CONSTRAINT to the optimization
task tree.
375
W1b.79
Optimization task (1/2)
1. Select the item OPTIMIZE from the optimization

task tree.
1
2. Select TOPO_CONTROLLER from the Strategy

dropdown list to choose the optimization
strategy. Design area and objective function are

selected automatically.
2
3. Click Add next to the DV Constraints field to

add the design variable constraints to the
optimization task. The Select Design
Variable Constraints dialog appears.
3
4. In the Select Design Variable
Constraints dialog, activate the design
variable constraint DVCON_CAST and press Ok.
The DVCON_CAST item appears in the DV 4
Constraints field.
W1b.80
Optimization task (2/2)
5. Click Add next to the Constraints field to add

the constraints to the optimization task. The 5
Select Constraints dialog appears.
6. Activate the constraint VOLUME_CONSTRAINT

and press Ok. The VOLUME_CONSTRAINT item
appears in the Constraints field. 6

MY_OPTIMIZATION_TASK to the optimization 7
task tree.
376
W1b.81
Start Optimization (1/2)
1. Switch to the Start Tosca Structure

module from the Module dropdown list in the
1
upper right corner.
2. Choose all from the Type dropdown list . This

option includes a preprocessing test and the
optimization run. 2
3. Select the solver of your choice from the

Solver dropdown list.
3
W1b.82
Start Optimization (2/2)
4. Click Start Tosca to start the optimization.

Status information about the optimization run is
4
displayed in the field below.
5. After approx. 15 design cycles the optimization

run is finished and the status Tosca job
finished is displayed. 5
377
W1b.83
Viewing the intermediate results using Tosca

Structure.report.

1. Switch to the Tosca Structure.report module

from the Module dropdown list in the upper right 1
corner.
2. Select the results by activating the buttons to the

left of the Results Controller Input and
Material Distribution. 2
W1b.84
3. To see every design cycle, click in the field

below Iter (concerning the result Controller
Input) and select All from the Iter dropdown 3
menu. Repeat this for the result Material
Distribution (second field below Iter).
4. Click Generate Report to start the generation

of the result file. Status information about the file
generation is displayed in the field below.
4
5. When the file generation is completed a

message about the successful job ending is 5
displayed in the status field.
378
W1b.85
6. Click View Report to view the material

distribution in the optimized structure. The Open 6
dialog appears.
7. In the open dialog select the generated .vtfx

file and press Open. Tosca Structure.view starts. 7
8. The Animation starts and stops by clicking on

The described example is generated using the
FE solver MSC Nastran. Please note that slight
differences in the optimized design are possible
for the different solvers. However the design 8
conception remains the same.
W1b.86
Result Transfer and Validation Run (1/2)
Generating the surface using Tosca

Structure.smooth.
Tosca Structure.smooth generates the surface of

the material remaining after the topology
optimization and improves the surface quality.
1. Switch to the Tosca Structure.smooth module

corner.
2. In the Tosca Structure.smooth module click

Select Job. The Open dialog appears. 2
3. In the Open dialog, select the Tosca Structure

parameter file and press Open. 3
379
W1b.87
Result Transfer and Validation Run (2/2)
4. Leave the default configuration unchanged and

click Start Smoothing. Status information 4
about the file generation is displayed in the field
below.
5. When the file generation is completed the

message Program finished is displayed in
5
the status field.
6. Click View Result to view the material

dialog appears.
7. In the Open dialog, select the corresponding

.vtfx file and press Open. Tosca
Structure.view starts. 7
W1b.88
Further processing of the optimized structure (1/2)
Using Tosca Structure.gui a complete

reconstruction of the model with the new design is
not possible. Therefore some additional steps are
required which should be performed manually by
the user.
380
W1b.89
Further processing of the optimized structure (2/2)
However Tosca Structure.gui offers several opportunities to generate a design model using Tosca
Structure.smooth as a base for further processing by the user. Different output formats for the smooth
surface can be chosen.
For example geometry surfaces can be created using the stl or igs format. In this case the geometry
can be loaded in a CAD tool for further handling or in a FE preprocessor for generating a new mesh.
Using solver output format (bdf, inp, cdb, etc.) Tosca Structure.smooth automatically generates a
mesh on the smooth structure in the corresponding solver format. However the boundary conditions for
the FE analysis must be generated manually by the user.
W1b.90
Result (1/5)
The topology optimization created a new design proposal for the control arm component. The result of
the topology optimization has to be discussed in several ways.
First of all the optimization result has to be checked. This can be done with viewing the convergence
plot and with checking TOSCA.OUT file for warnings and errors. If there is a critical error during the
optimization the optimization loop will be stopped. In other cases (if some results are missing) the
optimization system will continue but the result may be not sufficient.
Second the resulting model and the finite element analysis of the model has to be checked if the
displacements, the stresses and all other finite element related information are suitable.
Result Initial model (complete model with 70% of Final model

material homogeneously distributed)
Strain Energy 1645850 425093.5
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Result (2/5)
For this optimization task the stresses are in the

same range compared to the initial model but the
stiffness of the structure is higher and the material
amount necessary for the structure is lower. The
values to be compared are the volume or weight of
the structure and the sum of the strain energy. The
strain energy is the measure for the compliance

which is the reciprocal value of the stiffness.
von Mises stresses of optimized structure
W1b.92
Result (3/5)
After checking the results the remaining structure

can be passed to the design department as a CAD
model to be used as design proposal for the fine
tuning of the design. If the stresses within the
component are not below the allowed range the
shape optimization of Tosca Structure (Tosca
Structure.shape) will be able to remove the stress

peaks so that the component will be suitable from
the mechanical point of view.
Optimization result represented after data

reduction (IGES surfaces for CAD transfer)
382
W1b.93
Result (4/5)
The results can be transferred as surfaces in STL

format or IGES format. Another way to transfer less
data is to export the results as slices.
Optimization result represented as slices
W1b.94
Result (5/5)
For sharing the result and the animation with

colleagues or partners the VTFX format is a
comfortable way. This result format is able to
contain a full 3D animated model with the
optimization history. The model can be rotated and
zoomed during the animation. The viewer is
available for free for different platforms and there is

also a possibility to include the files into HTML-
pages and into PowerPoint presentations.
Material distribution after topology optimization
383
W1b.95
Solution (1/2)
! PARAMETER FILE FOR TOSCA STRUCTURE ! DESIGN AREA

OPTIMIZATION TASK DV_TOPO
! INPUT OF THE FEM FILE EL_GROUP = DESIGN_ELEMENTS
FEM_INPUT END_
FILE = control_arm.bdf ! CASTING RESTRICTION
END_ DVCON_TOPO
ID_NAME = DVCON_CAST
! GROUP DESIGN_ELEMENTS MID_PLANE = NONE
GROUP_DEF CHECK_GROUP = DESIGN_ELEMENTS
ID_NAME = DESIGN_ELEMENTS PULL_DIR = 0, 0, 1
TYPE = ELEM CHECK_TYPE = CAST
FORMAT = LIST EL_GROUP = DESIGN_ELEMENTS
LIST_BEGIN END_
10-59,67,69,70,72,75-192,194-250,253-348,
… ! VOLUME AS DESIGN RESPONSE
81310,81535,85943,86094,86720,87452 DRESP
END_ ID_NAME = DRESP_VOLUME
DEF_TYPE = SYSTEM
TYPE = VOLUME
GROUP_OPER = Sum
END_
W1b.96
Solution (2/2)
! SUM OF STRAIN ENERGY AS DESIGN RESPONSE ! RELATIVE VOLUME CONSTRAINT

DRESP CONSTRAINT
ID_NAME = DRESP_STRAIN_ENERGY ID_NAME = VOLUME_CONSTRAINT
DEF_TYPE = SYSTEM MAGNITUDE = REL
TYPE = STRAIN_ENERGY EQ_VALUE = 0.70
EL_GROUP = ALL_ELEMENTS DRESP = DRESP_VOLUME
GROUP_OPER = Sum END_
END_
! COMBINATION OF THE OBJECTIVE FUNCTION,

THE DESIGN AREA AND THE CONSTRAINTS IN
! OBJECTIVE FUNCTION IN COMBINATION WITH A THE OPTIMIZATION TASK
DESIGN RESPONSE OPTIMIZE
OBJ_FUNC ID_NAME = MY_OPTIMIZATION_TASK
ID_NAME = MY_OBJ_FUNC OBJ_FUNC = MY_OBJ_FUNC
TARGET = MINMAX DV = DESIGN_AREA
DRESP = DRESP_STRAIN_ENERGY, , DVCON = DVCON_CAST
END_ CONSTRAINT = VOLUME_CONSTRAINT
STRATEGY = TOPO_SENSITIVITY
END_
384
Notes
385
Notes
386
W1c.1
Workshop example topology optimization – crane hook
Task Minimize volume with displacement constraint

Keywords Objective function, constraint, sensitivity based optimization
Saving material is one of the main targets for

industrial production, while the component also has

to fulfill the mechanical requirement given from the
specific loadcases.
The aim of this section is to define a general,
sensitivity based topology optimization task. A crane
hook with a displacement constraint has to be
optimized under consideration of manufacturing
constraints.
30 min
W1c.2
Model
The mesh used is 3D tetrahedral.

The model contains two loadcases. One is
simulating lifting a component with a rope and the
other lifting a component without a rope.
The elements around the bend as well as the tip of

the hook and the support are combined into an
element group to allow the definition of a frozen
area. For Nastran users, a specific property is
defined for these elements.
The side of the hook that is visible in the pictures

points in direction of the positive z-axis.
387
W1c.3
Optimization task
The goal of the optimization is to minimize the

volume. The displacement of node 13298 has to be
restricted by 1.1 for each load case separately.
Define manufacturing constraints (casting
restrictions) to simplify manufacturing.

1 2 3
Define optimization Model import Design area
task cranehook.<ext> ALL_ELEMENTS
TOPO_SENSITIVITY
6 5 4
Objective function Constraints Frozen area
minimize volume demold control frozen_border_
displacement constraint ring
7 8 9
VTF_ RUN_SMOOTH reconstruct, remesh &
VISUALIZATION run validation
388
W1c.5
Model input

1
2. Create a new sensitivity based topology

optimization task (in Task Manager, select

TASKS | Tosca Structure Task | 2
TOPO_SENSITIVITY)
3. Choose your solver for the working deck and

the FE input file for the topology optimization
task: ”cranehook.ext“ (ext=inp, bdf, dat, ...)
from the subdirectory <solvername>/topo.
4. Choose ALL_ELEMENTS as design variables for

the topology optimization.
W1c.6
Design area
5. Now define your frozen area: PRE-PROCESSING

| TOPOLOGY_OPTIMIZATION_CONTROLLER
| DESIGN_AREA | DV_CONSTRAINTS |
New | FROZEN_AREA. Assign a group to the 5
frozen area:
6. Type "?" in the GROUP_DEF field. If you are not

working with Nastran choose your predefined
group from the pop-up menu, check using
highlighting and continue at step 8. 6
7. If you are working with Nastran, no predefined

groups may be available, but your model
contains two properties. The elements around
the ring and on the border at the hook are 7
grouped in one property. Create a new group
with the elements of this property:
SET HELP: Actions | New.
389
W1c.7
Frozen area and objective function
8. The database manager opens (Modifying

SET:<setname>). Choose PROPERTY with
double click and choose the 2nd property in the
list of the property window (for visual check
switch on the highlight button). Confirm with
middle mouse button. Enter a name for your
selected group (frozen_border_ring) and 8

assign group to FROZEN_AREA by double click
(check again your chosen group with
highlighting in SET Help window).
9. Define a casting restriction: Enter 0,0,1 as pull

direction (z-direction) and a midplane through
the point 0,0,0. 10
10.Define the volume of all elements as objective

function which is to be minimized
(OBJ_FUNC_ITEM_1 | New | Volume).
W1c.8
Constraints
10
11.Define two displacement constraints: The

absolute displacement of node 13298 has to be
restricted by 1.1 for each static loadcase
separately: Click CONSTRAINTS | New |
DISPLACEMENT_CONSTRAINT. Select ABS as
MAGNITUDE, enter 1.1 as VALUE and select
11
NODE as TARGET. Enter 13298 in NID field.
390
W1c.9
Start optimization task
12.Type "?" in LC_SET field (see above) and a

LC_SET dialog opens. Click More. Select
STATIC in APPROACH dropdown menu and
12
enter 1 in LOADCASE field. Click OK. Now define
a second displacement constraint with the same
settings, but with loadcase 2 in LOADCASE field.
13.Change the global stop condition to 40

iterations.
14.Define the output jobname cranehook.

Update. Check for the file cranehook.par in
your working directory.
15.Save your task and start the optimization

(RUN | UPDATE).
W1c.10
Post-processing
1. Visualize the optimization progress using

Tosca Structure.view (POST-PROCESSING |
GENERATE_REPORT_FILE | TOPO_MAT |
Update)
2. Perform a smoothing of your result using two

smooth cycles. 2
Please note: The following steps are only possible

using Tosca ANSA environment and cannot be
performed with Tosca Structure.gui!
391
W1c.11
Reconstruction of the mesh
3. Perform a batch reconstruction. Choose

SMOOTH | SMOOTH_INSTANCE | VALIDATE
| BATCH_RECONSTRUCT | Edit. Check
Preview and the Freeze SPC Nodes,
uncheck Automatic feature line
recognition at SMOOTH_CUT_ELEMENTS 3
area and click OK. Select

SMOOTH | SMOOTHINSTANCE | VALIDATE
| BATCH_RECONSTRUCT | Update. Validate
the mesh in the preview with OKAY.
4. Create a solid mesh with SMOOTH |

SMOOTH_INSTANCE | VALIDATE |
SOLID_MESH | Update. Choose your
property for the new mesh.
4
W1c.12
Validation run
5. Create an output name (e.g. cranehook_smooth.ext) for your validation file:

SMOOTH | SMOOTH_INSTANCE | VALIDATE | VALIDATION_OUTPUT | Edit. Write your
validation file using Update.
6. Start your validation run: SMOOTH | SMOOTH_INSTANCE | VALIDATE |

VALIDATION_OUTPUT | Update. Now your solver starts analyzing the validation output file.
7. After the solver has finished (Control returned to

Tosca ANSA environment), check the results in
your post-processor. In the seminar start
GLView Inova (Icon on the desktop). Open your
7
result file in your working directory
(File | Open Analysis File, choose
cranehook_smooth.ext). Check your results
(e.g. von Mises stress). If result browser is not
visible, open Window | Project workspace
and change to menu Results. Choose your
loadcase, result and your settings for the
visualization (e.g. show min/max values).
392
Workflow using Tosca extension for ANSYS/WB
1 2 3
Start Tosca extension Optimization Design area
for ANSYS/WB strategy
Sensitivity
6 5 4
Objective function Constraints Frozen area
minimize volume demold control
displacement constraint
7 8 9
reconstruct, remesh &
run validation
W1c.14
Procedure using Tosca Extension for ANSYS/WB
Loading the extension
Start ANSYS Workbench, click on

File | Restore Archive to open the
cranehook model (cranehook.wbpz) and save
the project in your working directory. Load the

extension by clicking Extensions | Manage
Extensions and select Tosca Extension for
ANSYS Workbench. Close the Extension
Manager.
393
W1c.15
Preprocessing (1/8)
1. Drag a Tosca Structure.topology system

to the project schematic onto the Model cell of
the Static Structural system. 1
2. Open the Setup cell of the Tosca 2

Structure.topology system.
3. A simulation and a deformation analysis of the

model have already been executed. The solution 3
values can be looked up by selecting the
different results under Solution of Static
Structural in Tree Outline. The tab in
Tabular Data lists the deformation values of
a node at the cranehooks tip for this example.
W1c.16
Preprocessing (2/8)
4. Check the Analysis Settings of the Tosca

Structure.topology system. Set the
Tosca bin folder ("...\bin") if you use the
extension for the very first time. Choose 4
Strategy | Sensitivity. Set Auto
Frozen to Off, Frozen Areas are defined later
on.
5. Choose a design area for the optimization.

