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Ansys Shapeopt

# Ansys Shapeopt

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Published by: api-3833671 on Oct 18, 2008

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03/20/2014

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ANSYS TUTORIAL \u2013 Shape Optimal Design of a Bracket
ANSYS Release 9.0
Dr. A.-V. Phan, University of South Alabama
1 Problem StatementFigure 1: Bracket to be designed

A bracket as shown in Fig. 1 is made of 7075-T651 aluminum (E = 71, 018 MPa,\u03bd = 0.33). An initial geometry of the bracket is given in the \ufb01gure (dimensions in mm). The bracket is clamped at the left hub and carries a downward load at the right hub. The load is modeled as a uniform pressurep = 50 N/mm2 as shown. Perform the minimum weight design of the structure while the allowable stress is assumed to beSy /1.5 where the yield strength of the material is assumed to beSY = 524 MPa. Here,R1 ,R2 ,R3 ,R4 andW are used as the design variables. Based on some physical constraints,R1 is limited to be no greater than 45 mm.

2 Data Preparation for the Bracket Geometry

Consider a general shape of the outer boundary of the bracket (thick solid lines) as shown in Fig. 2. Within ANSYS, this shape can be constructed using the four keypointsK1 throughK4. Their coordinates are

x1= R1cos \u03b1
y1= R1sin \u03b1= R1
\ue000
1\u2212 cos2\u03b1
x2= x1
y2=\u2212y1
x3= L+ R2cos \u03b1
y3= R2sin \u03b1= R2
\ue000
1\u2212 cos2\u03b1
x4= x3
y4=\u2212y3
where, from the triangle OAB,
cos\u03b1 =OB
OA=R1\u2212 R2
L
Similarly, the boundary of the cutout (shown by the dash lines in Fig. 2) can be constructed
using the keypointsK5 throughK8. The coordinates of these keypoints are given by
x5= (L\u2212 W)/2 + R4cos \u03b2
1
K
1
K
3
1
2
R
R
x
y
K4
\u03b1
O
A
BK2
K
KK
K
W
\u03b2L =200
4
R
3
R
7
8
65
Figure 2: Determination of keypoints
y5= R4sin \u03b2= R4
\ue001
1\u2212 cos2\u03b2
x6= x5
y6=\u2212y5
x7= (L+ W)/2 + R3cos \u03b2
y7= R3sin \u03b2= R3
\ue001
1\u2212 cos2\u03b2
x8= x7
y8=\u2212y7
where
cos\u03b2 =R4\u2212 R3
W
3 Problem Formulation
Note that, in addition to some physical constraints imposed onR1, the geometry of the bracket
also implies the following constraints:
R4 < R1\u226445 mm
R3 < R2\u226445 mm
30 +W +R3 +R4 < L
or
W+ R3+ R4 <170 mm
cos\u03b2 < 1
or
W2\u2212( R4\u2212 R3)2 >0
Thus, the problem formulation may be written as follows:
Minimize
Volume =f (R1 ,R2 ,R3 ,R4 ,W ) [\u00b110 mm3]
2
Subject to
0\u2264\u03c3VM \u2264 349.33
[\u00b11 MPa]
5\u2264S1 \u2264 45
[\u00b11 mm]
5\u2264S2 \u2264 45
[\u00b11 mm]
5\u2264S3 \u2264 160
[\u00b11 mm]
0\u2264S4 \u2264 1000
[\u00b10.1 mm2]
25\u2264R1 \u2264 45
[\u00b11 mm]
15\u2264R2 \u2264 45
[\u00b11 mm]
5\u2264R3 \u2264 45
[\u00b11 mm]
5\u2264R4 \u2264 45
[\u00b11 mm]
5\u2264W \u2264 170
[\u00b11 mm]
(1)
whereS1 =R1\u2212 R4,S2 =R2\u2212 R3,S3 =W +R3 +R4, andS4 =W2\u2212 (R4\u2212 R3)2.
4 Creating a Log File
An example of a log \ufb01le required for the optimization process is given as follows:
/BATCH
! /COM,ANSYS RELEASE 9.0A1 UP20050128
22:57:20
09/29/2005
!*
!* Fixed parameters

!*
*SET,L,200
*SET,R,10
!*

!* Initialize the design variables

!*
*SET,R1,40
*SET,R2,40
*SET,R3,20
*SET,R4,20
*SET,W,50
!*

!* Define the state variables due to geometry constraints

!*
*SET,S1,R1-R4
*SET,S2,R2-R3
*SET,S3,W+R3+R4
*SET,S4,W*W-(R4-R3)*(R4-R3)

3

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