Introduction to Workbench Simulation 11.

Workshop A11 Shape Finder

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Shape Optimization

Workshop A11 - Goals

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To use the DS shape optimization tool to indicate potential geometry changes that will result in a reduction in part mass. To request a 40% reduction in the part mass. To create multiple tree branches in the Workbench-Simulation Interface in order to allow results comparisons after solving.

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Introduction to Workbench Simulation ANSYS, Inc. Proprietary

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Shape Optimization

Workshop A11 - Assumptions

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The geometry for workshop 8 consists of 2 Parasolid files. In actual practice users would typically bring geometry from their preferred CAD system and simply update as needed. For training purposes we provide the original as well as the modified geometry files. The geometry and boundary conditions in this workshop is extremely simple. The workshop is intended to demonstrate the basics of shape optimization without undue time spent during preprocessing and solution.

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Shape Optimization

Workshop 11 - Start Page

1. From the launcher start Simulation.

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2. Close out the Map of Analysis Types.

3. Import the Geometry:

a. From the context menu choose Geometry >From file b. Browse to the file Bracket_Opt.x_t to open it

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Shape Optimization

. . . Workshop A11 - Start Page

4. Set the working unit system:
Units > Metric (mm, Kg, N, s) C,

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5. Modify the mesh:

a. Highlight the Mesh branch. b. In the detail window set the Relevance = 100

b.
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Shape Optimization

Workshop A11 - Preprocessing

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c. Highlight the Mesh branch, RMB > Insert > Method d. Select the part and click Apply e. Change Method from Automatic (default) to Tetrahedrons
Note : Because of the nature of topological optimization it is recommended that the mesh relevance be high during a shape run. Note : Shape optimization allows ONLY tetrahedral element shapes. While some geometry will automatically be tet meshed, other cases will require the mesh control for element shape be used. In this workshop, for example, the geometry could be sweep meshed resulting in a hex element mesh.

c. d.

e.
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Shape Optimization

Workshop A11 - Environment

6. Set the Analysis Type:
From the New Analysis menu, select Shape Optimization

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7. Apply constraints on model:

a. Switch to Face select mode b. Select the surfaces of the 2 cylinders shown below. c. RMB > Insert > Fixed Support

b.

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Shape Optimization

. . . Workshop A11 - Environment

8. Insert Loads on the model:
a. b. c. d. Select the surface of the cylinder shown below. RMB > Insert > Force. Change to Component method. Enter X = 10 N; Y = 5 N.

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a.

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Shape Optimization

Workshop A11 - Solution

9. Set Shape Finder options:
a. Highlight the solution branch. b. RMB > Insert > Shape Finder. c. Enter 40% in the Target Reduction field.

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10. Solve

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Shape Optimization

Workshop A11 - Result

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11. When the solution is complete highlight the shape finder branch to view the results.

Note : The red region in the plot indicates where we can potentially remove material while maintaining the parts structural integrity. Note : The detail shows that we have achieved a 40% reduction in mass.
Introduction to Workbench Simulation ANSYS, Inc. Proprietary

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Shape Optimization

. . . Workshop A11 - Result

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While the result is a conceptual guide to where material might safely be removed we can use the ruler tool in the graphics window to better quantify how to modify the part.

Based on these results we would typically return to the geometry source (CAD) to make modifications.
Introduction to Workbench Simulation ANSYS, Inc. Proprietary

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Shape Optimization

Workshop A11 - Verification

Workshop Supplement

Remember! The results of a shape optimization solution indicate only where the optimal regions are that material can be removed. Nothing is implied about how the part will perform after the material is removed. Sound engineering practice requires that we test any new design to insure its performance is not compromised. If we were using a commercial CAD system (or DesignModeler) we could simply modify the original geometry and Update the Simulation model to continue. In this workshop we began with a Parasolid file and will now import another Parasolid model representing the modified original part.

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Shape Optimization

Workshop A11 - Start Page

12. Import the modified CAD model:

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a. Highlight the Model branch and RMB > Duplicate. b. With Model 2 highlighted choose Geometry > From File . . . . c. Browse to the file Bracket_Opt_2.x_t and Open.

a. b.

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Shape Optimization

Workshop A11 - Verification

Since this new geometry represents our optimized part we wont use the shape finder again, rather we will now solve the model for the appropriate structural results. By duplicating the original model all definitions are in place, however the scope of the boundary conditions must be established on the new model.
a. Highlight the Shape Optimization branch under the Model 2 branch b. Change Analysis type to Static Structural

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13. Switch to Static Structural analysis:

a.

b.
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Introduction to Workbench Simulation ANSYS, Inc. Proprietary

Shape Optimization

Workshop A11 Environment

14. Re-apply Loads and Constraints:
a. Highlight the Fixed Support in environment 2 (notice the Geometry field is undefined; Status symbols show question marks). b. Select the cylindrical surfaces where the constraints are applied and Apply in the detail window. c. Highlight Force in environment 2 d. Select the cylindrical surface where the force is to be applied and Apply in the detail window.

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a.

d.

b.

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Shape Optimization

Workshop A11 - Solution

15. Request Results:

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1. Highlight the Shape Finder Result under the solution branch, RMB > delete 2. Highlight the solution branch, RMB > Insert > Stress > Equivalent (VonMises) Stress 3. RMB > Insert > Deformation > Total

16. Solve

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Shape Optimization

. . . Workshop A11 - Verification

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17. The final step in Shape Optimization is to evaluate structural results to determine if the changes in the geometry have degraded the desired performance of the structure.

Equivalent Stress
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Total Deformation
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