Therefore click Topology | Design Area
and assign the entire model as Geometry.
Make sure to select both bodies and not just
their surfaces. 5
394
W1c.17
Preprocessing (3/8)
6. Certain areas of the model can be excluded

from the optimization. Declare them as Frozen
Area by clicking Topology | Frozen Area. 6
Select Named Selection for Scoping
Method and choose Faces_Frozen as Named
Selection. The selected areas will be
highlighted.
7. It’s possible to show the elements, which will be

excluded from the optimization when using a
Frozen Area. Go to the Details View of the
Frozen Area and set Show Frozen
Elements to Yes. Activate the Wireframe
mode in the upper toolbar to hide the surface of 7
the model. Additionally the Show Mesh option
can be helpful.
W1c.18
Preprocessing (4/8)
8. To set a casting restriction, add a Demold

Control by clicking Topology | Demold
Control. Select the Global Coordinate
System as Coordinate System. Set the z-
axis as demolding direction by defining the
vector X=0, Y=0, Z=1. Select Automatic as 8
Mid Plane option. Make sure to select both

bodies of the hook as Geometry as well as
Check Group.
9. In order to use later the volume in an objective

function for minimization, create a Design
Response first by clicking Optimization | 9
Design Response. Choose Base as
Category, Volume as Response Type
and assign the entire model (2 bodies) as
Geometry.
395
W1c.19
Preprocessing (5/8)
10.It is recommended to rename the Design

Response by using the F2-button in order to find
and use it easier. Rename the Design Response
to "Dresp_Volume".
11.Insert the Design Response "Dresp_Volume"

into an Objective Function by clicking 11
Optimization | Objective Function.
Choose Minimize sum as Target and click
on Tabular Data.
12.As Design Response, create a new tab within

the pop up window and select the predefined
Design Response "Dresp_Volume". Click 12
Apply.
W1c.20
Preprocessing (6/8)
13.Create two more Design Responses, each for a

different load case.
Add them by clicking Optimization |
Design Response twice. For both, set the
Category to Displacement, Response
Type to Absolute. Choose Named
Selection as Scoping Method in order to

use the predefined selection
"Node_Selection" which represents a node in
the point of the hook.
Select Manual as Load Case Selection
and click Tabular Data.
396
W1c.21
Preprocessing (6/8)
14.Within the Load Cases pop up window, create

a new tab, choose Static Structural as
Analysis and select the first load case by
entering "1" in the Steps and "-" in
Substep/Mode cell. Click Apply and rename
the Design Response to "Dresp_Disp_LC1".
Repeat the entire procedure (creating a design

response) for the second design response,
choose the second load case (Steps "2") and
rename this design response to
“Dresp_Disp_LC2”.
W1c.22
Preprocessing (7/8)
15.Add two Constraints to the project, one for each

of the two displacement Design Responses. For 15
the first one click Optimization |
Constraint, then choose "Dresp_Disp_LC1"
as Design Response. Select Absolute as
Type and Less or equal as Constraint
Type while entering "0,4" as actual Value.
16.Repeat this to add a second Constraint that

refers to the Design Response 16
"Dresp_Disp_LC2".
17.Click Results | Optimization Result in

order to add a result to the Solution section in 17
the Tree Outline. Add a Smooth Result,
too, by clicking Results | Smooth Result.
Save your project by clicking File | Save
Project.
397
W1c.23
Preprocessing (8/8)
18.The structure within the Tree Outline should

look like the figure on the right by now.
Click Solve.
W1c.24
1. After the optimization has finished the results

can be displayed in the Mechanical
application: Click Optimization Result in
the Tree Outline.
1
2. To have a better view of the resulting structure,

elements with a low relative density can be
hidden. Change the Geometry option from
Exterior to Capped IsoSurfaces. Select 2
Bottom Capped IsoSurface to show all
elements with a relative density above a certain
value.
398
W1c.25
3. Click on Smooth Result in the Tree

Outline to view a smoothed model which will
be used for validation.
W1c.26
Validation (1/11)
1. To execute a validation run, click

1
Validation | Run. ANSYS/WB recycles the
smoothed model and reopens a derived solid
mesh model in the Mechanical application.
2. The validation might take a few minutes, and is

finished as soon as the new Mechanical
application is opened automatically
3. Due to the import of the new geometry, the initial

faces are lost and can’t be reassign as geometry
of boundary conditions anymore. You have to
use Virtual Topology to recreate the initial
3
faces.
399
W1c.27
Validation (2/11)
4. Open the Model cell of the latest Finite

Element Modeler in the Project 4
Schematic. Look for Problematic Faces. If
there aren’t any, skip the next steps and
continue with step 8.
5. If there are listed some Problematic Faces

in the Tree Outline, select the Skin
Detection Tool and set Forbid close
components to Yes. 5
6. Right click on Initial Geometry and select

Generate. These settings should avoid the 6
appearance of Problematic Faces.
W1c.28
Validation (3/11)
7. If Problematic Faces still exist, it might

additionally be necessary to reduce the Cut
Angle or the Tolerance Angle in the 7
Details View window of Skin Detection
Tool. Again, update Initial Geometry.
Close the Finite Element Modeler.
8. Update the Finite Element Modeler by

right clicking on the Model cell, Update.
8
9. Double click the Model cell of the Tosca

Optimizer Validation system. When
9
asked whether to read the upstream data or not,
choose Yes if there have been any
Problematic Faces before, otherwise click
No.
400
W1c.29
Validation (4/11)
10.Due to the optimization, the geometry has

changed and therefore faces, bodies etc. have
to be reassigned. Start with the mesh. Reassign
the body to the Body Sizing meshing option.
10
11.Some faces are needed for the boundary

conditions, so they have to be recreated using
Virtual Topology. Select Model in Tree
Outline, click on Virtual Topology in the 11
upper toolbar and activate the Edge-
Selection-Tool
W1c.30
Validation (5/11)
12.You have to add four splits at the edge of the

borehole. Click on the location on the edge were
you want to split and select Split Edge at
+. Your model might look slightly different due to
your Skin Detection Tool’s settings. 12
13.Due to the split there are new vertices which will

be used for cutting the face. Activate Vertex 13
selection and choose the new points on the
left side of the borehole. Click on Split Face
at Vertices.
401
W1c.31
Validation (6/11)
14.Select both vertices on the other side of the

borehole and click again Split Face at
Vertices. The virtual faces should look like the
following. 14
15.Select the faces which belong to the upper half-

shell of the borehole and assign them to the
Geometry of the Fixed Support in Tree
Outline.
15
W1c.32
Validation (7/11)
16.Next you have to recreate the face for the loads

for loadcase 1 (LC1). Use Virtual Topology
to create four new vertices where the curves of
the rope bearing become tangential.
16
17.Select both vertices on the left side of the rope

bearing and click Split Face at Vertices.
Repeat this procedure with the vertices on the 17
right to recreate the initial face.
402
W1c.33
Validation (8/11)
18.Select the faces of the rope bearing and assign

it to Geometry in Force_LC1 in Tree
Outline.
18
19.Check the initial faces of loadcase 2. Recreate

the lower edge by generating two new vertices
(Split Edge at +) and use them to split the 19
face (Split Faces at Vertices).
20.To create the upper edge use the Face

selection tool and click on a point on the
surface of the tip. Click on Hard Vertex at +
in the Virtual Topology Toolbar. Repeat 20
this procedure to create a second hard vertex.
Select both new vertices and press Split
Faces at Vertices.
W1c.34
Validation (9/11)
21.You have to create two more edges. Select one

of the new vertices and a vertex which is
connected to the edge below this point. Click on
Split Faces at Vertices. Repeat this 21
approach for the other side of the cranehook.
22.Select the new face at the tip and assign it to

Geometry in Force_LC2 in Tree Outline.
22
23. Create the mesh after adding Virtual

Topology. Therefore use right mouse button on
Mesh in Tree Outline and then Generate 23
Mesh.
403
W1c.35
Validation (10/11)
24.Finally, you have to reassign a node at the tip to

calculate its deformation. Therefore click on 24
Node_Selection under Named Selection
in Tree Outline. Activate Show Mesh and
Select Mesh in the upper toolbar.
25.Select a node at the tip of the hook and assign it

to Geometry. Deactivate the Show Mesh
option. 25
W1c.36
Validation (11/11)
26.The validation model is now completely set up.

The Tree Outline should look like the 26
following. Click Solve to start the computation
27.The solution values can be looked up by

selecting the different stress and deformation
results in Tree Outline.
27
404
1 2 3
Model import Design area Constraints
cranehook.<ext> ALL_ELEMENTS demold control
displacement constraint
5 4
Optimization task Objective function
TOPO_ minimize volume
SENSITIVITY
6
Start optimization
7 8
Post-processing Smoothing
visualize vtfx file Tosca
Structure.smooth
W1c.38
Procedure using Tosca Structure.gui (1/3)
1. Create a new topology optimization task (File | New File).
2. Choose the FE input file ”cranehook.ext“ (ext=inp, bdf, dat, ...) in the subdirectory
<solvername>/topo for the topology optimization task.
3. Choose the design variables (DV_TOPO) for the topology optimization. All elements of the FE model
are defined as design variables.
4. Define a design variable constraint for your frozen elements. When using Nastran create a group
containing all elements of set 1 of cranehook.bdf (click Read Nastran set and select
cranehook.bdf as file )and assign this group to the frozen elements.
5. Define a casting constraint for all elements with pull direction 0,0,1 and midplane through the point
0,0,0.
405
W1c.39
6. Define the required design responses (DRESP) for the definition of the objective function (volume of
all elements) and the constraints (absolute displacement of node 13298 for the static loadcases 1
and 2 respectively).
7. The objective function is chosen in the menu OBJ_FUNC. The volume of the structure is minimized.
Choose a well suited ID_NAME like minimize_volume.
8. Define the constraints (CONSTRAINT). Define an absolute value of 1.1 as upper constraint for the
design responses with the absolute displacement of node 13298. Note, that one should apply an
inequality constraint.
9. The optimization task is assembled using the command OPTIMIZE. Here, the individual definitions
are activated. In the text view on the left hand side you can easily check which definitions are
activated. Additionally, the optimization strategy is set to TOPO_SENSITIVITY.
10. Define a maximum number of 40 iterations in your STOP condition.
W1c.40
11. Save the parameter file with the name cranehook.par.
12. Start the optimization task in the mask Start Tosca Structure of Tosca Structure.gui.
13. Check the results after optimization: Create vtfx-sequences of the material distribution during the
optimization using the module Tosca Structure.report. Calculate a sequence of the type Material
Distribution for all iterations (select All from the Iter dropdown menu). Visualize the result
cranehook_report.vtfx.
14. Open the created sequence with Tosca Structure.view using the button View Report in the mask
Tosca Structure.report and by choosing the file cranehook_report.vtfx. Compare the result
with the results of the other workshop participants. Switch between the cases, start the animation
for the several steps and move the model in the viewer.
15. Create a smooth model in the mask Tosca Structure.smooth using two smoothing cycles. Visualize
your result using Tosca Structure.view.
406
W1c.41
Result (1/2)
The following figures show the optimization results before and after smoothing :
W1c.42
Result (2/2)
Validation of the model leads to following stress

distribution:
The result shows a stress concentration in the area

of the fixture. This is due to the unrealistic boundary

conditions in this area. One way to avoid this is to
perform the calculation with more realistic boundary
conditions.
If the stress concentrations are still present then a
shape optimization would be the next step where all
the stress concentrations will be removed or at
least reduced significantly. Topology optimization is
not capable to generate design proposals with a
level of detail which is able to consider all local
stress effect so a shape optimization which reduces
stresses will often be the following step.
407
W1c.43
Solution (1/4)
! PARAMETER FILE FOR TOSCA STRUCTURE ! DEFINITION OF THE DESIGN AREA

OPTIMIZATION TASK DV_TOPO
! INPUT OF THE FEM FILE EL_GROUP = ALL_ELEMENTS
FEM_INPUT END_
FILE = cranehook.bdf ! ASSIGNATION OF THE PROPERTY "FROZEN" TO

END_ THE FROZEN ELEMENTS GROUP
DVCON_TOPO
! DEFINITION OF FROZEN ELEMENT GROUP ID_NAME = MY_DVCON_TOPO_FROZEN
GROUP_DEF CHECK_TYPE = FROZEN
ID_NAME = FROZEN_BORDER_RING EL_GROUP = FROZEN_BORDER_RING
TYPE = ELEM END_
FORMAT = LIST
LIST_BEGIN
1-12,46,409,508,701,890,902
...
74451-74459,74500,74501
END_
W1c.44
Solution (2/4)
! DEFINITION OF THE CASTING RESTRICTION WITH ! DEFINITION OF A DISPLACEMENT OF ONE

A MID PLANE NODE FOR THE FIRST STATIC LOADCASE
DVCON_TOPO DRESP
ID_NAME = MY_DVCON_TOPO_CAST ID_NAME = DISPLACEMENT_1
MID_PLANE = POINT,0.,0.,0. DEF_TYPE = SYSTEM
CHECK_GROUP = ALL_ELEMENTS TYPE = DISP_ABS
PULL_DIR = 0.,0.,1. NODE = 13298

CHECK_TYPE = CAST GROUP_OPER = Max
EL_GROUP = ALL_ELEMENTS LC_SEL = MAX
END_ LC_SET = STATIC,1,,
CS_REF = CS_0
! DEFINITION OF THE VOLUME AS DESIGN END_
RESPONSE
DRESP
ID_NAME = MY_VOLUME
TYPE = VOLUME
DEF_TYPE = SYSTEM
GROUP_OPER = Sum
END_
408
W1c.45
Solution (3/4)
! DEFINITION OF A DISPLACEMENT OF ONE NODE ! DEFINITION OF THE VALUE AND THE

FOR THE SECOND STATIC LOADCASE MAGNITUDE OF THE NODE DISPLACEMENT,
DRESP DEFINED IN DESIGN RESPONSE DISPLACEMENT_1
ID_NAME = DISPLACEMENT_2 CONSTRAINT
DEF_TYPE = SYSTEM ID_NAME = DISPLACEMENT_CONSTRAINT_1
TYPE = DISP_ABS DRESP = DISPLACEMENT_1
NODE = 13298 MAGNITUDE = ABS

