Sei sulla pagina 1di 26

the optimization company

© FE-DESIGN
Carsten Gerdes-Götz, FE-Design GmbH
Dirk Pieper, pike-engineering & CAE-
Forum.de
the optimization company

Topologieoptimier-
ung als Ansatz für

© FE-DESIGN
Materialeinsparung
und Ressourcen-
schonung
the optimization company

„Es ist das Gesetz aller organischen und


anorganischen, aller physischen und
metaphysischen, aller menschlichen und
übermenschlichen Dinge, aller echten

© FE-DESIGN
Manifestationen des Kopfes, des Herzens und
der Seele, dass das Leben in seinem
Ausdruck erkennbar ist, dass die Form immer
der Funktion folgt.“

– aus Sullivans Aufsatz: „The tall office building


artistically considered“, veröffentlicht 1896, in dem er
den Ausspruch seines Partners Dankmar Adler
zitiert, der ihn seinerseits sinngemäß von Henri
Labrouste übernommen hatte.

-Quelle: Wikipedia
Structural optimization
Design process

► Reduction of weight
Optimized
► Enforcing desirable design Initial design
stiffness and dynamic geometry space geometry
process
► Maximize the maximum
stresses of several
Shape
loadcases

© FE-DESIGN
optimization Finite element model
► Minimize damage
and increase durability
► Include manufacturing
constraints
Validation run Optimization model
► Design for
displacements/forces/
eigenfrequences Smoothing and
generation of
validation file Topology optimization

03.12.2012
FE-DESIGN
Your partner for optimization

► FE-DESIGN combines development and


SOFTWARE-DEVELOPMENT
application of optimization methods
► FE-DESIGN has the ability to deliver best
solutions for our customers, benefiting from
many years of experience
► Our customers continuously improve their

© FE-DESIGN
ENGINEERING SERVICES
optimization processes due to a steady know-
how transfer through FE-DESIGN
► Customers leverage FE-DESIGN´s knowledge,
with long-term business relationships
TRAINING, SUPPORT AND CONSULTING

3.12.2012 г.
Product development values by using TOSCA

► Virtual prototypes accelerate the product


development cycle
► Numerical simulation increases product quality
► Economy of energy and resources
► Higher efficiency through lower masses, higher

© FE-DESIGN
accelerations, shorter cycle times
► Lower stresses increase durability
► Savings of material at ensured product quality
► Earlier product launches due to shorter
development times

03.12.2012
FE-DESIGN
Fields of application

Automotive Machine construction Aerospace

© FE-DESIGN
Wind power generation Marine technology Medical devices

Engines & turbo machinery Home appliances Consumer products

03.12.2012
the optimization company

Main Frame
Development

© FE-DESIGN
Courtesy of
Topology optimization of a main frame

Series production Conventional design

© FE-DESIGN
Design space for
Series production topology optimization

Assembly Optimization result

03.12.2012 Courtesy of
Main frame - comparison

1
0,9
0,8
Norm. mass/load 0,7
0,6
0,5

© FE-DESIGN
0,4
0,3
0,2
0,1
0
S.64 Conventional S.52 Optimized S.82 Optimized

40% savings on weight!!! (>1,0 Mio EUR in one year)

03.12.2012 Courtesy of
the optimization company

Hub
optimization

© FE-DESIGN
Topology optimization of a hub

CAD surfaces Applying loading

© FE-DESIGN
Verification of new
conceptual design Design space model

Verification of new
conceptual design Topology optimization

03.12.2012
the optimization company

Topology
Optimization

© FE-DESIGN
Example
Transverse Link at
AUDI With the friendly permission of
Initial situation

Transverse link at Audi


► A modification of the component was
necessary, because the load on the part
became too high with the new engines.
Topology optimization is used to derive a new
structure.

© FE-DESIGN
With the friendly permission of

03.12.2012
Topology optimization of a transverse link at AUDI

Redesign Existing design

© FE-DESIGN
Design
Cutting splines space model

Topology optimization

03.12.2012
Courtesy of
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

© FE-DESIGN
40

20

0
Weight Max. stress Max. displacement

Existing design New design (Image ATZ MTZ extra)

03.12.2012
the optimization company

Structural
Optimization of

© FE-DESIGN
Washing Mashine
Components
Parts in FEA model

H2

H1
H3

© FE-DESIGN
H4
H5
H6

H7
Traverse
(braces)

H9

03.12.2012
the optimization company

Topology
Optimization of a

© FE-DESIGN
Washing Mashine
Spider Arm
Definition of the optimization task

Objective ► Minimize volume

Constraints ► Displacement constraint on loaded nodes


► The maximum absolute displacement in z-direction for all nodes in the

© FE-DESIGN
displacement nodegroup is restricted to 4.5 mm

03.12.2012
Optimization I results (without cast constraint)

450000 6

400000
5
350000

300000 4

250000
3
200000

150000 2

100000
DRESP_VOL_TOPO 1
50000

© FE-DESIGN
DRESP_MAX_DISPLACEME

0 0
0 5 10 15 20 25 30 35

► Initial design: ► Optimized design:


► Volume = 398746. (100%) ► Volume = 214208. (53%)
► MAX_DISP_1 = 3.94601 ► MAX_DISP_1 = 4.44915
► MAX_DISP_2 = 3.93227 ► MAX_DISP_2 = 4.46176
► MAX_DISP_3 = 1.84903 ► MAX_DISP_3 =
► MAX_DISP_4 = 2.29052 0.619918E-01
► MAX_DISP_5 = 2.23707 ► MAX_DISP_4 = 3.81158
► MAX_DISP_6 = 1.83949 ► MAX_DISP_5 = 3.93099
03.12.2012
► MAX_DISP_6 = 1.07937
Optimization II results (considering cast constraint)

410000 7

400000 6

390000
5

380000
4
DRESP_VOL_TOPO
370000
DRESP_MAX_DISPLACEME 3
360000

2
350000

340000 1

© FE-DESIGN
330000 0
0 10 20 30 40 50 60

► Initial design: ► Optimized design:


► Volume = 398746. (100%) ► Volume = 340751. (85%)
► MAX_DISP_1 = 3.94601 ► MAX_DISP_1 = 4.46618
► MAX_DISP_2 = 3.93227 ► MAX_DISP_2 = 4.40698
► MAX_DISP_3 = 1.84903 ► MAX_DISP_3 = 1.72442
► MAX_DISP_4 = 2.29052 ► MAX_DISP_4 = 4.32224
► MAX_DISP_5 = 2.23707 ► MAX_DISP_5 = 4.52701
► MAX_DISP_6 = 1.83949 ► MAX_DISP_6 = 0.731727
03.12.2012
the optimization company

Optimization of
a bike stem

© FE-DESIGN
Topology optimization of a bike stem

Conventional design

New design

© FE-DESIGN
Load cases

Smoothed results

Design space
Customers of FE-DESIGN

Excerpt

© FE-DESIGN
3.12.2012 г.
the optimization company

Thank you for


your attention

© FE-DESIGN