Virtual Designing using Topology Optimizationcae-forum.de/sites/default/files/FE-Design_Posess.pdf-...
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Loading Example: F1 application - McLaren Racing Ltd Final validation using field testing Axial load Target: 2.75mm Torsional moment Target: 0.141rad Bending moment Target: 0.034rad M x M y F z Optimized design for minimum weight Determine material distribution External flux Iteration 1 Iteration 3 Iteration 6 Iteration 10 Iteration 20 Final Iteration Initial Optimized Temperature distribution hotspots removed Fluid Topology optimization - Minimize pressure drop - Design variables: porosity Example: Inlet for Heat Exchanger Design domain New Design Cross sectional velocity and heat exchanger efficiency Transfer efficiency + 45% Pressure Drop - 46 % Turbulent stationary flow Virtual Designing using Topology Optimization Iterative design process using rigorously calculated sensitivities: Design domain with boundaries Stiffer and lighter design Advantages: New conceptual designs Faster development cycles Optimization implementation using existing software for the “virtual” equilibrium Support e.g. non-linear modeling: - Contact - Large deformation - Non-linear materials Optimization Optimization New material distribution Preprocessing Preprocessing Equilibrium Equilibrium Results Optimization loop Finite element solver: - Abaqus - Ansys - Msc Nastran - NX Nastran CFD-solver: - Fluent - STAR-CD Material design variables: ρ (thousands!!!) Equilibrium: (high CPU-time) Optimization - Derivatives using adjoint method: (low CPU-time → free !!!) {} {} {} {} {} {} ρ λ ρ θ θ λ ∂ ∂ = ∂ ∂ - = ∂ ∂ R d d u u R T Finish {} {} 0 = R .......................................... Structural Topology Optimization - Minimize mass, Maximize stiffness, eigenfrequencies, etc. - Design variables: Young modulus, density, non-linear constitutive material laws e.g. plastic materials. Example: JCB Tractor Lift Mechanism a) c) b) Design Design domain domain Twice stiffness of new design compared to old design for equal mass a) Setting up the model in CAD and exporting model to CAE. b) Automated conceptual topological design process including manufacturing constraints. c) Transferring the optimized structure back into the CAD system using smoothed iso-surfaces. ………………………………………………………………………………………………………………... …………………………………………………… Thermal Topology Optimization - Minimize temperature, etc. - Design variables: conduction and convection ...................................................................... …………………………………………………… Claus B.W. Pedersen [email protected] FE-DESIGN GmbH http://www.fe-design.com Telephone: +49 40 1814695 - 90 Concept of Topology Optimization Determining material distribution ρ: ρ~1 solid and ρ~0 void 5 th optimization iteration 10 th optimization iteration 15 th optimization iteration 25 th optimization iteration Final – 33rd optimization iteration Topology optimization Verification New CAD design Design domain Enforce 120° symmetry Manufacturing constraints Feasible design Infeasible design Loads Wind turbine hub Example: Renewable energy – a hub
Transcript of Virtual Designing using Topology Optimizationcae-forum.de/sites/default/files/FE-Design_Posess.pdf-...
Loading
Example: F1 application - McLaren Racing LtdFinal validation
using field
testing
Axial loadTarget: 2.75mm
Torsional momentTarget: 0.141rad
Bending momentTarget: 0.034rad
Mx
My
Fz
Optimized
design for
minimum weight
Determine
material
distribution
External
flux
Iteration 1 Iteration 3 Iteration 6
Iteration 10 Iteration 20 Final Iteration
Initial
Optimized
Temperature
distribution
hotspots removed
Fluid Topology optimization- Minimize pressure drop - Design variables: porosity
Example: Inlet for Heat Exchanger
Design
domain
New Design
Cross sectional velocity and heat exchanger efficiency
Transfer
efficiency
+ 45%
Pressure
Drop - 46 %
Turbulent
stationary
flow
Virtual Designing using Topology Optimization
Iterative design
process using
rigorously calculated
sensitivities:
Design domain
with boundaries
Stiffer and lighter design
Advantages:
! New conceptual designs
! Faster development cycles
! Optimization implementation using
existing software for the “virtual”
equilibrium
! Support e.g. non-linear modeling:
- Contact
- Large deformation
- Non-linear materials
OptimizationOptimization
New material
distribution
PreprocessingPreprocessing
EquilibriumEquilibrium
Results
Optimization
loop
Finite element
solver:
- Abaqus
- Ansys
- Msc Nastran
- NX Nastran
CFD-solver:
- Fluent
- STAR-CD
Material design variables: ρ (thousands!!!)
Equilibrium: (high CPU-time)
Optimization - Derivatives using adjoint method:
(low CPU-time → free !!!)
{ }{ }
{ }{ }
{ } { }ρ
λρ
θθλ
∂
∂=!
∂
∂−=
∂
∂ R
d
d
uu
R T
Finish
{ } { }0=R
..........................................
Structural Topology Optimization
- Minimize mass, Maximize stiffness, eigenfrequencies, etc.
- Design variables: Young modulus, density, non-linear constitutive material
laws e.g. plastic materials.
Example: JCB Tractor Lift Mechanism
a)
c)
!!
!!b)
!!
DesignDesign
domaindomain
Twice stiffness of new
design compared to old
design for equal mass
a) Setting up the model in CAD and exporting model to CAE.
b) Automated conceptual topological design process including manufacturing constraints.
c) Transferring the optimized structure back into the CAD system using smoothed iso-surfaces.
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……………………………………………………Thermal Topology Optimization- Minimize temperature, etc. - Design variables: conduction and convection
......................................................................
……………………………………………………Claus B.W. Pedersen
FE-DESIGN GmbH
http://www.fe-design.com
Telephone: +49 40 1814695 - 90
Concept of Topology Optimization
Determining material distribution ρ:
ρ~1 solid and ρ~0 void
5th optimization
iteration
10th optimization
iteration
15th optimization
iteration
25th optimization
iteration
Final – 33rd
optimization iteration
Topology
optimization
Verification
New CAD design
Design domain
Enforce 120° symmetry
Manufacturing constraints
Feasible
design
Infeasible
design
Loads
Wind turbine hub
Example: Renewable energy – a hub