GROUP_OPER = Max LE_VALUE = 1.1
LC_SEL = MAX END_
LC_SET = STATIC,2,,
CS_REF = CS_0 ! DEFINITION OF THE VALUE AND THE
END_ MAGNITUDE OF THE NODE DISPLACEMENT,
DEFINED IN DESIGN RESPONSE DISPLACEMENT_2
CONSTRAINT
! DEFINITION OF THE OBJECTIVE FUNCTION IN
COMBINATION WITH A DESIGN RESPONSE ID_NAME = DISPLACEMENT_CONSTRAINT_2
OBJ_FUNC DRESP = DISPLACEMENT_2
ID_NAME = MINIMIZE_VOLUME MAGNITUDE = ABS
TARGET = MIN LE_VALUE = 1.1
DRESP = MY_VOLUME,, END_
END_
W1c.46
Solution (4/4)
! COMBINATION OF THE OBJECTIVE FUNCTION, THE ! DEFINITION OF A STOP CONDITION

DESIGN AREA AND THE CONSTRAINTS IN THE STOP
OPTIMIZATION TASK
ID_NAME = MY_STOP
OPTIMIZE
ITER_MAX = 40
ID_NAME = MY_OPTIMIZATION_TASK
END_
OBJ_FUNC = MINIMIZE_VOLUME
DV = DESIGN_AREA EXIT
STRATEGY = TOPO_SENSITIVITY
DVCON = MY_DVCON_TOPO_FROZEN
DVCON = MY_DVCON_TOPO_CAST
CONSTRAINT =
DISPLACEMENT_CONSTRAINT_1
CONSTRAINT =
DISPLACEMENT_CONSTRAINT_2
END_
409
410
Notes
411
Notes
412
W2.1
Shape Optimization
Procedure of Shape Optimization

The procedures used to define the optimization model are described briefly below. These procedures
are supported by the task manager in Tosca ANSA environment (TAE) as well as the command tree in
Tosca Structure.pre screen of Tosca Structure.gui (GUI). The analysis model must be defined prior to
starting.
ANSYS Workbench does not yet support shape optimization directly, but nevertheless Shape
optimization with Tosca Structure can be used in combination with ANSYS analysis models. The setup
of the optimization task is then done using Tosca ANSA environment (TAE) or Tosca Structure.gui
(GUI) as described below.
Analysis model
1. Question: Which file(s) contain(s) the FE-model for the optimization?
TAE: MODEL_LINK|FILE item, Edit, choose your model file.
GUI: Choose your model file in FEM_INPUT
W2.2
Design area
2. Question: Which surface area of the FE model should be selected for shape modifications?
Procedure: Assign node group with surface nodes to design area.
TAE: DESIGN_AREA | Edit, choose predefined group or select new group.
GUI: Choose or define the node group with the surface nodes of the selected design area
(GROUP_DEF) and define the design variables (DV_SHAPE).
3. Question: Which area of the model should be selected for smoothing of the FE mesh?
Procedure: Assign element group to MESH_SMOOTH area.
TAE: DESIGN_AREA | New | MESH_SMOOTH command, choose predefined group or select new
group.
GUI: Choose or define the element group defining the mesh smoothing area (GROUP_DEF) and
define the mesh smoothing (MESH_SMOOTH).
4. Question: Are there nodes in the design area or in the mesh smoothing area that are subject to
certain restrictions? How can these restrictions be described?
Procedure: Define design variable constraints for node group.
TAE: DESIGN_AREA | DV_CONSTRAINTS | New | <type of restriction> command,
choose predefined group or select new group. Evtl. define link conditions using modules buttons.
GUI: Choose or define node groups with common restrictions (GROUP_DEF). Define the restrictions
using LINK_SHAPE and DVCON_SHAPE.
413
W2.3
Objective function and Constraint
Objective function
maximized or otherwise combined?
Procedure: Choose terms for optimization (design responses) and target.
TAE: OBJ_FUNC_ITEM_1 | New | <term for optimization> command; apply Edit
command on OBJ_FUNC_ITEM_1 to choose whether the objective function is to be minimized or
maximized.
Constraint
6. Question: Which design response describes the constraint? Which value should the constraint
have?
Procedure: Choose term for constraint and set target value or upper/lower boundary.
TAE: CONSTRAINTS | New | <term for constraint> command.
W2.4
Optimization task
Optimization task
7. Question: Are all of the command definitions listed above complete
and ready for the optimization job?
Procedure: If necessary complete any additional required definitions
and prepare the optimization job.

Procedure: Choose corresponding strategy.
TAE: Chosen in the beginning with your task (SHAPE_CONTROLLER).
GUI: Set the correct value to SHAPE_CONTROLLER in OPTIMIZE subcommand STRATEGY.
Stop Condition
9. Question: Should the optimization stop after a number of iterations (or certain other conditions)?
Procedure: Define a stop condition
TAE: GLOBAL_STOP_CONDITION , apply Edit command and change number of iterations.
GUI: STOP.
414
W2.5
Check and Completion
Check Run
10.Question: Would prior testing of the restriction definitions be useful?
Procedure: Apply test displacements
TAE: New | TEST_SHAPE command on SHAPE_OPTMIZATION_CONTROLLER, or New |
TEST_SHAPE_CHECK command on CHECK_INPUTS.
GUI: TEST_SHAPE.
Completion
11.Question: Has all the required data been specified?
TAE: Click twice on OUTPUT item and enter the jobname (or proceed with the default jobname);
Update command writes the parameter file.
GUI: Save as <jobname>.par.
415
416
Notes
417
Notes
418
W2a.1
Workshop Example Shape Optimization – Holeplate
Task Minimize maximum stress

Keywords Design variables, objective function, constraint, Tosca Structure.gui wizard
The following model shows a simple shape optimization task including defining design variables,
constraints and objective function. Tosca ANSA environment or the Tosca Structure.gui wizard can both
be applied for defining the present standard optimization task. Both tools guide the user through the
basic parts and therefore supports less experienced Tosca Structure-user very well.
30 min
W2a.2
Holeplate
Model
A symmetrical hole plate where only a quarter of
the plate is modeled due to symmetry
considerations. Two load cases are considered
simultaneously in the optimization.
Optimization Task
Minimize the maximum von Mises stress in the
curve. The symmetrical node fixations for the
design nodes are defined using the boundary
conditions from the FE analysis.
419
1 2
Model import Design area
holeplate.<ext> GROUP_DEF
edge of hole 3
Design variable
constraints
4 CHECK_BC
Objective function
minimize SIG_MISES
stress
5
Save optimization
task
6 7
run
W2a.4
Importing model
1. Select File | New to open a new file and

press Discard in the Confirmation window.
2. In Task Manager, select Tasks | Tosca

Structure Task | SHAPE_CONTROLLER.
Click Expand to show the whole tree of the
optimization task.
3. Choose the FE input file, then select

PRE-PROCESSING | MODEL_LINK | Edit
3
and choose the solver that matches your input
file. Select PRE-PROCESSING | MODEL_LINK
| FILE | Edit and load the model
”holeplate.ext“ (ext=inp, bdf, dat, ...) from
the subdirectory <solvername>/shape. Right
click the item named after the file you have just
chosen and select Update to show the model in
the main window.
420
W2a.5
Design area (1/2)
4. Choose the design variables

(PRE-PROCESSING |
SHAPE_OPTIMIZATION_CONTROLLER |
DESIGN_AREA | Edit). A node group
containing the design nodes must be specified.
Switch the ND_GROUP operator to GROUP_DEF
and enter "?" in the GROUP_DEF field to activate 4

the SET HELP dialog. Then choose
Actions | New.
5. Afterwards, choose EDGE in the Database and

activate the whole edge of hole (hint: use feature
line). When the entire edge of the hole has been
chosen then click on the middle mouse key. 5
W2a.6
Design area (2/2)
6. Name the node group design_nodes_ansa

and click OK. Then double click on
design_nodes_ansa and thereby choose the
group as design nodes and click OK.
6
7. Define mesh smoothing for all elements.

Choose the item PRE-PROCESSING |
DESIGN_AREA | MESH_SMOOTH | Edit. In 7
the MESH_SMOOTH dialog, switch the FREE_SF
operator to FIX in order to fix all free surface
nodes. The value in the LAYERS field specifies
the number of layers where the nodes are free
for mesh smoothing.
421
W2a.7
Design variable constraints, Objective function
8. The nodes having boundary conditions in the FE

model have to be imported with the model.
These nodes are also constrained not to move
during the optimization. Select 8
PRE-PROCESSING |
DV_CONSTRAINTS | New | CHECK_BC and

switch the CHECK_BC operator to YES.

PRE-PROCESSING |
SHAPE_OPTIMIZATION_CONTROLLER | 9
OBJ_FUNC_ITEM_1 | New |
EQUIVALENT_STRESS. Select the design node
group and set the stress type to SIG_MISES.
W2a.8
Objective function
10.After defining the von Mises stress as a design

now choose its target. In this case the stress 10
should be minimized. Choose
PRE-PROCESSING |

to MIN.
11.The global stop condition for a controller based

shape optimization task is set to 5 iterations by
default. To allow one more design cycle, select
PRE-PROCESSING |
GLOBAL_STOP_CONDITION | Edit and
change the iteration number from five to 6.
422
W2a.9
Saving optimization task
12.The optimization task is set up and the

parameter file can now be saved. Click twice
Output under PRE-PROCESSING and enter 12
the new name holeplate for the parameter
file. The Output field is renamed to
holeplate. To save the parameter file choose
PRE-PROCESSING | holeplate | Update.

W2a.10
14.The optimization can be started from the Tosca

tosca <name>.par
423
W2a.11
Post-processing
15.Generate result file after optimization. Choose

POST-PROCESSING |
GENERATE_REPORT_FILE | SHAPE_CTRL |
Edit. There are two types of vtfx visualization
plots for shape optimization results (NODAL
DISPLACEMENT (SHAPE) or NODAL
CONTINUOUS (SHAPE)) - the nodal

displacements or the controller input, which
shows the change in the objective function. You
can specify the type of your plot and click OK.
Update SHAPE_CTRL (SHAPE_DISP if you
selected NODAL DISPLACEMENT) and the
POST_FILE will be generated. Afterwards the
viewer opens automatically. You can also open
the viewer by choosing POST-PROCESSING |
GENERATE_REPORT_FILE |
VTF_VISUALIZATION | View.
1 2
holeplate.<ext> DESIGN_NODES
node numbers 3
Objective function
minimize maximum
4 stress
Design variable
constraints
5 CHECK_BC
Save optimization
task
6 7
run
424
W2a.13
1. Define a new shape optimization task using

Tosca Structure wizard.
2. Choose the input file holeplate.ext (ext =

inp, bdf, dat, ...)
2
W2a.14
3. Define as design area a group which contains

the nodes of the curve (create new Node
Group). Apply the new group name
design_nodes. Add the following node
numbers in the data window: 3
6, 10-13, 30, 34-36, 109, 114, 119, 124, 189,
194, 199, 204
4. Define your optimization task: Choose

minimization of the maximum stress. The
constraint is not activated for this model. 4
5. Define an area for mesh smoothing (Mesh

Smooth Group). Choose the element group
ALL_ELEMENTS and fix the free surface nodes 5
of the mesh smooth area with Fix Surface
Nodes.
425
W2a.15
6. The boundary conditions of the FE model have

to be imported with the model data to use them
defining specific constraints. Activate the
6
checkbox CHECK_BC (check boundary
conditions) in the window Options.
Furthermore, limit the number of optimization
steps to 6 (Number of Iterations).
7. Check your definitions in the summary. Using

the button Finish your definitions are written to
Tosca Structure.pre and can be seen in the text
view.
7
W2a.16
8. Save your definitions to a parameter file named

holeplate.par.
8
9. Start the optimization in the module Start

Tosca Structure: Choose your parameter file 9
holeplate.par using the file dialog next to
the JobName field. Choose your solver and start
the optimization.
426
W2a.17
10.Create vtfx sequences using the module Tosca

Structure.report. Choose all visualization types
and combine all iterations.
10
11.Start Tosca Structure.view and choose the file

holeplate_ctrl.vtfx. Start the animation. Open the
window Info Dialog (Display | Info
Dialog), choose the item node and click on a
node in the design area of the model. Observe 11
the Stress value at the beginning and at the end
of the optimization. (Note: Values in the info
dialog are not automatically updated, the
referenced node must be clicked again for an
update).
W2a.18
Result
Original and optimized contour with info windows showing the maximum equivalent stresses.
427
W2a.19
Solution (1/3)
! PARAMETER FILE FOR SHAPE OPTIMIZATION: ! DESIGN AREA

HOLEPLATE GROUP_DEF
ID_NAME = DESIGN_NODES
! CONSIDERATION OF BOUNDARY CONDITION TYPE = NODE
OPTIONS
FORMAT = LIST
READ_BC = ALL LIST_BEGIN
END_
6, 10-13, 30, 34-36, 109, 114, 119,
124, 189, 194, 199, 204
! INPUT OF THE FEM FILE END_
FEM_INPUT
ID_NAME = INPUT_FILE ! DESIGN VARIABLES
FILE = holeplate.bdf DV_SHAPE
END_ ID_NAME = DESIGN_VARIABLES
ND_GROUP = DESIGN_NODES
! BOUNDARY CONDITION CHECK END_
DVCON_SHAPE
ID_NAME = dvcon_spc
ND_GROUP = ALL_NODES
CHECK_BC = YES
END_
W2a.20
Solution (2/3)
! MESH SMOOTH ! OBJECTIVE FUNCTION IN COMBINATION WITH

MESH_SMOOTH A DESIGN RESPONSE
ID_NAME = mesh_definition OBJ_FUNC
EL_GROUP = ALL_ELEMENTS ID_NAME = minimize_max_mises
FREE_SF = fix, 0 DRESP = dresp_max_mises
END_ TARGET = MIN
END_
! MAX VON MISES STRESS AS DESIGN RESPONSE
DRESP
ID_NAME = dresp_max_mises
DEF_TYPE = SYSTEM
TYPE = SIG_MISES
GROUP_OPER = MAX
UPDATE = EVER
END_
428
W2a.21
Solution (3/3)
! COMBINATION OF THE OBJECTIVE FUNCTION, THE

DESIGN AREA AND THE CONSTRAINTS IN THE
OPTIMIZATION TASK
OPTIMIZE
ID_NAME = SHAPE_OPTIMIZATION
DV = DESIGN_VARIABLES
OBJ_FUNC = minimize_max_mises
MESH_SMOOTH = mesh_definition
DVCON = dvcon_spc
END_
! NUMBER OF ITERATIONS
STOP
ID_NAME = STOP_CONDITION
ITER_MAX = 6
END_
EXIT
429
430
Notes
431
Notes
432
W2b.1
Workshop example shape optimization – connecting rod (conrod)
Task Minimize maximum stress from two loadcases

