Al Musanna College of Technology

Engineering Department

Mechanical Engineering Section

Laboratory Report
Code: ACT/M&I/MIME4222/Semester II 2016-17
Revision : First issue Version : 01
Students Name :
Seat number : Section :

I. Course Description ENGINEERING DESIGN II

II. Course Code: MIME 4222
III. Exercise No:
IV. Duration: 1 Hr
V. Title: Design optimization
VI. Objectives:

Determine if weight reduction pockets can be generated in the L-shaped structure

shown below. The structure is 2 mm thick and is made of structural steel. The
boundary and loading conditions are specified as follows: A downward force of 300 N
is applied at the bottom edge of the free end, and the top face of the L-shape is fixed.
The allowed maximum deformation in the structure is 0.3 mm. (a) Perform topology
optimization to achieve 60% weight reduction. (b) Redesign the structure based on
the results from topology optimization, and conduct parametric optimization to
minimize weight subject to the deformation constraint.

VII. Procedure
Solution steps for portion (A):
Step 1: Start an ANSYS Workbench Project
Launch ANSYS Workbench and save the blank project as Lshape.wbpj.
Step 2: Create a Shape Optimization Analysis System
Drag the Shape Optimization icon from the Analysis Systems Toolbox window and drop
it inside the highlighted green rectangle in the Project Schematic window.
Note: If Shape Optimization does not appear in the Toolbox of Analysis Systems, you
may have to turn on the beta option. Go to Tools > Options > Appearance, and
check the box next to Beta Options. If beta options are on and the analysis system still
is not coming up, go to the bottom of the Toolbox in Workbench and click View
All/Customize and make sure that there is a check mark next to Shape Optimization
(Beta).
Step 3: Launch the Design Modeler Program
Double-click the Geometry cell to launch Design Modeler, and select Millimeter in
the Units pop-up window.
Step 4: Create the Geometry
Click on the Sketching tab. Draw a sketch of the L-shape on the XY Plane, . An entity
named Sketch1 will be shown underneath XY Plane of the models Tree Outline.
Extrude Sketch1 to create a 2 mm thick solid body.
Step 5: Launch the Shape Optimization Program
Double-click on the Model cell to launch the Shape Optimization program. Change the
Units to Metric (mm, kg, N, s, mV, mA).
Step 6: Generate Mesh
Click on Mesh in the Outline tree. In the Details of Mesh, enter 1.0 mm for the
Element Size. Right click on Mesh and select Generate Mesh.
Step 7: Apply Boundary Conditions
Right-click on Shape Optimization (A5). Choose Insert and then Fixed Support from the
context menu. Click on the top face, and apply it to the Geometry selection in the
Details of Fixed Support. The top face of the L-shape is now fixed.
Step 8: Apply Loads
Right-click on Shape Optimization (A5). Choose Insert and then Force. In the Details of
Force, apply a 300 N force to the top edge of the free end in the Y-direction.
Step 9: Define Target Weight Reduction
Click on Shape Finder underneath Solution (A6) in the Outline tree. In the Details of
Shape Finder, enter 60% for the Target Reduction. Right-click on Solution (A6) and
select Solve.
Step 10: Retrieve Solution
Click on Shape Finder underneath Solution (A6) in the Outline tree to review results.
The region marked in grey is suggested as the optimal shape for the design under the
given loads. Save project and exit the ANSYS Workbench.
Solution steps for portion (B):
Step 1: Start an ANSYS Workbench Project
Launch ANSYS Workbench and save the blank project as Lshape_DOE.wbpj.
Step 2: Create a Static Structural Analysis System
Drag the Static Structural icon from the Analysis Systems Toolbox window and drop it
inside the highlighted green rectangle in the Project Schematic window.
Step 3: Launch the Design Modeler Program
Double-click the Geometry cell to launch Design Modeler, and select Millimeter in
the Units pop-up window.
Step 4: Create the Geometry
Click on the Sketching tab. Draw a sketch of the L-shape on the XY Plane, . An entity
named Sketch1 will be shown underneath XY Plane of the models Tree Outline.
Apply fillets of radius 1 mm to the six interior corners . Apply the EqualRadius
constraint to all six fillets. Turn on the Name option for the Display of Dimensions. In
the Details View, click on the box to the left of the dimension name V5. In the pop-up
window, enter height1 as the parameter name and then click OK. Repeat the steps
for the dimension name V15 and enter height2 as the corresponding parameter
name (note your dimension names may not be the same as they appear here). A
letter D will be marked on the box to the left of the two selected dimensions in the
Details View.
Extrude Sketch1 to create a 2 mm thick solid body, and close DesignModeler. Note
that a Parameter Set bus is added to the project schematic.
Double-click on the Parameter Set. Note that the selected dimension parameters,
namely, height1 and height2, are now included as two design variables in the Outline
window.
Step 5: Launch the Static Structural Program
Double-click on the Model cell to launch the Static Structural program. Change the
Units to Metric (mm, kg, N, s, mV, mA).
Step 6: Generate Mesh
Click on Mesh in the Outline tree. In the Details of Mesh, enter 1.0 mm for the
Element Size. Right-click on Mesh and select Generate Mesh.
Step 7: Apply Boundary Conditions
