tosca topology optimization

Documents · Tosca Structure.nonlinear: · Course objectives. Upon completion of this course you will be able to perform topology, shape and sizing. Stand: 28.10.05 EM5/ALH 09.11.05 1 Copyright HELLER Topology Optimization of Machine Tools to improve the Stability in high performing Metal Cutting. A corresponding topology optimization feature is provided by SIMULIA-Tosca. By following a standard workflow of design optimization. tosca topology optimization

Tosca Structure is the market leading technology for structural optimization based on the industry standard finite element analysis (FEA) package Abaqus, to create innovative and sustainable designs. From early conceptual design through to detailed design improvements Tosca Structure offers the full range of optimization solutions:

  • Tosca Structure.topology
  • Tosca Structure.sizing
  • Tosca Structure.shape
  • Tosca Structure.bead
  • Optimization module in Abaqus/CAE
  • Tosca Structure.gui
Key Benefits
  • Economic use of existing IT investments
  • Faster turnaround from analysis to design or manufacturing
  • Less prototypes or right the first time
  • Accelerated product development for a shorter time-to-market
  • More durable and lightweight designs
  • Optimized products drive innovations in your market
Technical Highlights
  • Seamless integration with leading FEA & durability solvers
  • Direct use of existing knowledge and models
  • Full design flexibility without time-consuming parameterization
  • Fast and easy creation of design variants avoiding intermediate CAD modifications using shape morphing capabilities
  • High fidelity optimization for nonlinear analysis and durability
  • Tosca topology optimization optimization to meet static, dynamic, and thermo-mechanical requirements
  • Handling of complex manufacturing conditions
  • Automatic validation analysis runs and direct data transfer to CAD systems with selected graphical user interfaces

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Lesson content:

Topology Optimization


Example: Topology Optimization of a Control Arm

Theory of Topology Autodesk Fabrication Crack

Controller-based Optimization

Sensitivity-based Optimization

Design Responses

Settings and Options

Optimization Control

Lesson 2: Topology Optimization: Overview and Special Features

1.5 hours

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    TOSCA ANSYS Optimization of machine tools .Topology Optimization of Machine Tools to improve the

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    Copyright HELLER

    Topology Optimization of Machine Tools to improve the

    Stability in high performing Metal Cutting Processes

    Gebr. HELLER Maschinenfabrik GmbHDr. Gerhard Kehl, Harald Altstdter

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    Manufacturing Systems for Automotive Industry

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    MCH 250 G

    MCH 350 GE

    MCH 250 C

    MCH 250 HSM

    Simulation Disciplines at Machine Tools

    Static Dynamic


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    Mechanical Structures in complex Systems



    2 Volumes

    3 Couplings

    17 Volumes

    12 elastic Couplings

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    Modeling of the mechanical Structure for Optimization

    + =

    Non-Design Area Designspace Simulation Model

    + =

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    Optimization Strategies

    Combined Topology Optimizationstatic loads + eigenfrequencies

    specific frequency constraints

    f1= 60 Hz > f


    f2= 90 Hz > f


    f3= 120 Hz > f


    Static Topology Optimization with weighted load cases (up to now max. 44)

    moving loads (weight)

    acceleration loads (quasi-static)

    process loads






    Opt imierungsergebnis

    (Nachgiebigkeitsf requenzgang)

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    Initial model for head (Realistic boundary conditions)

    Loadcase 1(x-direction)

    Flexible beam elements for

    boundary conditions

    Beam elements


    to rigid mass

    Loadcase 2 (y-direction)

    Beam elements


    to rigid mass

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    Static optimization

    Minimize: Maximize of { abs(ux), abs(uy)}

    Mass < Mass* = 35%

    Important: the static optimization

    showed that sony vegas pro 15 price - Crack Key For U frequency responses also

    have to be considered in the optimization.

    The rigid mass is no


    attached to structure !!!!

    Number Eigenfrequency

    1 ~0

    2 ~0

    3 ~0

    4 2.4

    5 3.0

    6 3.5


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    1 3 5 7 9

















    Frequency optimization

    Maximize the eigenfrequencies from f1 to f6

    Mass < Mass* = 35%

    Mass constraint is not active

    Important: Model the correct physical

    boundary conditions. The optimization

    should include static and frequency results.

    Number Eigenfrequency

    1 83

    2 105

    3 112

    Shaft hardly tosca topology optimization to structure.