Keywords Cast restriction, symmetry MINMAX, group definitions on complex geometry
The following model shows some advanced parts of a shape optimization task: definition of design
variable constraints, such as casting restrictions and symmetry. The latter calls for group definitions on
complex geometry.
Hint: Defining the MESH_SMOOTH elements as the first thing is often a good idea by shape
optimization with complex geometries. Why? Because all manufacturing restrictions may only be active
on the surface of the MESH_SMOOTH elements.
45 min
W2b.2
Model
Design area
Mesh smooth area
Model of the connection rod with design area

defined by nodes and mesh smooth area
433
W2b.3
Loads (1/2)
The component optimized in this example is a connecting rod (conrod). The model is built with an
automatically generated tetrahedron mesh symmetric to the xz and yz plane.
Loaded nodes are connected with MPCs to the inner side of the conrod mounts. There are five
loadcases realized in the model (see Fig. 2):
Loadcase 1:
Centrifugal force, 15000 N applied in z-direction; Screw fixation
Loadcase 2:
Gas pressure, 25000 N applied in negative z-direction; Fixation in nodes of big eye
Loadcase 3:
Bending about the x-axis; Fixation in nodes of big eye
Loadcase 4:
Bending moment about the y-axis; Fixation in nodes of big eye
Loadcase 5:
Torsion about the z-axis; Fixation in nodes of big eye.
W2b.4
Loads (2/2)
a
b
Loads and boundary conditions of the model conrod: (a) centrifugal force,
right: force caused by gas pressure (b), bending and torsion about x-, y- and z-axis.
434
W2b.5
Optimization task
Both radii of the conrod model are optimized. The

radii should be manufactured by stamping so the
nodes in the stamping direction must be linked.
Another restriction is that both radii must have the
same form after optimization - i.e. a symmetry
constraint has to be introduced. A free optimization
without manufacturing constraints would result in

different geometries for the left and the right side as
the stresses on the right side are higher than the
stresses on the left side of the conrod. The stress
distribution of the start model is illustrated in Fig. 3.
Stress distribution of the initial and the

optimized model.
1 2
conrod.<ext> GROUP_DEF
MESH_SMOOTH 3
Casting restriction
Symmetry constraint
4
Objective function
MINMAX
5 SIG_MISES
Volume constraint
of 100%
6 7
Save and start Post-processing
optimization run
435
W2b.7
Procedure using Tosca ANSA environment
1. Define a SHAPE_CONTROLLER optimization task

for the conrod (model file: conrod.ext). You
should follow the standard procedure to create
your basic parameter file.
2. Groups can be defined manually or predefined

groups can be used. In this case both ways are
described. Continue either with the following
chapter for using predefined groups or skip to
chapter “Creating groups manually” for creating
groups manually.
W2b.8
Using predefined groups
3. For Nastran users the group definitions must be

loaded into Tosca ANSA environment - users of
all other solvers may continue with 5). Rightclick
MODEL_LINK and select New | ADD_FILE.
Choose conrod_groups.
4. Update this file: A window called Set Type

Definition opens. Apply the corresponding
types to the groups: Each group is a node group 4
except the mesh smooth group: this is an
element group. Select the predefined group,
choose the corresponding type at the dropdown
menu and apply by clicking Set. Repeat this
with each group and click OK. Now you can find
these groups in SET window.
436
W2b.9
Design area and mesh smoothing
5. Define mesh smoothing for the element group

MESH_SMOOTH_ELEMENTS
6. Define a design area containing the node group
DESIGN_NODES.
7. Define the design variable constraint
DOF_CONTROL (PRE-PROCESSING |
DV_CONSTRAINTS | New | DOF_CONTROL)
with the node group FIXED_NODES. These
nodes have to be fixed in all three directions
W2b.10
Cast restriction
8. Define a cast restriction (PRE-PROCESSING |

DV_CONSTRAINTS | New |
DEMOLD_CONTROL) for one half of the design
area of the conrod. Select the group
SURF_DEMOLD_POS. The demold direction
should be the positive x-axis of the global

coordinate system (1,0,0). Select
SURF_DEMOLD_POS also as check group.
9. Repeat the previous steps to define a cast
restriction for the other half of the design area of
the conrod: node group SURF_DEMOLD_NEG and
demold direction (-1,0,0).
10.Continue with chapter Completion of the
optimization task
437
W2b.11
Creating groups manually (1/6)
1. For defining a group for mesh smoothing the NOT button

easiest way is to reduce the model view to the
mesh smoothing area first and to define the
element group afterwards. If needed, bring the
model to the view shown in the figure by
pressing F2 key. Then press the NOT button and
select the faces of the part shown in the left

figure by enclosing them in a frame drawn with
the mouse while holding the left mouse button.
The framed part disappears. Press NOT button
again and select the faces of the part shown in
the right figure.
W2b.12
2. Save this view by clicking the key button and

select Store Lock. Enter a name, for example
MESH_SMOOTH, and press Enter.
Now this view is saved and can be selected by

key button | MANAGE LOCKs and right
clicking the chosen name | Show only.
To see the whole model again, make sure that key-button unlocked ALL-button
the view isn’t locked and press the ALL button.

The whole model will appear.
438
W2b.13
3. Define mesh smoothing for the element group

MESH_SMOOTH_ELEMENTS (PRE-PROCESSING
| SHAPE_OPTIMIZATION_CONTROLLER |
DESIGN_AREA | MESH_SMOOTH | Edit).
Select your predefined view (key button |
MANAGE LOCKs, then rightclick on
mesh_smoothing_elements | Show
only). In Modifying SET window click
SOLID item (under ELEMENT item) once in order
to highlight it and deactivate all others. Now, all
elements of the predefined model view can be
chosen using the mouse. Click with the middle
mouse button to confirm the selection and to
proceed to SET window.
W2b.14
4. Define a design area containing the node group

DESIGN_NODES: Keep view from selecting
MESH_SMOOTH, select SOLIDFACET in
Modifying SET window and activate the
Feature Area button with a corresponding
angle to choose the surface. Make sure only to bushing
choose surface outside of geometry and not

inside the mesh. Neglect the intersection plane
and the bushing. Deselect the last three or four
layers at each end
Deselect also the three layers at the front and

the back side with an angle of 10° at the
Feature Area button
439
W2b.15
5. Define the design variable constraint

DOF_CONTROL (PRE-PROCESSING |
DV_CONSTRAINTS | New | DOF_CONTROL) 5
with the nodes of the two inner layers of the eye
at the front and back side and the bushing: Keep
view from selecting MESH_SMOOTH, select

SOLIDFACET in Modifying SET window and
activate the Feature Area button with an
angle of 10°. These nodes have to be fixed in all
three directions.
6. For casting restriction (demoldability in positive

x-direction) save a modified view first: For group 6
selection start with MESH_SMOOTH group and
choose view point [F3]. Again use NOT button to
deselect the elements in negative x-direction.
Save this view.
W2b.16
7. Define a cast restriction (PRE-PROCESSING |

DEMOLD_CONTROL) for one half of the design
area of the conrod. Define a new group called
SURF_DEMOLD_POS: Select the SOLIDFACETS
at the exterior (not at the cut surface) of the

positive half by using Measure button
(Shells/Solid facets, for example 40°).
8. The demold direction should be the positive x-
axis of the global coordinate system (1,0,0).
Select SURF_DEMOLD_POS also as check group.
9. Repeat the previous steps to define a cast
restriction for the other half of the design area of 8
the conrod (node group SURF_DEMOLD_NEG).
The demold direction should be the negative x-
axis of the global coordinate system (-1,0,0).
Select the same group as check group.
440
W2b.17
Completion of the optimization task
1. Define symmetry (PRE-PROCESSING |

SYMMETRY_CONTROL) for all design nodes. The
normal vector for the symmetry plane should be 1
in y-direction and a point in the plane defined by
x and y both being zero. Note, mesh also has to

be symmetric.
2. Define the objective function as a MINMAX
function of the maximal von Mises stresses for
all design nodes (PRE-PROCESSING |
OBJ_FUNCTION | New |
EQUIVALENT_STRESS) of all five loadcases.
Remember, to set the objective to MINMAX
function.
3. Define a volume constraint. Define a relative
target volume of 100% (1.00) in order to keep
the conrod volume unchanged.
W2b.18
Save and set optimization task
4. Save the optimization task under the name

conrod.
5. Save the optimization database including all
optimization definitions using File | Save
as in the main menu (use a meaningful
filename).
6. Apply a virtual test shape before starting the 6

actual shape optimization. The shape testing
can for example indicate if all manufacturing
constraints are defined correctly.
CHECK_INPUTS | New |
TEST_SHAPE_CHECK, then CHECK_INPUTS|
TEST_SHAPE_CHECK | New | TEST_SHAPE.
Initially, set the DISPLACEMENT to be 4.0 and
INCREMENT to be 10. Chose DIRECTION to be
RANDOM. Update TEST_SHAPE and add
CHECK_INPUTS | TEST_SHAPE_CHECK |
VTF_VISUALIZATION and View for a
visualization of the shape testing.
441
W2b.19
Run optimization task
7. The optimization can be started with


tosca <name>.par
7. Check the optimization results using post-

processing.
1 2
conrod.<ext> DESIGN_NODES
3
Mesh smoothing
MESH_SMOOTH_
5 4 ELEMENTS
Objective function Casting restriction
MINMAX Symmetry constraint
6 7 8
Volume constraint Save and start Post-processing
of 100% optimization run
442
W2b.21
Procedure using Tosca Structure.gui
1. Start Tosca Structure.pre to define the optimization task.

2. Import the analysis model conrod.ext (ext=inp,bdf,dat ...).
3. The group DESIGN_NODES contains the design nodes (DV_SHAPE). If you are using Nastran, the
group is defined as set 1 of the file conrod_groups.bdf and can be loaded into Tosca
Structure.gui in the command GROUP_DEF, Read Nastran Set.
4. The mesh smoothing area (MESH_SMOOTH, which can be found at tab Command) should contain
the element group MESH_SMOOTH_ELEMENTS. Using Nastran the elements are defined in set 2
of the file conrod_groups.bdf. All free surface nodes should be fixed. For more details please
refer to the Tosca Structure reference manual.
W2b.22
DV constraint and casting restriction
5. Define a design variable constraint

DOF_CONTROL (DVCON_SHAPE) which should
contain the element group FIXED_NODES. Using
5
Nastran the elements are defined in set 3 of
the file conrod_groups.bdf.
6. Define a cast restriction (LINK_SHAPE with

client SURF_DEMOLD) for one half of the design
area of the conrod (node group
SURF_DEMOLD_POS). Using Nastran the nodes
for SURF_DEMOLD_POS are contained in set 4. 6
The demold direction should be the positive x-
axis (1,0,0) of the global coordinate system
CS_0. Select the node group
SURF_DEMOLD_POS as check group. Assign the
link condition to a design variable constraint
(DV_CON), selecting the same node group.
443
W2b.23
Symmetry for the design nodes
7. Repeat the previous step to define a cast

restriction for the other half of the design area of
the conrod (node group SURF_DEMOLD_NEG).
The demold direction should be the negative x-
axis (-1,0,0) of the global coordinate system
CS_0. Using Nastran the nodes are defined in
set 5.
8. Define symmetry for all design nodes with a

symmetry plane normal to the y-axis through the 8
point (0,0,100). First define a Cartesian
coordinate system with origin in point (0,0,100).
Then define plane symmetry using
LINK_SHAPE: The symmetry plane contains the
origin of the referenced coordinate system and
the normal vector is defined by CLIENT_DIR.
Third, reference LINK_SHAPE in DVCON_SHAPE
for all design nodes.
W2b.24
Objective function and volume constraint
9. Define the objective function as a MINMAX function of the maximal von Mises stresses in the design
area from both loadcases (default). A design response should be defined where the von Mises
stresses in the design node group of all five loadcases are taken into account. Afterwards, define an
OBJ_FUNC using MINMAX.
10.Define a volume constraint. Define a relative target volume of 100% in order to keep the conrod
volume unchanged. First a design response should be defined where the whole volume of the
conrod (ALL_ELEMENTS) is required. Afterwards, define a CONSTRAINT where the relative volume
is 100%.
11.Compose the optimization task (OPTIMIZE) and select the pre-defined definitions. Choose a
SHAPE_CONTROLLER strategy. Please note that all the definitions have to be referenced in the
OPTIMIZE command.
444
W2b.25
Test run
12.Add a TEST_SHAPE (menu item COMMAND |

TEST_SHAPE) command to test the smoothing
of the mesh with MESH_SMOOTH. A maximum
displacement of 4.0 should be specified. The 12
number of increments should be 10. Choose
ONF output format if you want to convert the
data for Tosca Structure.view. Please note that

you should change your filename if you want to
calculate variants with random displacement
(Direction = RANDOM), pure growth (GROW) or
pure shrinking (SHRINK). Select DIRECTION =
GROW for your TEST_SHAPE definition.
13.Save the parameter file under the name

conrod.par.
Start the beam optimization in mode test1 (see
13
the Manual or Tosca–help).
W2b.26
Start optimization
14.Visualize your TEST_SHAPE-results using

Tosca Structure.view. Switch to the module
Tosca Structure.report to create vtfx-sequences.
Choose your parameterfile using the file dialog
next to the JobName field (if it is not already
14
preset). At Result Selection select the file
TEST_SHAPE and all steps (Iter All). Start with

Generate Report.
15.Afterwards, start the complete Tosca Structure

optimization changing the start option type in
Start Tosca Structure module to Type = all.
445
W2b.27
Results
W2b.28
Solution: FEM input and group definitions
! PARAMETER FILE FOR TOSCA OPTIMIZATION TASK ! DESIGN NODE GROUP

GROUP_DEF
! INPUT OF THE FEM FILE ID_NAME = DESIGN_NODES
FEM_INPUT TYPE = NODE
ID_NAME = MY_INPUT_FILES Format = LIST
FILE = conrod.bdf LIST_BEGIN
END_ 1,181-201,207-211,230,232-236,
...
END_
! GROUP OF MESH SMOOTH ELEMENTS

GROUP_DEF
ID_NAME = MESH_SMOOTH_ELEMENTS
TYPE = ELEM
Format = LIST
LIST_BEGIN
3297,31689,31843,31884,31893,31918,
...
END_
446
W2b.29
Solution: Group definitions
! DEMOLDABLE NODES IN POSITIVE X-DIRECTION ! GROUP OF FIXED_NODES NODE GROUP

GROUP_DEF GROUP_DEF
ID_NAME = SURF_DEMOLD_POS ID_NAME = FIXED_NODES
TYPE = NODE TYPE = NODE
Format = LIST FORMAT = LIST
LIST_BEGIN LIST_BEGIN
1,236,252-261,508,510,511,513,514, 1162,1450-1471,1473-1483,1485-
... ...
END_ END_
! DEMOLDABLE NODES IN NEGATIVE X-DIRECTION ! COORDINATE SYSTEM FOR SYMMETRY CONTROL

GROUP_DEF CS_DEF
ID_NAME = SURF_DEMOLD_NEG ID_NAME =
TYPE = NODE ORIENTATION_R_1_SYMMETRY_CONTROL
Format = LIST DEF_TYPE = LOCAL
LIST_BEGIN CS_TYPE = RECTANGULAR
181-201,207-211,230,232-235,251, CS_REF = CS_0
... ORIGIN_123 = 0,0,100
END_ ROTATION_321 = 0,0,0
END_
W2b.30
Solution: Design area and DV constraints (fixations)
! DESIGN AREA ! DOF CONTROL

DV_SHAPE DVCON_SHAPE
ID_NAME = DESIGN_AREA ID_NAME = DVCON_SHAPE_DOF_CONTROL
ND_GROUP = DESIGN_NODES ND_GROUP = FIXED_NODES
END_ CHECK_BC = NO
CHECK_DOF = CS_0,FIX,FIX,FIX
FEASIBLE_START = YES
END_
! ASSIGN SYMMETRY RESTRICTIONS

