The 4nd Altair Optimization Competition

Copyright 2009 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

2011 Altair

: : : : (3) : : : : : (3) :

www3.altair.co.kr/aoc09

(CAx- )

Contents

Summary

A : Battery Tray Topology Optimization 6

: Bike Frame Topology & Size Optimization

20

A (Design Concept, Final CAD design, Optimization )

( Design Concept, Final CAD design, Optimization )

Battery Tray Optimization Result : Summary

Initial Design

Topology Optimization

Final CAD Design Magnitude of Disp. (mm)

Mass (kg)
3.98 3.91

1.7%

Base Analysis

Final Topology Optimization

Bike Frame Optimization Result : Summary

Initial Design
Mass (kg)

Topology Optimization
Max.V-M Stress (kgf/mm2 )
33.58

Final Size Optimization

Max. Displacement (mm)
0.12

-35.5%

-62.9%
15.19

20.71

-61.7%
0.04

Final Size Topology Optimization Optimization

Redesign Analsys

Final Size Optimization

Redesign Analsys

Final Size Optimization

 A
Topology Optimization ( Battery Tray )

Contents
1.Whats Battery Tray ? 8 2.Base Analysis FE Model 9 3.Setup for Optimization Analysis 11 4.FRF Modal Method(Lanczos)Analysis Result 12 5.Analysis Direction for Topology Optimization 13 6.Paramter Study 14 7.Optimization Result 17

1.What`s Battery Tray?

Battery Tray
Battery

Battery Tray

2.Base Analysis FE Model

FE Model
Battery Tray (Sheet metal, t = 2mm)
Youngs Modulus (E) : 2.1105 N/mm2 Poisson Ratio () : 0.3 Density () : 7.810-9 N-s2/mm4

Center Point(ID : 136718)

Measurement Point for Displacement

Center Point of Design Space Part (ID:136718) Displacement 0.25 mm Average Mesh Size : 5 mm (Using Size and Bias in Hypermesh) Target Object for Optimization
Battery Tray

Design Space
Design : PSHEEL(t0 : 2mm)
298.2 mm

Component Property Material

Non-Design : PSHEEL(t0 : 2mm) Vertical-Non-Design : PSHEEL(t0 : 2mm)

Steel
235 mm 500.4 mm

2.Base Analysis FE Model

Part for Battery Tray Model

Design Region

Initial Design Model

Non-Design Region
10

3.Setup for Optimization Analysis

Condition for Topology Optimization
Frequency Response Function : Modal Method(Lanczos)
Response Analysis : 0 EIGRL 3000Hz Disp. Value for Frequency : 0 FREQI 1000Hz

Constraint Condition
FRF Disp. 0.25 mm Rib Thickness 3 mm

All Fixed

Objective Function
Min. Mass

Force:50N

Battery Tray for Boundary Condition

11

4.FRF Modal Method(Lanczos)Analysis Result

Frequency Response Analysis
0, 50, 200 Hz Constraint Condition

12

5.Analysis Direction for Topology Optimization

Change for Thickness of Design Region
Constraint Condition 3mm
Topology Condition : 2mm Based Thickness 3mm Initial Mass for Design Region : 2.36 kg Objective Function : Min. Mass Rib ( )

Design Region

Optimized Design Region

13

6.Paramter Study : Effect of Upper Bound

Upper Bound 0.25 mm Upper Bound 0.24 mm Upper Bound 0.23 mm

Mass : 1.66 kg 29.73%

Mass : 1.68 kg 28.91%

Mass : 1.71 kg 27.70%

Max. Magnitude (50Hz) 0.25 mm 0.25 mm

Max. Magnitude (50Hz) 0.24 mm 0.25 mm

Max. Magnitude (50Hz) 0.23 mm 0.25 mm

Selected
14

6.Paramter Study : Pattern Grouping

1-plns-sym 2-plns-sym cyc 1-pln

Max. Thickness 3mm 3mm

Max. Thickness 3mm 3mm

Max. Thickness 3mm 3mm

Max. Magnitude (50Hz) 0.251mm > 0.25mm

Max. Magnitude (50Hz) 0.25 mm 0.25mm

15

Max. Magnitude (50Hz) 0.25 mm 0.25mm

Selected

6.Paramter Study : Pattern Grouping

Comparison of the Mass for Pattern Grouping
2-plns-sym cyc 1-pln

Mass : 1.66 kg 29.73%

Mass : 1.65 kg 30.04%

Selected

16

7.Optimization Result
CAD Modeling based on Optimization
Constraint Condition Rib(z1,z2,z3)
3 mm 2.01 mm 3 mm 2.5 mm z2 z3 z1

Initial Design SHELL

t :2.01 mm

Topology Optimization

Modeling Design
25 mm

SOLID
t : 1.005 mm

z3 z1 37 mm 25 mm

15 mm

Design Region

z1,2,3 mm

Drag (+Z ) z1 = 3.0 mm 1.005 mm = 1.995 mm z2 = 3.0 mm 1.005 mm = 1.995 mm z3 = 2.5 mm 1.005 mm = 1.495 mm