Right-click on Static Structural (A5). Choose Insert and then Fixed Support from the
context menu. Click on the top face, and apply it to the Geometry selection in the
Details of Fixed Support. The top face of the L-shape is now fixed.
Step 8: Apply Loads
Right-click on Static Structural (A5). Choose Insert and then Force. In the Details of
Force, apply a 300 N force to the bottom edge on the right along negative Y-
direction.
Step 9: Retrieve Solution and Define Response Parameters
Insert Total Deformation by right-clicking Solution (A6) in the Outline tree. Right-click
on Solution (A6) and select Solve. Click on Total Deformation in the Outline to review
deformation results. Next, click on the box to the left of Maximum in the Details of
Total Deformation. Note that a letter P is added to the box. In the Details of
Solid, click to the left of Mass under Properties. Note that a letter P is added to the
box. Exit the Static Structural window.
Step 10: Explore the Parameter Set
Double-click the Parameter Set in the project schematic. The input parameters (design
variables) and output parameters (responses) are listed with their corresponding base
values in the Outline window. In the Table of Design Points, the current design is
shown as the only design point, click Return to Project.
Step 11: Create Response Surface Optimization
Double-click the Response Surface Optimization underneath Design Exploration from
the Toolbox. A Response Surface Optimization system will be added to the project
schematic. The optimization system is linked to the Parameter Set indicating that it
has access to the design and response parameters. Double-click on the Design of
Experiments tab in the project schematic.
Step 12: Generate DOE Table
In the Outline of Schematic B2: Design of Experiments, click on the P1-height1 tab.
Enter the Lower Bound and Upper Bound values.
In the Outline of Schematic B2: Design of Experiments, click on the P2-height2 tab.
Enter the Lower Bound and Upper Bound values in the Properties of Schematic B2:
Design of Experiments.
In the Outline of Schematic B2: Design of Experiments, click on the Design of
Experiments tab. Turn on Preserve Design Points after DX Run. Change the Design
Type to Face-centred.
In the toolbar, click Preview. A DOE table listing nine design points is generated.
Then click Update in the toolbar to run finite element simulations for the nine different
design scenarios. It will take a while to finish running all the simulations. After
completion, review the nine design points (simulation results) listed in the Table of
Schematic B2, and click Return to Project.
Step 13: Build Response Surface
Double-click the Response Surface tab in the project schematic. Turn on the two
options underneath Design Points in the Properties of Schematic B3: Response
Surface. Click Update to create the response surface.
To view the response surface, click on the Response tab in the Outline of Schematic
B3: Response Surface. Select 3D for Mode in the Properties of Outline: Response. The
response surface of the maximum total deformation as a function of height1 and
height 2 is shown in the Response Chart. Review the response surface chart, and click
Return to Project.
Step 14: Set Up Objectives and Constraints
Double-click the Optimization tab in the project schematic. Click on the Objectives
and Constraints tab in the Outline of Schematic B4: Optimization. Set up the objective
and constraints in the Table of Schematic B4: Optimization. Click on the Optimization
tab in the Outline of Schematic B4: Optimization. Select Screening for Optimization
Method in the Chart: Response Chart for P3. Click Update. Three candidates for best
design are now listed in the Table of Schematic B4: Optimization. Review the best
design candidates in the Candidate Points table. Click Return to Project.
Step 15: Update Current Design
Double-click the Parameter Set in the project schematic. In the Table of Design Points ,
DP1, DP2, and DP3 are feasible solutions that meet the design requirements. Among
them, DP3 achieves the best result in minimizing the total weight while meeting the
maximum total deformation requirement. It has a value of 21 mm for height1 and 8
mm for height2.
We will now update the current design with this design point (DP3), which can then be
served as the base case for another round of optimization iteration if necessary.
Right-click on the DP3 tab in the Table of Design Points, and select Copy inputs to
Current in the drop-down menu. This will update the Current design point with the
selected design point DP3.
Right-click on the Current tab in the Table of Design Points, and select Update
Selected Design Points. This will update the results of the Current design point. Click
Return to Project.
Double-click the Geometry tab in the project schematic to open Design Modeller. Note
that the geometry displayed in the Graphics window is now updated based on the
current design point (21 mm for height1 and 8 mm for height2). Close the Design
Modeler. Double-click the Results tab in the project schematic to view the updated
deformation results from the Static StructuralMechanical program.
IX. Result / Conclusion
In this experiment, we briefly discussed design optimization problems and the type of
optimizations. We also learnt how to apply FEA in design optimization studies. A case
study is demonstrated using ANSYS Workbench to reduce the weight of an L-shaped
structure.