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    Combined static and frequency optimization

    Purpose: To improve the static stiffness for both loadcases including constraints

    on the eigenfrequencies.

    Objective: Minimize: Maximize of { abs(ux), abs(uy)}

    Constraints: Mass < Mass* = 35%

    f1> f

    1* = 60 Hz f

    1> f

    1* = 75 Hz

    f2> f

    2* = 90 Hz f

    2> f

    2* = 100 Hz

    f3> f

    3* = 120 Hz f

    3> f

    3* = 125 Hz

    f4> f

    4* = 150 Hz f

    4> f

    4* = 150 Hz

    f5> f

    5* = 180 Hz f

    5> f

    5* = 175 Hz

    f6> f

    6* = 210 Hz f

    6> f

    6* = 200 Hz

    Example 1

    Example 2

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    Combined static and frequency optimization: Topology

    Example 1:

    Number Initial example 1

    1 48 60

    2 60 90

    3 94 137

    4 137 181

    5 260 256

    6 265 345

    Example 2:

    Number Initial example 2

    1 48 75

    2 60 101

    3 94 145

    4 137 191

    5 260 268

    6 265 377

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    Examples for Topology optimized Machine Components

    Tool Changer Arm Rod and Plain Eye hydr. Rundtisch Brake


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    Examples for Topology optimized Machine Components

    Machine Stand

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    Examples for Topology optimized Machine Components

    Machine Stand

    Milling and Boring Carriage

  • Источник:

    Tosca Topo

    ANSA v.13.x

    Optimization with ANSA


    OPTIMIZATION WITH TOSCATOPO OPTIMIZATIONTable of Contents1. Introduction.2 1.1. Prerequisites .2 1.2. What is the Topology optimization .2 1.3. The Model.3 1.4. Optimization Task .4 1.5. Data files.4 2. Recipe .5 3. Preprocessing.6 4. Start Optimization .13 5. Postprocessing - Viewing the intermediate results using 6. Result Transfer and Validation Run.14 6.1. Generating the surface using TOSCA.smooth .14 6.2. Modifying the surface using RECONSTRUCT .15 6.3. Remeshing the model .15 6.4. Saving the resulting model in solver format .16 6.5. Running the solver with the new model .16 7. Result Discussion .17

    BETA CAE Systems S.A.


    ANSA v.13.x

    Optimization with ANSA

    1. IntroductionThis tutorial presents the set up of a simple Topo optimization task tosca topology optimization TOSCA Structure Optimizer and the TOSCA Environment of ANSA. 1.1. Prerequisites - The user should be familiar with the basic functionality of ANSA and TOSCA Structure. - In this tutorial the NASTRAN solver is used and the model has been prepared to run to this solver. If another solver has to be used, the user must update the model properly.

    1.2. What is the Topology optimization At the beginning of the conventional design process the design engineer defines the shape and the topology of new components using the experience and the results gained from the forerunner. This results in an evolution process which might lead to an optimum design after some iterations and a long period of time. Nowadays, it is necessary to shorten the development process of new components. Therefore tools are necessary that replace the natural evolution process by an automatic procedure. With TOSCA Structure it is possible to carry out topology and shape optimization in the CAE environment. Topology optimization is a tool to generate a design proposal and is often used within the concept finding for a new component. Starting with the design area which is the maximum allowed area for the component and with the boundary conditions, such as loads, fixtures and manufacturing conditions, the optimization system will determine a new material distribution by removing material from the design area. This design proposal fulfills all mechanical requirements and represents a weight-optimal design proposal. For the optimization the following constraints and objectives can be realized: stiffness (compliance and displacements) eigenfrequencies internal and reaction forces dynamic compliance dynamic displacements, velocities and accelerations weight, volume center of gravity moment of inertia

    BETA CAE Systems S.A.