Rib Part

z2 90 mm

17 mm

Modeling for Thickness

17

Dimensions for Modeling

7.Optimization Result (Cont`d)

Analysis for Modeling
Max. Displacement : 0.237 mm (50 Hz) 0.25 mm

18

7.Optimization Result : Summary

Initial Design

Topology Optimization

Final CAD Design Magnitude of Disp. (mm)

Mass (kg)
3.98 3.91

1.7%

Base Analysis

Final Topology Optimization

19


Topology & Size Optimization
for Weight Reduction of a Bike Frame

20

Contents
1.Whats Bike Frame 2.Base Analysis Model 3.Setup for Analysis

22 23

4.Optimization Result
5.Setup for Size Analysis 6.Size Optimization Result 7.Bike Frame Topology & Size Optimization Result of a Bike Frame

24

27

30 32

34

21

1.Whats Bike Frame

Bike Frame

Bike Frame

22

2.Base Analysis Model

Material
Aluminum 6061
Youngs Modulus (E) : 6.9104 kgf/mm2 Poisson Ratio () : 0.33 Density () : 2.7710-9 kgf/mm4

Model
Target
Object for Optimization Component Property

Bike Frame
Design Design PSOLID Non-Design PSOLID

Material

Aluminum 6061

Shape of Bike Frame

23

3.Analysis Setup
Part for Bike Frame Model
Head Tube

Non Design Region

Design Region

Seat
Bottom Wheel Connect Frame Body

Head Tube

Seat

Non-Design

Bottom

Wheel Connect

Initial Design
24

Design

3.Analysis Setup (Contd)

Boundary Conditions for Bike Analysis

Normal
- 2 3000N(1 150kg )

Force

Bottom

Frame
-125cc 500N

Body

Bike ,
- : 900N , : 1800N

Brake

Brake
-5600N

Corner
- Conner (45)

Direction of Force

: Honda Fact Book VT250F

25

3.Analysis Setup (Contd)

Boundary & Optimum Design Condition
Objective function : Min. Volume Constrain Condition : 24 kgf/mm2 Constraints Normal Disp. Bottom Disp. Body Disp. Brake Disp. Conner Disp.
1000N 3000 N 1000N

900N

Body
3000N

0.05 mm 0.05 mm 0.05 mm 0.05 mm 0.05 mm

5600N

Normal

500N 500N 900N

Conner
26

Brake

Bottom

4.Optimization Result
Iteration Objective Function
59 Iteration

Iteration 0

Iteration 29

Iteration 58

27

4.Optimization Result (Contd)

CAD Modeling based on Optimization

28

4.Optimization Result (Contd)

Initial Design

Topology Optimization

CAD Design

29

5.Setup for Size Analysis

Initial guess
Load Case Top Tube Down Tube Seat Tube Seat Stay
30

Optimum Design Condition

Thickness(mm)
2 2 2 2 40 2 30 40 30 30

Diameter(mm)

Objective function : Min. Volume

Constraints Normal Disp. Bottom Disp. 1.0 mm 0.5 mm 1.0 mm 1.0 mm 1.0 mm

Top Tube Seat

Body Disp. Brake Disp. Spin Disp.

30mm

Seat Tube Stay Down Tube

40mm

Initial Condition for Bike Frame

30

5.Setup for Size Analysis (Cont`d)

Condition for Size Optimization
Using the Discrete Design Variable Size Panel
2mm 10mm 0.5mm

Load Case Down Tube Stay

Constraints
From : 2 To : 10 Increment : 0.5 From : 2 To : 5

Optimum Size Load Case

Thickness(mm)
Top Tube Down Tube Seat Tube Seat Stay
2 2.5 5 2.5 7

Top Tube
Seat Seat Tube

Increment : 0.5

Condition for Size Optimization

Result for Size Optimization

31

6.Size Optimization Result (Contd)

Redesign Model Result(t0:2mm)
Size Optimization Result

Normal

Displacement (mm)

Max : 0.12

Max : 0.04

Normal

V-M Stress (kgf/mm2)

Max :33.58
32

Max : 20.71

6.Size Optimization Result (Contd)

Topology Optimization
40.86

Mass (kg)

Final Shape for Size Optimization

-62.9%
15.19

Topology Optimization

Final Size Optimization

33

7.Optimization Result : Summary

Initial Design
Mass (kg)

Topology Optimization
Max.V-M Stress (kgf/mm2 )
33.58

Final Size Optimization

Max. Displacement (mm)
0.12

-35.5%

-62.9%
15.19

20.71

-61.7%
0.04

Final Size Topology Optimization Optimization

Redesign Analsys

Final Size Optimization

Redesign Analsys

Final Size Optimization

34