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Matthew Hopkins, Ann-Marie Lambert
Tortworth Court, South Gloucestershire
SIMULIA Tutorial

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SIMULIA Tutorial
Agenda
ATOM Abaqus Topology Optimisation Module
Introduction and demonstration

Latest Enhancements in Abaqus/CAE
A summary of enhancements and demonstration

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Abaqus Topology Optimisation Module (ATOM)

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SIMULIA Tutorial
ATOM
What is ATOM?
ATOM stands for Abaqus Topology Optimization Module
It allows for convenient setup and postprocessing of two classes of
Structural optimization problems
1. Topology optimization




2. Shape Optimization

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SIMULIA Tutorial
Topology Optimization
Given an initial material distribution (left), topology optimization produces
a new landscape (right) by scaling the relative densities of the elements
in the design domain.
Elements with large relative densities are retained whilst those
elements whose relative densities have become sufficiently small
are assumed to be voids. Thus a new landscape is obtained.

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SIMULIA Tutorial
Shape Optimization
Shape optimization refers to procedures that result in the prediction of a
boundary (or shape) of the design domain of the structural/mechanical system
to be optimized.
In a finite element analysis, nodes on the boundary are displaced in order
to achieve an objective (minimise the stress on the surface for example).
Thus, a new shape is obtained.

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SIMULIA Tutorial
ATOM
Both Topology and Shape Optimisation support:
Contact
Geometric non-linearity
Nonlinear Materials:
Within the design area: *plastic, *hypoelastic, most *hyperelastic
Outside design area: all
Manufacturing restrictions
Export smoothed shape to STL or INP

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SIMULIA Tutorial
ATOM Workflow: Setup
The flow chart on the left shows the user
actions required to setup the optimization
Each user action is associated with a
manager in the Optimization module
accessible from the Optimization
Module Toolbox or the Model Tree

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SIMULIA Tutorial
ATOM: Basic Terminology
Design Responses provide variables for the optimization
solver
For example: Strain Energy, Displacement etc.
Objective Functions define how those
Design Responses should be used
(sum/min/max/formula/etc)
Minimise Strain Energy (maximise stiffness)
Constraints determine bounds for the optimization solver
For example: Constraint the volume to be less than
35% of the original volume
Geometric Restrictions provide for manufacturing
restrictions
For example: de-molding direction with draft angle
Stop conditions
Maximum number of iterations

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SIMULIA Tutorial
ATOM Workflow: Execution and Monitoring
Once an Optimization Task is setup, an Optimization
Process needs to be defined to execute the optimization
Users may have multiple Abaqus models and optimization
tasks defined. An optimization process refers to a unique
Model and Task combination.
Right-click on the optimization process to access: Validate,
Submit, Restart, Monitor, Extract and Results postprocessing

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SIMULIA Tutorial
ATOM Workflow: Results
The Abaqus Visualization module allows for convenient
visualization of optimization results
Postprocessing will be shown in more detail during
the demonstration

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SIMULIA Tutorial
ATOM Workflow: Extraction
Optimization
results can be
smoothed and then
extracted as
Abaqus input files
or STL files

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SIMULIA Tutorial
SIMULIAs Design Exploration and Optimization Tools
ATOM Isight
Tuned for topology and shape
optimization
A general purpose design exploration
and optimization package
Non parametric Parametric
Can handle a very large number of
design variables. (~100K-1000K)
Meant for small number of design
variables(~10-100)
Multiple objectives are summed up to
single objective
Multi-objective, multi-discipline
optimizations possible
ATOM Isight
DOE
Monte Carlo
Exporation
Taguchi RD
Six Sigma
Optimization
Topology
optimization
Shape
optimization
Test Data
Match

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Optimisation of a Brake Pedal
Demonstration

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SIMULIA Tutorial
ATOM Brake Pedal Demonstration
Linear elastic Steel material
Nonlinear Geometry
Loading causes out of plane warping effects

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SIMULIA Tutorial
ATOM Brake Pedal Demo
Objectives
To maximise the stiffness (minimise Strain Energy)
Constraints
Final volume <=40% of original volume
Lateral Displacement <=2mm

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Leveraging the Latest Enhancements
in Abaqus/CAE

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SIMULIA Tutorial
Summary
CAD Interfaces
Demonstration: CATIA V5 bidirectional
Midsurfacing and meshing
Demonstration
Results visualisation
Demonstration: Contour of beam stresses

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SIMULIA Tutorial
CATIA V5 Bidirectional Associative Interface
Abaqus 6.10-EF
One directional associatively for
CATIA V5
SolidWorks
Pro/ENGINEER (Wildfire)
UG NX
Bidirectional associatively for
Pro/ENGINEER (Wildfire)