DVCON_SHAPE
ID_NAME =
DVCON_SHAPE_SYMMETRY_CONTROL
CHECK_BC = NO
CHECK_LINK =
LINK_SHAPE_SYMMETRY_CONTROL
END_
447
W2b.31
Solution: Casting restrictions
! DEMOLDING IN POSITIVE X-DIRECTION ! PLANE SYMMETRY CONDITIONS

LINK_SHAPE LINK_SHAPE
ID_NAME = LINK_SHAPE_DEMOLD_POS ID_NAME = LINK_SHAPE_SYMMETRY_CONTROL
CLIENT = SURF_DEMOLD CLIENT = PLANE_SYM
MASTER = CRIT_1 MASTER = CRIT_1
DEMOLD_DIR = 1, 0, 0 TOL = 0.01,0.01,0.01
CS = CS_0 CLIENT_DIR = 0.,1.,0.
ANGLE = 0.0 CS = ORIENTATION_R_1_SYMMETRY_CONTROL

CHECK_GROUP = SURF_DEMOLD_POS END_
END_
! DEMOLDING IN NEGATIVE X-DIRECTION

LINK_SHAPE
ID_NAME = LINK_SHAPE_DEMOLD_NEG
CLIENT = SURF_DEMOLD
MASTER = CRIT_1
DEMOLD_DIR = -1, 0, 0
CS = CS_0
ANGLE = 0.0
CHECK_GROUP = SURF_DEMOLD_NEG
END_
W2b.32
Solution: Assigning restrictions
! ASSIGN DEMOLDING RESTRICTIONS IN POSITIVE

X-DIRECTION
DVCON_SHAPE
ID_NAME = DVCON_SHAPE_DEMOLD_POS
CHECK_BC = NO
ND_GROUP = SURF_DEMOLD_POS
CHECK_LINK = LINK_SHAPE_DEMOLD_POS
END_
! ASSIGN DEMOLDING RESTRICTIONS IN NEGATIVE

X-DIRECTION
DVCON_SHAPE
ID_NAME = DVCON_SHAPE_DEMOLD_NEG
CHECK_BC = NO
ND_GROUP = SURF_DEMOLD_NEG
CHECK_LINK = LINK_SHAPE_DEMOLD_NEG
END_
448
W2b.33
Solution: Design responses for different loadcases
! VON MISES STRESS AS DESIGN RESPONSE FOR ! VON MISES STRESS AS DESIGN RESPONSE FOR
THE FIRST LOADCASE THE THIRD LOADCASE
DRESP DRESP
ID_NAME = DRESP_MISES_LC1 ID_NAME = DRESP_STRESS_LC3
DEF_TYPE = SYSTEM DEF_TYPE = SYSTEM
TYPE = SIG_MISES TYPE = SIG_MISES
ND_GROUP = DESIGN_NODES ND_GROUP = DESIGN_NODES
LC_SET = ALL,1,All LC_SET = ALL,3,All

GROUP_OPER = Max GROUP_OPER = Max
END_ END_
! VON MISES STRESS AS DESIGN RESPONSE FOR ! VON MISES STRESS AS DESIGN RESPONSE FOR
THE SECOND LOADCASE THE FOURTH LOADCASE
DRESP DRESP
ID_NAME = DRESP_STRESS_LC2 ID_NAME = DRESP_STRESS_LC4
TYPE = SIG_MISES TYPE = SIG_MISES
ND_GROUP = DESIGN_NODES ND_GROUP = DESIGN_NODES
LC_SET = ALL,2,All LC_SET = ALL,4,All
GROUP_OPER = Max GROUP_OPER = Max
END_ END_
W2b.34
Solution: Volume
! VON MISES STRESS AS DESIGN RESPONSE FOR ! VOLUME AS DESIGN RESPONSE

THE FIFTH LOADCASE DRESP
DRESP ID_NAME = DRESP_VOLUME
ID_NAME = DRESP_STRESS_LC5 DEF_TYPE = SYSTEM
DEF_TYPE = SYSTEM TYPE = VOLUME
TYPE = SIG_MISES EL_GROUP = ALL_ELEMENTS
ND_GROUP = DESIGN_NODES GROUP_OPER = Sum
LC_SET = ALL,5,All END_

GROUP_OPER = Max
END_ ! DEFINITION OF THE VOLUME RESTRICTIONS
CONSTRAINT
ID_NAME = MY_CONSTRAINT
MAGNITUDE = REL
EQ_VALUE = 1.0
DRESP = DRESP_VOLUME
END_
449
W2b.35
Solution: Mesh smoothing and optimization task
! OBJECTIVE FUNCTION IN COMBINATION WITH THE ! MESH SMOOTH

STRESS DESIGN RESPONSES MESH_SMOOTH
OBJ_FUNC ID_NAME = MY_MESH_SMOOTH
ID_NAME = MY_OBJ_FUNC EL_GROUP = MESH_SMOOTH_ELEMENTS
TARGET = MINMAX END_
DRESP = DRESP_STRESS_LC1, ,
DRESP = DRESP_STRESS_LC2, , ! COMBINATION OF MESH SMOOTH, OBJECTIVE
DRESP = DRESP_STRESS_LC3, , FUNCTION, DESIGN AREA AND CONSTRAINTS

DRESP = DRESP_STRESS_LC4, , OPTIMIZE
DRESP = DRESP_STRESS_LC5, , ID_NAME = MY_OPTIMIZATION_TASK
END_ MESH_SMOOTH = MY_MESH_SMOOTH
OBJ_FUNC = MY_OBJ_FUNC
DV = DESIGN_AREA
DVCON = DVCON_SHAPE_DOF_CONTROL
DVCON = DVCON_SHAPE_DEMOLD_POS
DVCON = DVCON_SHAPE_DEMOLD_NEG
DVCON = DVCON_SHAPE_SYMMETRY
CONSTRAINT = MY_CONSTRAINT
END_
W2b.36
Solution: Test run
! DEFINITION OF A STOP CONDITION

STOP
ID_NAME = MY_STOP
ITER_MAX = 5
END_
! DEFINITION OF THE TEST OPTIMIZATION

TEST_SHAPE
INCREMENT = 10
DIRECTION = GROW
FILE_NAME = TEST_SHAPE
FORMAT = ONF
OPTIMIZE = MY_OPTIMIZATION_TASK
DISPLACEMENT = 4.0
END_
450
Notes
451
Notes
452
W3.1
Sizing Optimization
Procedure Sizing Optimization
The following describes the general procedure for defining an optimization task. These procedures are
supported by the command tree in Tosca Structure.pre screen of Tosca Structure.gui (GUI), and Tosca
ANSA environment. The CAE analysis model must previously be completely defined.
Analysis Model
1. Question: Which file(s) contains the FE- model for the optimization?
TAE: MODEL_LINK | FILE item, Edit, choose your model file.
GUI: Choose your model file in FEM_INPUT.
W3.2
Design area
2. Question: Which part of the FE model should be selected as the design space?
Procedure: Assign an element group to the design area.
GUI: Choose or define the element group for the selected design area (GROUP_DEF) and define the
design variables (DV_SIZING).
3. Question: Are there elements in the design space which have to have certain restrictions (e.g.
symmetry and manufacturing restrictions)? How can these restrictions be described?
Procedure: Define design variable constraints for element group.
TAE: DESIGN_AREA | DV_CONSTRAINTS | New | <type of restriction> command,
choose predefined group or select new group. Evtl. define link conditions using modules buttons.
GUI: Choose or define element groups with restrictions (GROUP_DEF). Define the restrictions using
DVCON_SIZING command.
TAE: DESIGN_AREA | DV_CONSTRAINTS | New | SYMMETRY_CONTROL command, choose
predefined group or select new group, also define origin and coordinate system.
GUI: Create a LINK_SIZING condition and reference it in the restriction command.
453
W3.3
Objective and constraint
Objective Function
5. Question: Which terms describe the values to be optimized? Should these values be minimized
or maximized or otherwise combined using the minmax formulation? Are any special weighting
factors or target values required?
Procedure: Choose the terms for optimization (design responses) and the target type.
TAE: OBJ_FUNC_ITEM_1 | New | <term for optimization> command; apply Edit

command on OBJ_FUNC_ITEM_1 to choose whether the objective function has to be minimized,
maximized or the combined term minmax should be used.
Constraint
6. Question: Which terms describe the constraint? What value should the constraint have?
Procedure: Choose the term for the constraint and set the target value or upper/lower boundary.
TAE: CONSTRAINTS | New | <term for constraint> command.
W3.4
Saving Task
job?
Procedure: If necessary, make the additional definitions and prepare the optimization job.
Stop Condition
6. Question: Should the stop condition be modified?
Procedure: Modify stop condition
TAE: GLOBAL_STOP_CONDITION , apply Edit command and change number of iterations.
GUI: STOP.
Completion
7. Question: Is all required data specified?
TAE: Click twice on OUTPUT item and enter the jobname (or proceed with the default jobname);
rightclick on the previously defined jobname, then click Update to write the parameter file.
GUI: Save as <jobname>.par
454
Notes
455
Notes
456
W3a.1
Workshop Example Sizing Optimization – Holder
Task Maximize stiffness

Keywords Cluster groups, free sizing, upper/lower bounds
For sheet metal structures ideal sheet thicknesses according to the existing load and boundary
conditions have to be derived. With Tosca Structure, it is possible to carry out sizing optimization in
the existing CAE environment. Within this process shell thicknesses are calculated automatically to
obtain optimal sheet metal structures. In this section a standard sizing optimization example is set
up.
30 min Sizing for chassis components
W3a.2
Optimization Task
The optimization task is to find a structure with maximum stiffness for an holder for a gear shift control
for both static load cases. Additionally, a weight constraint of maximum 100 % of the initial weight
should be considered.
The shell thicknesses should vary between an absolute value of 0.1 and 3.0.
Four variants of the optimization can be performed:
• Free sizing (i.e. the shell thicknesses of all design elements can be modified independently)
• Clustering with horizontal areas (the design area is split horizontally into several areas in which the
shell size will vary simultaneously)
• Clustering with vertical areas (the design area is split vertically)
• Clustering with "circular" areas (the design area is split into several "round" areas) - this cluster
variant is motivated by the result of the free sizing.
457
W3a.3
Model
The component to be used within the tutorial

represents a holder for a gear shift control. The
model is meshed with linear homogenous shell
elements with an initial thickness of 3.5.
Loads and boundary conditions:
1. bending loadcase with a load Fx = -2500N at

node 5
2. torsional moment Mx = 80000 Nmm at node 5
3. all drill holes are fixed in all directions
The design area consists of the elements in the
interior of the structure, colored yellow in the figure.
The elements of the design area are combined to a Original design of a holder with loads and
group design_all which can later be used for the design area (yellow)
optimization.
W3a.4
Cluster groups
To assure easy manufacturing, the final shell

thickness must be identical in certain (connected)
areas. These areas are combined to “cluster
groups”. For further tasks using clustering the
design domain is split into several subgroups as
described below:
Cluster groups:
• Horizontal clustering groups named DES_HOR1
(on the top) until DES_HOR12 on the left,
• Vertical clustering groups named DES_VER1
(left group) until DES_VER6 in the middle and
• Circular clustering groups named DES_RING1
(outer ring) until DES_RING3 on the right.
458
Workflow using Tosca ANSA Environment
1 2 3
Model import Design area Optional Clustering
holder.<ext> DESIGN_ALL CLUSTER_GROUPS
6 5 4
Save task Volume constraint Objective function
holder.par COMPLIANCE
7 8 9
Start task Post-processing Report generation
Tosca Structure.report View Report
W3a.6
Model import

2
Structure Task | SIZING. Click the
Expand-button to show the whole tree of the
optimization task.
3. Choose the FE input file for the optimization

task. Select PRE-PROCESSING | 3
MODEL_LINK | FILE | Edit, load the model
holder.ext (ext=inp, bdf, dat, ...) from the
subdirectory <solvername>/sizing and
choose the solver that matches your input file.
4. Right click the item named after the file you 4

have just chosen and select Update to show
the model in the main window.
459
W3a.7
Design Area
The design area contains a specific element group:
5. Choose the design variables for the optimization

(PRE-PROCESSING |
SIZING_OPTIMIZATION | DESIGN_AREA |
Edit). In the EL_GROUP dropdown menu
choose GROUP_DEF and type “?” in the field

GROUP_DEF. In the pop-up window choose the
group DESIGN_ALL.
W3a.8
Design Variable Constraints: Thickness bounds
6. For defining a thickness restriction in the design

area click PRE-PROCESSING |
SIZING_OPTIMIZATION |
THICKNESS_BOUNDS and define a lower and
upper bound of 0.1 and 3.0 respectively in the
corresponding fields.
Select Magnitude = ABS for absolute magnitude.
Also select GROUP_DEF, type “?” in the field and
choose DESIGN_ALL group from the list.
460
W3a.9
Optional: Design Variable Constraints: Clustering (1/2)
It is always recommended to perform a first sizing optimization without too much additional constraints
to use the maximum design flexibility for the task. Influenced by a first design proposal clustering may
be introduced. With clustering, certain areas of the model are grouped to keep the same shell thickness
during the optimization. Clustered areas may later be manufactured by sheets of constant thickness. An
example is the optimization of an assembled sheet structure like a car body, where each sheet has one
thickness.
7. To define cluster groups, select PRE-

PROCESSING | SIZING_OPTIMIZATION |
CLUSTER_GROUPS you have to define each
cluster group individually.
W3a.10
Optional: Design Variable Constraints: Clustering (2/2)
8. In the pop-up window, type “?” in the

GROUP_DEF field. For horizontal clustering
choose the groups DES_HOR1 until DES_HOR12,
for vertical clustering choose the groups
DES_VER1 until DES_VER6 and for circular
clustering choose the groups DES_RING1 until
DES_RING3.
461
W3a.11

PRE-PROCESSING |
OBJ_FUNC_ITEM_1 | New | COMPLIANCE. 9
The compliance is equivalent to the total strain
energy of the structure. In the pop-up window,
type “?” in the field GROUP_DEF and select the

group DESIGN_ALL.
10
10.In the field LC_SET type “?”, then click MORE and
select STATIC in the APPROACH field. Then
write “1” into the LOADCASE field. Click OK.
11.Create another objective function repeating step

7 and 8 (just enter “2“ in the LOADCASE field).
11
W3a.12
12.After defining the compliance as a design

now choose its target. In this case the
compliance should be minimized corresponding
to maximizing the stiffness. Choose
PRE-PROCESSING |
to MINMAX.
462
W3a.13
Volume constraint
13.Define a volume constraint (PRE-PROCESSING

| SIZING_OPTIMIZATION | CONSTRAINTS
| VOLUME_CONSTRAINT | Edit). Define a
relative target volume of 100%. As GROUP_DEF
13
select DESIGN_ALL, then click OK.
14.The optimization task is now completed and the

parameter file can now be saved. Click twice at
Output under PRE-PROCESSING and enter the
new name “holder” for the optimization job (and
thus the parameter file). To save the parameter 14
file choose PRE-PROCESSING | holder |
Update.
15.Save the optimization database including all 15

File | Save as in the main menu (use a
W3a.14



tosca <name>.par
463
W3a.15
Post-processing
17.After the optimization click POST-PROCESSING

| GENERATE_REPORT_FILE |
SIZING_THICKNESS | Edit and select
ELEMENT_THICKNESS or
ELEMENT_DELTA_THICKNESS in the 17
TYPE_PROPERTY dropdown list. Delete the
value 1. in the FILTER MAX field (the

maximum thickness displayed in the report,
elements with higher thickness values are
hidden).
18.Check the results visually after optimization.