    ANSA v.13.x

    Optimization with ANSA

    In addition, a number of manufacturing constraints can be applied so that the design proposal can be produced with casting or stamping. For this casting constraints, member size constraints, freezing, symmetry and coupling constraints can be defined. As result the optimization system creates a design proposal with the information where the material has to be positioned. This design proposal has to be interpreted and be used for the more detailed analysis. For supporting this step, the TOSCA Structure system supports the generation of a verification model within ANSA. This means a new model based on the results of the topology optimization can be created easily without the necessity of applying the loads and boundary conditions to the verification model. All loadcases and boundary conditions of the optimization model are transferred automatically to the verification model. With tosca topology optimization results of the verification run it is possible to perform a normal FE postprocessing step within the postprocessing environement suitable for the relative solver. Alternatevely, a CAD model can be generated which then can be transferred back to the CAD system. 1.3. The Model The model for the topology optimization was modified in such a way that the inner areas of the component are filled with elements to create a design area. In that area, the optimization system can remove or rearrange elements for getting a better solution with lower weight and the same mechanical behavior. The start model for the optimization represents a design of a control arm for a car. The component has to be manufactured by forging and consists of aluminum.

    The red areas of the component are not free for the optimization because they are used for the fixtures and for the load application. One red area is used for the mounting of a sensor for the headlight range adjustment. The fixture is realized with spring elements on the right upper red area. The springs represent a rubber bearing. The left bearing is fixed in all three translation degrees of freedom. As loading, 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.

    Optimization model representing the design area of the model.

    BETA CAE Systems S.A.


    ANSA v.13.x1.4. Optimization Task

    Optimization with ANSA

    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 the reciprocal value of 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 57% of the initial volume/ weight of the structure. As manufacturing constraint 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). 1.5. Data tosca topology optimization The files of this tutorial are located in the directory /ANSA-installationdirectory/docs/tutorials/MORPH_OPTIMIZATION/tosca_topo/tutorial_files The file is: Control_arm_tosca_env.bdf initial FE-model in NASTRAN format Note: in case another solver is needed to tosca topology optimization used,the appropriate input files are also located tosca topology optimization the same path.

    BETA CAE Systems S.A.


    ANSA v.13.x

    Optimization with ANSA

    2. RecipeIf you have never worked with ANSA-TOSCA Environment before, skip this summary and go directly to the detailed description. If you do have some experience with ANSA-TOSCA Environment you can try to generate your parameter file just using the recipe summary. Recipe summary Preprocessing 1. Load the ANSA-TOSCA Environment Task in Task manager: Tasks> TOSCA Structure Task> TOPO_CONTROLLER. 2. Input file: PRE_PROCESSING> MODEL_LINK(NASTRAN)> New> FILE PRE_PROCESSING> MODEL_LINK>FILE> Update 3. Design area: PRE_PROCESSING> TOPOLOGY_OPTIMIZATION_CONTROLLER> DESIGN_AREA> Edit 4. Design constraints: PRE_PROCESSING> TOPOLOGY_OPTIMIZATION_CONTROLLER> DESIGN_AREA> DV_CONSTRAINTS 5. Objective function: PRE_PROCESSING> TOPOLOGY_OPTIMIZATION_CONTROLLER> OBJECTIVE_FUNCTION 6. Constraints: PRE_PROCESSING> TOPOLOGY_OPTIMIZATION_CONTROLLER> CONSTRAINTS 7. Saving TOSCA Structure Anytrans 6.3.5 Crack + Keygen Full Version Free Download file: PRE_PROCESSING> TOPOLOGY_OPTIMIZATION_ CONTROLLER> Output Start Optimization 8. Running TOSCA Structure: START_OPTIMIZATION> RUN Postprocessing 9. Viewing the intermediate results: POST-PROCESSING> GENERATE_POST_FILE Result Transfer and Validation Run 10. Smooth surface: SMOOTH> SMOOTH_INSTANCE> RUN_SMOOTH 11. Modified surface: SMOOTH> SMOOTH_INSTANCE> VALIDATE> BATCH_RECONSTRUCT 12. Remeshing: SMOOTH> SMOOTH_INSTANCE> VALIDATE> SOLID_MESH 13. Saving the result: SMOOTH> SMOOTH_INSTANCE> VALIDATE> VALIDATION_OUTPUT 14. Running the solver: SMOOTH> SMOOTH_INSTANCE> VALIDATE> VALIDATION_RUN Please note that TOSCA Structure 7.0 is required in order to complete the optimization task. With previous


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    Lesson content:

    Structural Optimization including Nonlinearities

    Nonlinear Constitutive Material Laws

    Plastic Strain Minimization in Pure Mechanical Applications

    Plastic Strain Minimization in Thermo-mechanical Applications

    Shape Optimization of Contact Areas

    Chassis Arm: Geometric Nonlinearities

    Workshop 2

    1.5 hours

    Lesson 6: Shape Optimization for Structures with Nonlinearities

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