New in 6.11
Bidirectional associative interface for
CATIA V5
Both R19 & R20 version
CATIA parameters can be modified from
within Abaqus/CAE
Model is updated in Abaqus/CAE.
CAD geometry and parameters
exported to Abaqus/CAE
Updated parameters
export to CATIA V5

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SIMULIA Tutorial
CATIA V5 Bidirectional Associative Interface
Create/Define Parameters in CATIA V5
Parameters defined in CATIA with ABQ_ prefix are exported
Parameters should be defined at part level
Only Real, Integer, Length and Angle type parameters with single value are
supported.
User parameters will appear in the specification tree under Parameters

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SIMULIA Tutorial
CATIA V5 Bidirectional Associative Interface
Exporting the Geometry and Parameters from CATIA

1) Ensure that CATIA V5 connection is enabled
2) In CATIA, use Abaqus plug-in or Abaqus/CAE icon to export the model.
3) CATIA writes a parameter file(.par_abq) and exchange (.eaf) file.
4) Parameter file is xml based
Contains parts and parameters information

Quick Export
Menu which allows user to set/change the
export option and export the model

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SIMULIA Tutorial
CATIA V5 Bidirectional Associative Interface
Viewing/Modifying parameters

Parameters can be viewed in
Part/Assembly module.
In the Part module, /CAE will
display parameters of active
part only.
In the assembly level, /CAE
will display parameters of all
the parts in the assembly.
In Part module use,
ToolsCAD Parameters

In the Part module use
ToolsCAD InterfacesCAD
Parameters

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SIMULIA Tutorial
CATIA V5 Bidirectional Associative Interface
Viewing/Modifying parameters

Selecting a row in CAD
Parameters dialog will highlight
the geometric faces associated
the selected parameter.
To modify the values from
/CAE, change one or more
parameters values and click
update.
Update will propagate the
changes to the CATIA model
and re-export the model to
/CAE.
/CAE will regenerate the
assembly/part.

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CATIA V5 Bidirectional Interface
Demonstration

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Midsurfacing and Meshing

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SIMULIA Tutorial
Mid-surfacing
Manually create mid-surface representation
of thin solids using geometry edit tools:
Face offset
Face extend/blend
Auto-trim
Benefits beyond mid-surfacing
Mechanism for capturing thickness of
parent solid geometry and association with
shell mesh.
Thickness query and display tools

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SIMULIA Tutorial
Mid-surfacing
Examples: Wheel hub (shown with view cut)

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SIMULIA Tutorial
Mid-surfacing enhancements
Reduce picking needed to create mid-surface
Improved robustness
Offset operation performance
Feature regeneration
New tool for partitioning faces by edge projection
Enhanced heuristics for Extend and Blend geometry tools

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SIMULIA Tutorial
Midsurfacing Enhancements
Auto-selection of Target Faces
Selection of target faces can be time-consuming
Option to automatically select target faces based on proximity
Manual modification of selection
Available only if faces being offset belong to reference representation


Target faces auto-selected
Source face to be offset

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SIMULIA Tutorial
Midsurfacing Enhancements
Option to Extend Target Faces Before Trimming
Using target faces to limit extension is a useful way to fill gaps between
neighboring shell faces
Target faces may sometimes need to be extended (internally) for the
purposes of trimming the selected faces
Allows user to decide whether to extend target faces
OFF by default. Turn ON only when needed


Target face needs to be
extended for trimming
Extend
target
face
Target face need not
be extended
Selected face
being extended
Target face
gap

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SIMULIA Tutorial
Midsurfacing Enhancements
Thickness Attributes on Faces Created by Blend/Cover
Faces created by Blend or Cover will have thickness automatically assigned to
them if the neighboring faces have thickness attributes


2 Offset Faces
Thickness data on
the Offset Faces
New blend face with
thickness inherited
from neighbors
GUI to verify
assigned thickness

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SIMULIA Tutorial
Mesh Editing
New mesh edit functions
Merge/subdivide elements
Grow/collapse short element edges
Bottom-up meshing
Now available for orphan meshes
Generate elements by offsetting
Additional options for extrude method

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Midsurfacing and Meshing
Demonstration

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Results Visualisation

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SIMULIA Tutorial
Contour of beam stresses
New field output identifier
BEAM_STRESS
Mises = Von Mises stress
S11 = Axial stress
S12 = Shear stress along local
beam section 2-axis
S13 = Shear stress along the
local beam section 1-axis
Stress distributions derived using
section/moment values from
linear elastic beam theory
SF (section force) and SM (section
moment) required

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Beam Contouring Demonstration

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Presented at the
2011 SIMULIA UK RUM


Leveraging the Latest Enhancements
in Abaqus/CAE