Choose POST-PROCESSING |
SIZING_THICKNESS | Update. The 18
generation of the output file is set automatically.
Navigate the results by clicking the start, stop,
forward and backward button.

1 2 3
Model import Design area Optional Clustering
holder.<ext> DESIGN_ALL
6 5 4
Optimization task Constraints Objective function
SIZING_ DRESP_VOLUME DRESP_STRAIN_
SENSITIVITY ENERGY
7 8 9
Save & start task Post-processing Report generation
Tosca Structure.report View Report
464
W3a.17
Preprocessing
In the following detailed description the setup of a

typical sizing optimization task with Tosca
Structure.gui is shown.
Starting Tosca Structure Preprocessor

Tosca Structure.gui starts and the Tosca

Structure.pre module is displayed. Click on the
Tree button to change the view of the optimization
task structure on the left side to tree mode.
W3a.18
Model input
1. Select the item FEM_INPUT from the

optimization task tree. The FEM_INPUT menu
2. In the Input Files area, click Add to select

the model for the optimization. The Open dialog
2
appears.
3. In the Open dialog, choose the FE model for

your solver (holder.<ext> where <ext> is the
extension your FE-solver uses.) and press 3
Open. The model name with its full path appears
in the The finite element input files
field.
4. Left click on Create to add the item

4
MY_INPUT_FILES to the optimization task tree.
465
W3a.19
Design area
In sizing optimization, the design area denotes the

set of elements that may be changed (whose
thicknesses are modified) during the optimization.
1. Select the item DV_SIZING from the

optimization task tree. The DV_SIZING menu
2. Choose the group DESIGN_ALL from the

dropdown list next to EL_GROUP and click
Create to add the item MY_DV_SIZING to the
optimization task tree.
2
W3a.20
Thickness settings
Please note that the ID_NAME is a special mark of

any component of the optimization task. The
ID_NAME must be unique for each component.
Using the ID_NAME you can select between
different components of the same type during the
optimization setup. If no other component of the
same type appears in the optimization task, the

change of the ID_NAME is optional and the Tosca
Structure default ID_NAME can be used.
3. For defining a thickness restriction for the

selected element group activate the radio button
Thickness Bounds and define a lower and
upper bound of 0.1 and 3.0 respectively in the
corresponding fields.
Select Magnitude = ABS for absolute magnitude.
466
W3a.21
Optional: Cluster groups (1/2)
It is always recommended to perform a first sizing optimization without too much additional
constraints to use the maximum design flexibility for the optimization. Influenced by a first design
proposal cluster groups may be introduced. With cluster groups, certain areas of the model are
grouped to keep the same shell thickness during the optimization. Cluster groups may later be
manufactured by sheets of constant thickness. An example is the optimization of an assembled
sheet structure like a car body in white, where each sheet has one thickness.
1. Select the item DVCON_SIZING from the

optimization task tree. The DVCON_SIZING
menu appears on the right.
W3a.22
Optional: Cluster groups (2/2)

example DVCON_CLUSTERING. Activate the
button Clustering and Select all element
2
groups for which elements the thicknesses shall
remain the same.
3. For horizontal clustering choose the groups

DES_HOR1 until DES_HOR12, for vertical
clustering choose the groups DES_VER1 until
DES_VER6 and for circular clustering choose the
groups DES_RING1 until DES_RING3.
467
W3a.23
Design response: volume
In order to specify optimization target and constraints you must first define design responses. The
design responses are assigned to output parameters from the FE analysis. In this example design
responses for the volume and the strain energy will be needed.
1. Select the item DRESP from the optimization
task tree. The DRESP menu appears on the 1
right.
DRESP_VOLUME, and choose the type VOLUME
in the field Type of the Base category.
3. Choose DESIGN_ALL from the
2
Element/Elementgroup dropdown list and
set the Group Operator to Sum to build the
sum of the volumes of each element in the
model. Thus the whole volume of the structure is
determined.
Click Create to add the design response 3
DRESP_VOLUME to the optimization task tree.
W3a.24
Design response: sum of strain energy
4. Repeat step 1 to define another design

response.
5. Type a ID_NAME for the new design response,

for example DRESP_STRAIN_ENERGY_1, in the
corresponding field and choose

Stress/Strain from the Category dropdown 5
list and in the Type field choose the type
STRAIN_ENERGY.
6. Activate the Element/Elementgroup button

and select ALL_ELEMENTS from the 6
7. Set the Group Operator to Sum.
468
W3a.25
6. Activate the Element/Elementgroup radio

button and select ALL_ELEMENTS from the 6
7. Set the Group Operator to Sum.

8. Click Add LC to select the load case for the

design response. The Select Loadcase 8
dialog appears.
9. In the Select Loadcase dialog, choose

Static as Analysis Type and enter 1 as
Loadcase Number. Click OK: The new entry
9
appears in the Loadcase Selection field.
W3a.26
10.Click Create to add the design response

DRESP_STRAIN_ENERGY_1 to the optimization 10
task tree.
11.Repeat steps 4-10 to define a second design

response for the strain energy of loadcase 2.
469
W3a.27
Objective function

settings.
1. Select the item OBJ_FUNC from the optimization

task tree. The OBJ_FUNC menu appears on the
right. 1
2. Click Add Dresp to select a design response

for the objective function. The Select Design
Responses dialog appears. 2
3. In the Select Design Responses dialog,

activate the design responses
DRESP_STRAIN_ENERGY_1 and
DRESP_STRAIN_ENERGY_2 and click Ok. The 3
window closes and the selected design
responses appear in the field.
W3a.28
Objective function
4. Select the button MinMax next to Target and

click Create to add the item MY_OBJ_FUNC to
the optimization task tree.
470
W3a.29
Constraint

optimization.
1. Select the item CONSTRAINT from the

optimization task tree. The CONSTRAINT menu
1
appears on the right.

VOLUME_CONSTRAINT, and choose the design
response DRESP_VOLUME from the Design 2
Response dropdown list.
3. Select the button Relative next to Type to set

the constraint type and push the slider to 100 or 3
type the value in the field manually.
W3a.30
Constraint
4. Select the less or equal radio button next to

Constraint Type, thus the target volume for
the optimization is restricted by 60 percent of the
original volume, and click Create to add the
item VOLUME_CONSTRAINT to the optimization
task tree.
471
W3a.31
Optimization task
1. Select the item OPTIMIZE from the optimization

task tree. The OPTIMIZE menu appears on the
1
right.
2. Select SIZING_SENSITIVITY from the

Strategy dropdown list to choose the
optimization strategy. Design area and objective 2

function are selected automatically.
3. Click Add next to the DV Constraints field to

add the design variable constraints to the
optimization task. The Select Design 3
Variable Constraints dialog appears.
W3a.32
Optimization task
4. In the Select Design Variable

Constraints dialog, activate the design
variable constraints DVCON_SIZING and 4
DVCON_CLUSTER and press Ok. The
corresponding items appear in the DV
Constraints field.
5. Click Add next to the Constraints field to add

the constraints to the optimization task. The 5
Select Constraints dialog appears.
6. Activate VOLUME_CONSTRAINT and press Ok.

The corresponding items appear in the
Constraints field. 6

MY_OPTIMIZATION_TASK to the optimization 7
task tree.
472
W3a.33
Saving Tosca Structure parameter file
The Tosca Structure parameter file contains ASCII

commands which define all settings for the
optimization task.
1. Select File from the main menu and pick Save

As from the File dropdown list. The Save As
dialog appears. 1
2. In the Save As dialog choose a name for the

optimization task, enter the filename in the field
below and press Save As. The file
automatically receives the extension .par and 2
becomes the parameter file for Tosca Structure.
W3a.34
Start optimization
1. Switch to the Start Tosca Structure

module from the Module dropdown list in the 1
upper right corner.
2. Choose all from the Type dropdown list . This

option includes a preprocessing test and the

optimization run. 2
3. Select the solver (Abaqus or ANSYS) of your

choice from the Solver dropdown list.
3
473
W3a.35
Start optimization
4. Click Start Tosca to start the optimization.

Status information about the optimization run is
4
displayed in the field below.
5. After approx. 15 design cycles the optimization

run is finished and the status Tosca job
5
finished is displayed.
W3a.36
Post-processing
Viewing the intermediate results using Tosca

Structure.report.

1. Switch to the Tosca Structure.report module

corner.
2. Select the results by activating the buttons to the

left of the Results ELEMENT_THICKNESS and
ELEMENT_DELTA_THICKNESS. A standard 2
report is available in the directory <jobname> |
TOSCA_POST after each optimization which can
be visualized using Tosca Structure.view.
474
W3a.37
Post-processing
3. To see every design cycle click in the field below

Iter (result for ELEMENT_THICKNESS) and 3
select All from the Iter dropdown menu
(default). Repeat this for the result
ELEMENT_DELTA_THICKNESS (second field
below Iter).
4. Click Generate Report to start the generation

of the result file. Status information about the file
generation is displayed in the field below.
4
5. When the file generation is completed a

message about the successful job ending is 5
displayed in the status field.
W3a.38
Post-processing

dialog appears.
7. In the open dialog select the generated .vtfx

file and press Open. Tosca Structure.view starts.
8. The animation starts and stops by clicking on

The described example is generated using the
FE solver Abaqus. Please note that slight 8
differences in the optimized design are possible
for the different solvers. However the design
conception remains the same.
475
W3a.39
Report Generation

dialog appears. Open your vtfx file.
2. Under View | Viewports you can select up

to four viewports in different positions. Choose

two viewports: You see the relative material 2
distribution of your model on the left side of the
split window. The right side is still empty.
3. Select Case 2 in the Table of Cases and

drag it onto the right part of the window. Another
possibility is to rightclick at case two and select 3
Assign Case In View | View 1.
W3a.40
Report Generation
4. To move both views synchronously select

View | Synchronous Navigation.
4
5. Click at the left model: Now, this model is

activated and its frame becomes green. Choose

the last iteration step by using the Step
Backward button and move both views
synchronously in an appropriate position (hold 5
Ctrl and the appropriate mouse button while
moving the mouse).
6. To generate a report activate the left window and

click Capture active view in the quick
access toolbar or select File | Capture 6
Situation.
476
W3a.41
Report Generation
7. A new window opens: Enter an appropriate

description, select Image as Situation type for
capturing and press OK. A new window named 1
GLview Report Builder opens. Keep this
window open until the end of this chapter!
8. In GLview Report Builder window click

File | Save Repository as to save the
chosen positions to a file. If you close the Tosca
Structure Report Builder window, you can
3
continue by opening your saved repository.
9. Switch back to Tosca Structure.view window.

Repeat steps 6 and 7, but select 3D model as
situation type for capturing.
4
W3a.42
Report Generation
10.In Tosca Structure Report Builder window both

model situations are now listed. By rightclicking
at the situation you can delete it or change the
order.
11.Switch back to Tosca Structure.view window.

Now, select the right window and click Quick
Capture active view in the quick access 11
toolbar or select File | Quick Capture
Situation.
12.The last setting is used for capturing, thus, the

smoothed optimization result is loaded as 3D
model into the Tosca Structure Report Builder.
477
W3a.43
Report Generation
13.Load the optimization result

ELEMENT_DELTA_THICKNESS (right window in
Tosca Structure.view) as image into the Tosca
Structure Report Builder. (Look at step 6 and 7,
if necessary, and do not forget to activate the
window).
14.In Tosca Structure.view doubleclick at

CONSTRAINT_NORM in the Table of Cases.
This case cannot be displayed with another
viewport. By selecting Capture Situation
or Capture active view load the plot as
Image into the Tosca Structure Report Builder. 14
15.Repeat step 13 with the same plot as Table.
16.Repeat step 12,13 and 14 with the objective

function (OBJ_FUNC in the Table of Cases).
W3a.44
Report Generation
17.Now there should be 8 entries in the Situations

window. Doubleclick at one entry to deactivate
this situation for the transfer. The same effect is
given by rightclicking and selecting
Deactivate. 17
18.Transfer these situation into a PowerPoint

document by clicking
File | Create PowerPoint Report.
18
478
W3a.45
Report Generation
19.For template selection click Browse and select

TOSCA_Structure_PowerPoint_Template
_GenericTags.pptx under
<directory>\report\Templates. Select a file
location and the media type. Click OK.
W3a.46
Report Generation
20.A PowerPoint file is created. The order of figures

and tables is determined by the template.
21.For transferring into a word file use Create

WordReport and the template
TOSCA_Structure_Word_Template_
GenericTags.docx, for a HTML file

Create HTMLReport and the template
TOSCA_Structure_HTML_Template_
GenericTags.html.
As the vtfx plug-in only works in combination
with internet explorer, you can choose Video
and image as Media type for other browsers.
479
W3a.47
Result Discussion
A free sizing optimization without additional

restrictions leads (naturally) to the best results with
a reduction of the maximum displacement by 45%.
An optimization with cluster groups (circular in the
case at the bottom), required by manufacturing, still
leads to an improvement of 30%.
Displacement magnitude: initial model,

optimization result with free shell size
modification and with circular cluster groups
(top to bottom)
W3a.48
Result for different cluster groups
Shell thickness distribution in the design area:

The differences in the results of the optimization without clustering and with the several kinds of cluster
groups are obvious. Furthermore, the optimization result with vertical cluster groups indicates the
asymmetric load.
Free sizing optimization horizontal cluster groups vertical cluster groups circular cluster groups
480
Notes
481
Notes
482
W4.1
Procedure Bead Optimization
The following slides describe the general procedure for the definition of an optimization task. These
procedures are supported by the task manager in Tosca ANSA environment (TAE) as well as the
command tree in Tosca Structure.pre screen of Tosca Structure.gui (GUI). The analysis model must be
completely defined in advance.
30 min
W4.2
Bead Optimization (1/5)
Analysis Model
1. Question: Which file(s) contain(s) the FE- model for the optimization?
TAE: MODEL_LINK | FILE | Edit, choose your model file.
GUI: Choose your model file in FEM_INPUT
Design Area
2. Question: Which surface area of the FE model should be selected regarding bead optimization?
Procedure: Assign node group with surface nodes to design area.
GUI: Choose or define the node group with the surface nodes of the selected design area
(GROUP_DEF) and define the design variables (DV_BEAD).
483
W4.3
3. Question: Are there nodes in the design area that are subject to certain restrictions? How can these
restrictions be described?
Procedure: Define design variable constraints for node group. For sensitivity based bead
optimization nodes must be constrained in maximum positive and negative displacement.
TAE: DESIGN_AREA | DV_CONSTRAINTS | New | <type of restriction>, choose
predefined group or select new group for this restriction. Evtl. define link conditions using modules
buttons.
GUI: Choose or define node groups with common restrictions (GROUP_DEF). Define the restrictions
using DVCON_BEAD.
TAE: DESIGN_AREA | DV_CONSTRAINTS | New | SYMMETRY_CONTROL.
GUI: Create a LINK_BEAD condition and reference it in a restriction command (DVCON_BEAD).
LINK_BEAD is not supported by sensitivity based bead optimization.
W4.4
Objective Function
maximized or otherwise combined?
Procedure: Choose terms for optimization (design responses) and target.
TAE: OBJ_FUNC_ITEM_1 | New | <term for optimization>, OBJ_FUNC_ITEM_1 |
Edit for choice of target (min, max) .

Constraint
6. Question: Which design response describes the constraint? Which value should the constraint
have?
Procedure: Choose term for constraint and set target value or upper/lower boundary.
TAE: CONSTRAINTS | New | <term for constraint>.
484
W4.5
Optimization Task
job?
Procedure: If necessary complete any additional required definitions and prepare the optimization
job.

Procedure: Choose corresponding strategy.
TAE: Chosen in the beginning with your task (BEAD_CONTROLLER, BEAD_CONTROLLER_MST or
BEAD_SENSITIVITY).
GUI: Set the correct value to either BEAD_CONTROLLER, BEAD_CONTROLLER_MST or
BEAD_SENSITIVITY in OPTIMIZE subcommand STRATEGY.
W4.6
Stop Condition
9. Question: Should the optimization stop after a number of iterations (or certain other conditions)?
Procedure: Define a stop condition
TAE: GLOBAL_STOP_CONDITION | Edit and change number of iterations.
GUI: STOP.
Check Run
10.Question: Would prior testing of the restriction definitions be useful?
Procedure: Apply test displacements
TAE: BEAD_OPTIMIZATION... | New | TEST_BEAD or CHECK_INPUTS | New |
TEST_BEAD_CHECK.
GUI: TEST_BEAD.
Completion
11.Question: Has all the required data been specified?
TAE: Click OUTPUT twice and enter jobname
GUI: Save as <jobname>.par.
485
486
Notes
487
Notes
488
W4a.1
Workshop Example Bead Optimization – Hood
Task Maximize stiffness

Keywords BEAD, Tosca Structure wizard
Sheet metal structures can be stiffened by creating bead stiffeners. The Tosca Structure.bead module
helps to find the optimum location and orientation during bead pattern designing.
30 min
W4a.2
Hood
Model
The present model is a simple hood-like shell
structure which is loaded with two separate
loadcases. In the first optimization task we only
consider the structural response of loadcase 2 (F2).
First optimization task

It is assumed that the pulling force (F2) is the most
critical loadcase. Initially, the beads of the hood boundary conditions and stress/displacement
leading to the highest stiffness for this loadcase plot of the initial design for loadcase 1 and 2,
have to be determined in the optimization. respectively.
489
1 2
hood.<ext> ALL_NODES
3
Objective function
minimize compliance
4
Constraints
Bead height of 0.5
Bead width of 3.0
5
Save optimization
task
6 7
run
W4a.4
Create bead controller task and load input model
1. Select File | New to open a new file and

press Discard in the Confirmation window.
Structure Task | BEAD_CONTROLLER.
Select Expand to show the whole tree of the
optimization task.
3. Choose the FE input file for the topology

optimization task. Select PRE-PROCESSING |
MODEL_LINK | Edit and choose the solver 3
that matches your input file. Select
PRE-PROCESSING | MODEL_LINK | FILE
| Edit and load the model ”hood.ext“
(ext=inp, bdf, dat, ...) from the subdirectory
<solvername>/bead. Right click the item named
after the file you have just chosen and select
Update to show the model in the main window.
490
W4a.5
Design area and design variable constraints
4. Choose the design variables for the bead

optimization (PRE-PROCESSING |
BEAD_OPTIMIZATION_CONTROLLER |
DESIGN_AREA | Edit). All nodes are allowed
to be modified in the optimization.
5. The boundary conditions of the FE model have

to be imported with the model data. The
boundary conditions on the nodes in the FE-
model are applied for defining constraints on the 5
design nodes in the optimization. Select
PRE-PROCESSING |
DV_CONSTRAINTS | New | CHECK_BC and
switch the CHECK_BC operator to YES.
W4a.6
Objective function

PRE-PROCESSING |
OBJ_FUNC_ITEM_1 | New | COMPLIANCE.
We only want to optimize with respect to the 6
structural response of loadcase number 2 (the
pulling force), which must be referenced in the

design response definition. In the LC_SET field
type ”?“ to call the LC_SET dialog. In the
LC_SET dialog, add a loadcase by selecting
MORE and enter 2 in the LOADCASE field.
7. After defining the compliance as a design
now choose the target of the design response.
In this case the compliance should be 7
minimized. Choose PRE-PROCESSING |
OBJ_FUNC_ITEM_1 | Edit. The target of
the objective function is set to MIN.
491
W4a.7
Constraint
8. Define a constraint on the bead height. Choose

PRE-PROCESSING |
CONSTRAINTS | New | 8
BEAD_HEIGHT_CONSTRAINT. Switch the
magnitude to ABS and enter the value of 0.5 for
the maximal allowed bead height.

9. Define some additional parameters to the
optimization task. Choose PRE-PROCESSING |
BEAD_OPTIMIZATION_CONTROLLER | New
| SETTINGS and enter the value of 3.0 for the
bead width.
10.The definitions for the optimization are now
finished and the parameter file can now be
saved. Click twice on Output under PRE-
PROCESSING and enter the new name hood for 10
the parameter file. The Output field is renamed
to hood. To save the parameter file choose
PRE-PROCESSING | hood | Update.
W4a.8
Saving and starting optimization task


TOSCA.OUT or optimization_report.csv (in the 12
tosca <name>.par
492
W4a.9
Post-processing
13.Generate result file after the optimization has

ended. Choose POST-PROCESSING |
GENERATE_REPORT_FILE | BEAD_DISP | 13
Edit. There are two types of vtfx visualization
plots for bead optimization results; the plot of the
nodal displacements corresponding to the
change in the design variables (NODAL

DISPLACEMENT (BEAD)) or the plot of the
controller input which shows the change in the
objective function for each node (NODAL
CONTINUOUS (BEAD)). You can specify the
type of your plot and click OK. Update
BEAD_DISP (BEAD_CTRL if you selected
NODAL CONTINUOUS) and the POST_FILE will
be generated. Afterwards the viewer opens
automatically. You can also open the viewer by
choosing POST-PROCESSING |
VTF_VISUALIZATION | View.
Workflow using Tosca structure.gui
1 2
hood.<ext> ALL_NODES
3
Objective function
minimize compliance
4
Constraints
Bead height of 0.5
Bead width of 3.0
5
Save optimization
task
6 7
run
493
W4a.11
Create bead controller task and load input model
1. Define a bead optimization task using the Tosca

Structure wizard
1
2. Select the input file hood.<ext>

(<ext> = inp, bdf, dat, ...)
2
3. All nodes of the hood model should be used for

optimization. Select the Tosca Structure group
ALL_NODES as design node group. 3
W4a.12
Optimization task and design variable constraints
4. The optimization task is defined in the next step.

The standard objective function for bead
optimization is to Minimize the 4
compliance, which leads to a maximization of
the stiffness.
5. Afterwards, the values for the constraint

definitions of the bead height and bead width
have to be entered. Please enter a value of 0.5
for the minimal allowed bead height and a value 5
of 3.0 for the maximal allowed bead width.
Additionally, the CHECK_BC check box should be
activated. All nodes that are fixed in the finite
element analysis are also fixed during the
optimization if this parameter is active.
494
W4a.13
Design response settings (1/2)
6. Check your definitions in the summary. Using

the button Finish your definitions are written to
Tosca Structure.pre and can be visualized in the 6
text view.
7. When the definitions in the bead wizard are

finished an additional definition has to be done.
We only want to optimize with respect to the
loadcase number 2 (the pulling force).
Therefore, we have to edit the design response
(DRESP). Choose the Tree-view then the DRESP
7
dresp_compliance. In this dialog box choose
and delete the current loadcase reference
(„STATIC,ALL,ALL“). This old reference simply
references all static loadcases in our finite
element input deck.
W4a.14
Design response settings (2/2)
8. Now add the correct loadcase by pressing Add

LC. In the Select Loadcase dialog choose
STATIC as analysis type and the loadcase
number 2. Press OK. Now, to apply your
modification press Modify.
9. Save the definitions to the parameter file

hood.par.
9
495
W4a.15
Optimization and post-processing
10.Start the optimization in the module Start

Tosca Structure in the upper right corner of the
window: Choose your parameter file hood.par
using the file dialog next to the jobname field. 10
Choose your solver and start the optimization.
11.Create vtfx sequences using the button

Generate Report at the module Tosca
Structure.report. At Result Selection choose the
File type BEAD and combine all design cycles.
11
12.Start the Tosca Structure.report module using

the View Report button and load the result file
hood_bead_opt.vtfx.
W4a.16
First result
!Remarks
Not all solvers give the exact same results as
presented in this work (done using Nastran). The
reason is that the shell-formulations and types often
differ much for the different solvers. Obviously, the
optimization can not give the same optimization
results when the results from the solvers are not the
same.
Visualization of the results using

496
W4a.17
Second optimization task
After this we will now try to add some more

advanced features to the bead optimization. This
part is optional. The subjects are:
• Penalty functions
• Several load cases
• Symmetry conditions
The explanations in this part are not as detailed as
in the previous parts of the workshop because the
aim here is to force the user to explore different
settings in Tosca Structure.bead without strictly
following simple instructions.
W4a.18
More load cases
Using more loadcases with Tosca Structure.bead is actually simple. The wrong way of combining more
loadcases in a DRESP is to apply all loadcases in the loadcase selector for the design responses:
LC_SET = All, All, All WRONG
Instead one should create one DRESP for each loadcase. This is mainly because it gives the user
control over the loadcases which can be weighted differently in the objective function (OBJ_FUNC).
497
W4a.19
More load cases
Using Tosca ANSA environment:

• Select PRE-PROCESSING | BEAD_OPTIMIZATION_CONTROLLER | OBJ_FUNC_ITEM_1 |
New | COMPLIANCE. Reference the first loadcase in the design response definition. In the
LC_SET field type "?" to call the LC_SET dialog. In the LC_SET dialog add a loadcase by selecting
MORE and enter 1 in the LOADCASE field.
• The objective function target should remain unchanged

• Run optimization and view results.
Using Tosca Structure.gui:

• Create a DRESP for shear force, ’F1’, (For inspiration, see step 7 and 8 at chapter B-1.2.2
Procedure using Tosca Structure.gui)
• Reference also this new DRESP so the objective function now consists of 2 DRESPs both with the
weighting of 1.0.
• Run optimization and view results
W4a.20
Symmetry conditions
Symmetry can be enforced e.g. due to manufacturing, irregular mesh, non symmetric loading, etc.
Symmetry can be enforced by creating a LINK-condition in spite of asymmetric loadcases.
The goal is to force plane symmetry in the vertical plane (AXIS_3 is normal) for the middle of the hood.
A point in the middle is given by [5.0, 0.0, 10.0].
498
W4a.21
Symmetry conditions using Tosca ANSA environment:
• Try at first to solve the assignment just

described without following this „cook-book-
recipe“
1. Select PRE-PROCESSING |
SYMMETRY_CONTROL. Define the origin using
the nodal coordinates (5,0,10). Specify the
global z-axis as normal direction for the
symmetry plane.
2. Run optimization and visualize results
W4a.22
Symmetry conditions using Tosca Structure.gui:
• Try at first to solve the assignment just

described without following this „cook-book-
recipe“
1. Create a coordinate system in [5.0, 0.0, 10.0]
o Choose CS_DEF
o The options „rectangular Cartesian“ and „local“

o Now insert the coordinate values and a zero
rotation
2. Create a BEAD_LINK condition according to the
assignment
3. Reference the LINK-condition in a DV_CON-
entry Visualization of the second optimization task
4. This DV_CON-entry must be referenced in the
OPTIMIZE command. Otherwise, the symmetry
condition is not included in the optimization
5. Run optimization and visualize results
499
W4a.23
Solution: Input model, Design variables
! PARAMETER FILE FOR BEAD OPTIMIZATION ! DESIGN VARIABLES

DV_BEAD
! CONSIDERATION OF BOUNDARY CONDITION ID_NAME = DESIGN_VARIABLES
OPTIONS ND_GROUP = ALL_NODES
READ_BC = ALL END_
END_
! BOUNDARY CONDITION CHECK

! INPUT OF THE FEM FILE DVCON_BEAD
FEM_INPUT ID_NAME = dvcon_fix_spc
ID_NAME = OPTIMIZATION_MODEL ND_GROUP = ALL_NODES
FILE = hood.bdf CHECK_BC = YES
END_ END_
W4a.24
Solution: Optional symmetry control
! COORDINATE SYSTEM FOR SYMMETRY CONTROL ! ASSIGNATION OF SYMMETRY RESTRICTIONS TO

CS_DEF CORRESPONDING NODE GROUP
ID_NAME = MY_CS DVCON_BEAD
DEF_TYPE = LOCAL ID_NAME = my_dvcon
CS_TYPE = RECTANGULAR CHECK_LINK = my_link_plane
CS_REF = CS_0 ND_GROUP = all_nodes
ORIGIN_123 = 5.0, 0.0, 10.0 END_

ROTATION_321 = 0.0, 0.0, 0.0
END_
! PLANE SYMMETRY CONDITIONS

LINK_BEAD
ID_NAME = my_link_plane
TYPE = PLANE_SYM, AXIS_3
CS = MY_CS
END_
500
W4a.25
Solution: Design responses
! STRAIN ENERGY AS DESIGN RESPONSE FOR THE ! OBJECTIVE FUNCTION BASED ON COMPLIANCE
FIRST LOADCASE DESIGN RESPONSES
DRESP OBJ_FUNC
ID_NAME = dresp_compliance_1 ID_NAME = minimize_compliance
… DRESP = dresp_compliance_1,
LC_SET = STATIC,1,ALL 1.0
LC_SEL = MAX DRESP = dresp_compliance, 1.0

END_ TARGET = MIN
END_
! STRAIN ENERGY AS DESIGN RESPONSE FOR THE
SECOND LOADCASE
DRESP
ID_NAME = dresp_compliance
…
LC_SET = STATIC,2,ALL
LC_SEL = MAX
END_
W4a.26
Solution: Bead height constraint
! BEAD HEIGHT AS DESIGN RESPONSE

DRESP
ID_NAME = dresp_bead_height
DEF_TYPE = SYSTEM
TYPE = BEAD_HEIGHT
GROUP_OPER = MAX
UPDATE = EVER
END_
! BEAD HEIGHT CONSTRAINT

CONSTRAINT
ID_NAME = bead_height_constraint
DRESP = dresp_bead_height
MAGNITUDE = ABS
EQ_VALUE = 0.5
END_
501
W4a.27
Solution: Optimization
! COMBINATION OF OBJECTIVE FUNCTION, DESIGN ! BEAD WIDTH

AREA AND CONSTRAINTS IN OPTIMIZATION TASK OPT_PARAM
OPTIMIZE ID_NAME = OPT_PARAMS
ID_NAME = BEAD_OPTIMIZATION OPTIMIZE = BEAD_OPTIMIZATION
STRATEGY = BEAD_CONTROLLER BEAD_WIDTH = 3
DV = DESIGN_VARIABLES END_
OBJ_FUNC = minimize_compliance
DVCON = dvcon_fix_spc
DVCON = my_dvcon
CONSTRAINT = bead_height_constraint
END_
502
Notes
503
Notes
504
W4b.1
Workshop example: Optimization of natural frequencies – Oil pan
Task Maximization of the lowest natural frequency

Keywords BEAD, TEST_BEAD
Beads are often implemented to improve the vibrational behavior of sheet metal structures. The
following workshop introduces the procedure for defining a bead optimization task based on a modal
analysis.
30 min
W4b.2
Oil pan
Model
The present model is an oil pan. The initial design
with the boundary conditions and the first mode is
illustrated below.
The initial design has the following modal

eigenfrequency values: Initial model ’oil pan’.
Frequency 1: 177 Hz Boundary conditions and first mode
Frequency 2: 301 Hz
Frequency 3: 336 Hz
Frequency 4: 393 Hz
Frequency 5: 474 Hz
505
W4b.3
Optimization task
All nodes of the analysis model are used as design nodes. The domain which is fixed in the analysis
model will also be fixed during optimization. This is done by defining a CHECK_BC parameter in the
DVCON_BEAD.
The objective function is to maximize the first natural frequency. This is done by minimizing the bending
equivalent stress calculated from the modal stresses. The first mode is used for determining the design
response. The beads should be generated towards the inner side (positive y-direction of the global
coordinate system).
The bead height should not be higher than 5 mm and the bead width should be 25 mm.
1 2 3
Model import Define Design area Objective function
oil_pan.<ext> ALL_NODES maximize 1st
eigenfrequency
5 4
Check definitions Constraints
TEST_BEAD Bead height 5 mm
Bead width 25 mm
6
Save optimization
task
7 8
run
506
W4b.5
1. Define a BEAD_CONTROLLER optimization task for the oil pan (model file: oil_pan.<ext>). You
should follow the standard procedure to create your basic parameter file.
2. Define a design area containing all nodes.
3. Define a constraint on the design nodes so the design nodes having boundary conditions in the
finite element input model are not allowed to be modified (PRE-PROCESSING |
BEAD_OPTIMIZATION_CONTROLLER | DV_CONSTRAINTS | New | CHECK_BC).

4. As objective function define the maximization of the first natural frequency (PRE-PROCESSING |
BEAD_OPTIMIZATION_CONTROLLER | OBJ_FUNC_ITEM_1 | New | EIGENFREQUENCY).
Specify the first eigenfrequency by activating the LC_SET dialog and entering 1 in the SUBSTEP
field. Edit the OBJ_FUNC_ITEM_1 item and set the target to MAX.
5. Define a bead height constraint (PRE-PROCESSING | BEAD_OPTIMIZATION_CONTROLLER |
CONSTRAINTS | New | BEAD_HEIGHT_CONSTRAINT) where the bead height is set to 5 mm.
6. Define 25 mm bead width as additional parameter (PRE-PROCESSING |
BEAD_OPTIMIZATION_CONTROLLER | New | SETTINGS) and save your optimization task.
W4b.6
7. You can check your definitions before starting

the optimization task (CHECK_INPUTS | New
| TEST_BEAD_CHECK). Specify a bead test
(CHECK_INPUTS | TEST_BEAD_CHECK |
New | TEST_BEAD) and set 5 mm test 7
displacement in positive direction (GROW) using 3
increments.
8. Start the test run an check the results after that.
All design nodes will be displaced in the
optimization displacement direction. In this
example, the design nodes should be displaced
in positive y-direction. Due to the element
orientation the nodes are displaced in the wrong 8
direction. The displacement direction may easily
be inverted in Tosca Structure by the definition
of a negative scale factor. Select
PRE-PROCESSING |
SETTINGS | Edit and set a -1 scale factor.
507
W4b.7
9. Save the optimization database including all optimization definitions using File | Save as in
the main menu (use a meaningful filename).
10.Start the optimization. During the optimization please check the files TOSCA.OUT or
optimization_report.csv (in the Output directory (evtl. changed name) or subdirectory
TOSCA_POST):
11.Check the optimization results using post-processing.
Workflow using Tosca Structure.gui environment
1 2 3
Model import Define Design area Objective function
oil_pan.<ext> ALL_NODES maximize
eigenfrequency
5 4
Check definitions Constraints
TEST_BEAD Bead height 5 mm
Bead width 25 mm
6
Save optimization
task
7 8
run
508
W4b.9
1. Start Tosca Structure.gui, change to the module

Tosca Structure.pre and create a new
optimization task: File | New File. Switch
to the tree view of Tosca Structure.pre. The most
important commands for an optimization task
are listed here and can be processed gradually.
2. Define the options that have to be considered

during the import of the finite element model.
The node fixations of the finite element model
have to be read in via the interface. In the
OPTIONS command, the parameter 2
READ_BC = ALL has to be set.
W4b.10
3. Choose the first command FEM_INPUT in the

tree view. Choose the analysis file
oil_pan.<ext> (ext = inp, bdf, dat, ...) using 3
the file browser and add the command to the
tree structure using the button CREATE.
4. Define the design variable using the DV_BEAD
command. All nodes (node group ALL_NODES)

have to be selected for the design area.
4
5. The nodes which are fixed in the analysis model
should also be fixed during optimization. This
can be achieved by defining a DVCON_BEAD
command where the previously read boundary
conditions are activated for optimization.
Open the DVCON_BEAD dialog and select the
node group ALL_NODES. The CHECK_BC
5
parameter has to be activated. The nodes which
are fixed in the finite element model are also
fixed for the design nodes in the optimization. All
other nodes may be displaced.
509
W4b.11
6. In the next step the design response for the

definition of the objective function has to be
defined. Select DYN_FREQ as Type and add the
loadcase MODAL,ALL,1.
6
7. The design response is now selected in the

OBJ_FUNC command. The optimization task is
to maximize the first natural frequencies. The
defined design response has to be selected and 7
the Target = MAXIMIZE has to be activated.
W4b.12
8. The constraint for the optimization problem is

formulated in the next step. First, the design
response containing the maximum bead height
(node displacement corresponding to the start
model) has to be defined. The BEAD_HEIGHT
design response is listed in the standard design 8
responses.
9. This design response is now used for the

definition of the constraint. Choose the
CONSTRAINT command by selecting the
BEAD_HEIGHT design response and define an 9
absolute constraint value of 5.
510
W4b.13
10.Compose the optimization task by activating all

the previously defined definitions. Select
BEAD_CONTROLLER as Strategy. The
DVCON_BEAD command has to be added and
the CONSTRAINT definition has to be activated. 10
11.In the next step the bead width of 25 mm has to

be specified. This parameter can be defined in
the OPT_PARAM command. 11
W4b.14
12.Add a TEST_BEAD (menu item COMMAND |

TEST_BEAD) command to test the definitions. A
maximum displacement of 5 should be
specified. The number of increments should be 12
3. Choose ONF output format if you want to
convert the data for Tosca Structure.view.
13.Save your definitions in the parameter file

oil_pan.par and switch to the Start Tosca
Structure module. Start Tosca Structure in the
test1 mode. 13
511
W4b.15
14.Visualize your TEST_BEAD results using Tosca

Structure.view. Switch to the module Tosca
Structure.report to create vtfx-sequences.
Choose your parameter file using the file dialog
next to the jobname-field (if it is not already 14
preset). Choose the file type TEST_BEAD and
change the preset name root of the result to the

name of your TEST_BEAD-files (in this case to
TEST_BEAD). Choose all steps (Iter: All).Start
with Generate Report.
W4b.16
15.Start the Tosca Structure.view module using the

View VTF button and load the result file
oil_pan_bead.vtfx. All design nodes will be
displaced in the optimization displacement
direction. In the animation in Tosca
Structure.view you can quickly control if the
elements are correctly oriented i.e. if the

optimization displacement direction is correct
and if all restrictions are considered during
optimization.
512
W4b.17
16.For this example the design nodes should be

displaced in positive y-direction. Due to the
element orientation the nodes are displaced in
the wrong direction. The displacement direction 16
may easily be inverted in Tosca Structure by the
definition of a negative scale factor. Reopen the
parameter file in Tosca Structure.pre and open

the OPT_PARAM dialog. Set the Scale
parameter to a negative value. Tosca Structure
will only interpret the sign of the defined scale
factor - the displacements will not be scaled if a
value <> 1 is specified.
W4b.18
17.Variables have to be defined before the

optimization is started for tracking the values of
the frequencies during optimization. The
variables are added to a tabular output using the
USER_FILE command.
The following entries have to be defined for the 17
frequency variable:
• DEF_TYPE = SYSTEM, for the definition
of a loadcase dependent variable
• TYPE = DYN_FREQ, selecting a
frequency value
In the loadcase section the first frequency has to
be selected (MODAL, ALL, 1)
18.Generate the entry in the Parameterfile

(CREATE) and generate a second variable
containing the 2nd natural frequency (same
definition, but loadcases: MODAL, ALL, 2).
513
W4b.19
19.Define a numerical variable containing the

actual iteration counter
19
20.Define a USER_FILE that generates a tabular

output for the frequencies. Select the
FORMAT = ASCII, the TYPE = TABULAR, the
FILE_OPTION = ADD and the parameter
WRITE = EVER. Select the variables in the drop
down menu and add them to the output list.
Remark for evaluation in Excel:
If you want to evaluate the tables in Excel, you
may directly generate Excel CSV files (Comma 20
Separated Values). Add the extension .csv to the
filename definition and select the COMMA
separator.
Add the variables FREQ_1, FREQ_2 and Iter.
W4b.20
21.Start the optimization in TYPE ALL
22.Generate the vtfx sequence containing the

optimization results and postprocess your
optimization results in Tosca Structure.view.
Additionally you may have a look at the output

table in an ASCII editor or generate x-y-plots in
Excel.
514
W4b.21
Results
Visualizing the Tosca Structure.bead results in

W4b.22
Solution: Input model, Design variables
! PARAMETER FILE FOR TOSCA OPTIMIZATION TASK ! DESIGN VARIABLES

DV_BEAD
! CONSIDERATION OF BOUNDARY CONDITION ID_NAME = DESIGN_VARIABLES
OPTIONS ND_GROUP = ALL_NODES
READ_BC = ALL END_
END_
! BOUNDARY CONDITION CHECK

! INPUT OF THE FEM FILE DVCON_BEAD
FEM_INPUT ID_NAME = MY_DVCON_BEAD
ID_NAME = MY_INPUT_FILES CHECK_BC = YES
FILE = oil_pan.bdf ND_GROUP = ALL_NODES
END_ END_
515
W4b.23
Solution: Variables
! VARIABLE TO TRACK VALUES OF FREQUENCY OF ! DEFINITION OF A NUMERICAL VARIABLE

FIRST LOADCASE DURING OPTIMIZATION CONTAINING THE ACTUAL ITERATION COUNTER
VARIABLE VARIABLE
ID_NAME = FREQ_1 ID_NAME = Iter
TYPE = DYN_FREQ TYPE = ITER
LC_SET = MODAL,ALL,1 END_

LC_SEL = MIN
END_
! VARIABLE TO TRACK VALUES OF FREQUENCY OF

SECOND LOADCASE DURING OPTIMIZATION
VARIABLE
ID_NAME = FREQ_2
DEF_TYPE = SYSTEM
TYPE = DYN_FREQ
LC_SET = MODAL,ALL,2
LC_SEL = MIN
END_
W4b.24
Solution: Design responses
! FIRST EIGENFREQUENCY AS DESIGN RESPONSE

DRESP
ID_NAME = DRESP_FREQ
DEF_TYPE = SYSTEM
TYPE = DYN_FREQ
LC_SET = MODAL,ALL,1
LC_SEL = MIN
END_
! OBJECTIVE FUNCTION IN COMBINATION WITH THE

FREQUENCY DESIGN RESPONSES
OBJ_FUNC
ID_NAME = MY_OBJ_FUNC
TARGET = MAX
DRESP = DRESP_FREQ
END_
516
W4b.25
Solution: Bead height constraint
! BEAD HEIGHT AS DESIGN RESPONSE

DRESP
ID_NAME = DRESP_BEAD_HEIGHT
TYPE = BEAD_HEIGHT
DEF_TYPE = SYSTEM
GROUP_OPER = Max
END_
! DEFINITION OF THE BEAD HEIGHT CONSTRAINT

CONSTRAINT
ID_NAME = MY_CONSTRAINT
MAGNITUDE = ABS
EQ_VALUE = 5
DRESP = DRESP_BEAD_HEIGHT
END_
W4b.26
Solution: Optimization and bead width
! COMBINATION OF THE OBJECTIVE FUNCTION, THE ! DEFINITION OF BEAD WIDTH

DESIGN AREA AND THE CONSTRAINTS IN THE OPT_PARAM
OPTIMIZATION TASK ID_NAME = MY_PARAMETERS
OPTIMIZE OPTIMIZE = MY_OPTIMIZATION_TASK
ID_NAME = MY_OPTIMIZATION_TASK BEAD_WIDTH = 25
OBJ_FUNC = MY_OBJ_FUNC SCALE = -1.0
DV = DESIGN_VARIABLES END_
DVCON = MY_DVCON_BEAD
CONSTRAINT = MY_CONSTRAINT
STRATEGY = BEAD_CONTROLLER
END_
517
W4b.27
Solution: Output control and Test optimization
! DEFINITION OF A TABULAR OUTPUT FOR THE ! DEFINITION OF THE TEST OPTIMIZATION

FREQUENCIES TEST_BEAD
USER_FILE INCREMENT = 3
ID_NAME = MY_USER_FILE DIRECTION = GROW
SEPARATOR = COMMA FILE_NAME = TEST_BEAD
TYPE = TABULAR FORMAT = ONF
FORMAT = ASCII OPTIMIZE = MY_OPTIMIZATION_TASK

FILE_OPTION = ADD DISPLACEMENT = 5
DATA_TAB = Iter END_
DATA_TAB = FREQ_1
DATA_TAB = FREQ_2 EXIT
FILE_NAME = result.csv
END_
518
Notes
519
Notes
520

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SIMULIA Tosca Structure Seminar

Layout mit Marginalspalte Layout mit Marginalspalte Layout mit Marginalspalte

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Lesson 9 2/14 Updated for TOSCA 8

Lesson 10 2/14 Updated for TOSCA 8

Lesson 11 2/14 Updated for TOSCA 8

Lesson 12 2/14 Updated for TOSCA 8

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SIMULIA Tosca Structure Seminar

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SIMULIA Tosca Structure Seminar

Layout mit Marginalspalte Layout mit Marginalspalte Layout mit Marginalspalte

Success factors for product development

Costs Cost pressure

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Quality Innovation pressure

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Optimization driven design development

Reduction of development time

Optimized Design Development Conventional Design Development

Optimize Design Design

Design Analyze Build

Build Build Test

Costs and their influence in the development cycle

► The total costs are mainly defined in an early

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► Significant cost reduction with good design

Changes should be inserted as early as possible

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SIMULIA Tosca Structure Seminar

Mathematical description of an optimization task

Design variables Minimize f(x)

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How can you modify a structure?

Problem One DV = thickness

Two DV = thickness, angle

Several DV = variable thickness

More design variables

Best design obtained by free („non-parametric“) modification

How can you modify a structure?

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What are your targets?

► The objective is maximized or minimized

What are your restrictions?

► Frequently, the constraints are geometrical Constraint

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Which sources provide you with inputs for the optimization?

► Finite element analysis

► CAE model Combine (sum, max,...) for areas

Optimization definitions required

Model: design variables

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Inputs (responses): FE analysis

Update design variables