Topology Optimization For Designers

NX 12 Topology Optimization for
Designers
Guy Wills – Topology Optimization Product Manager
Restricted © Siemens AG 2017 Realize innovation.

Agenda
• Product Highlights
• Uses for Topology Optimization results
• Model Construction Opportunities
• Optimization Features
• Design Constraints
• FE Loads & Constraints
• Materials
• Optimization
• Results
• Summary
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Product Highlights
• Uses a different workflow than traditional Topology Optimization solutions.

• Works in the NX CAD work part in the context of an assembly.
• Single or multiple Design Spaces. Each has it’s own:
• Construction method
• Material
• FE loads & constraints
• Optimization constraint value, eg mass target
• Model construction uses the product Functional Requirements, eg:
• Keep in/out volumes.
• Cylindrical holes with offset material around the hole.
• Counter bore holes with space for screw head, nut, socket wrench etc.
• 5mm clearance.
• Level of resolution control.
• Highly smoothed, organic shapes with sharp edges where required.

Uses for Topology Optimization Results
Topology Optimization is not the finish, for many parts it’s

just the start. Many opportunities exist to use the Topology
Optimization results.
1. Direct to AM machine for printing.
2. Direct to cast, mold or multi-axis machining.
3. Use for further Design or Simulation using Convergent
models.
• Convergent model is a new Parasolid data format
introduced in NX 11.
• Single data format for both/either NURBS and Facet
geometry. Existing modelling functionality will work
on both in the same CAD body.
4. Guidance for re-modelling using traditional CAD tools.
Holes cut into Convergent Facet model

Workflow
Workflow is centred around the

management of the Design Manage Bodies
Space(s) and Scenery bodies. Connections
Assign Materials Design

Constraints
Manage Bodies
Optimization
Manage Global Loads or Scenery
Features
Setup & Run Load Cases

Optimization
View Results

Topology Optimization in the Assembly Context
• Works in the NX CAD Work part in the context

of an assembly.
• Enables users to reference the context
geometry to:
• Build the design space shape.
• Locate connecting holes, pads, plates etc.
• Define keep-in/out geometry relative to the
context geometry.
• Define load vectors relative to the context
geometry.
• Assembly components need to be
WAVE Linked to the Work Part.

Single & Multiple Design Spaces
• Single Design Space or the ability to solve

the Topology Optimization problem as a Design Space
(Aluminium)
connected assembly
• Design Space
• This is the body that encompasses
a space assigned for the Optimizer Scenery Scenery
Design Space
Body Body
to work with. (Aluminium)
(Steel01) (Steel02)
• Scenery Body
• This is any other body connecting
with Scenery Scenery Scenery
a Design Space that will transfer Body
Design Space
Body Body
loads (Aluminium)
(Steel01) (Steel02) (Steel02)
through to a Design Space. It is not
optimized.
• Multiple Design Spaces will be solved at Scenery Design Space Design Space Scenery
the same time. Body 01 02 Body
(Steel01) (Aluminium) (Brass) (Steel02)

Design Space
• The Design Space is the envelope that the Topology Optimization engine will see.
So to be included in the solution, the Optimization Features must lie wholly or
partially within the Design Space.
• The Design Space can be
• any Solid body (no limit on creation method)
• or a closed (water tight) Faceted body
Design Space

Manage Bodies
Bodies that are to be used as a Design

Space or for Scenery.
Bodies must exist in the Work Part.
Design Spaces
• Loads
Table Reordering
Scenery bodies
• Loads

Connection Construction
Use Case 1 Use Case 2 Connection types:

• Glue
• Rigid (NX 12.0.1)
Connection Region Pair of bodies
Scenery Design Scenery

Design Space
Body Space Body
Connection Region Pair of bodies
Connection Bodies are the Scenery & Orange bodies associated to the Scenery Body
Design Bodies. Blue bodies associated to the Design Space
Scenery Body is used as an Optimization
feature in the Design Space as Keep Out
or Shell.

Connections
Selecting two bodies enables the user to create

Connection between them.
Types of Connection:
• Glue
• Similar to the NX Nastran Glue type
• Rigid (12.0.1)
Manage overlapping bodies
• No change to either body
• Subtract body A from body B
• EXTRUDE(12) from EXTRUDE(6)
• Subtract body B from body A
• EXTRUDE(6) from EXTRUDE(12)
EXTRUDE(12)
EXTRUDE(6)

Optimization Features
• Design Spaces and Scenery Body can have Optimization Features.

• Functional Requirements are described by the use of Optimization
Features.
• Some NX modelling features are mapped to the optimization application
features. These include the following types:
• Cylinder, Block and Sphere primitives
• Copy Face
• Simple Hole
• Counter Bored Hole
• Further solid bodies (no limit on creation method) can also be added to
the Optimization Features list.
• The Design Space is the envelope that the Topology Optimization
engine will see. So to be included in the solution, the Optimization
Features must lie wholly or partially within the Design Space.

Introductory Demos

Optimization Features
The combination of the Design Space & the Optimization Features define
the space that the Topology Optimization has to work with.
The order of the Optimization Features list can be important. Features Reorder
below will cut through the ones above, if they intersect. Re-ordering the
Optimization Features enables the user to control which feature will cut
others.
If the Optimization Features don’t intersect, Red block moved to

the bottom of the list
the user has the freedom to organize as desired.

Optimization Feature – Properties
Each Optimization Feature will have properties that define it’s use in the Topology
Optimization. Some Features have fixed properties.
• Keep-In/Out
• A feature can be defined as a
• Keep-In – there must be material in that volume
during the Topology Optimization.
• Keep-Out – there must be no material in that
volume during the Topology Optimization.
• Shell – this creates a constant wall thickness
shell around the selected feature
• Simplified Holes and Counter Bored Holes are always
Keep-Out Optimization features.

Keep In Optimization Feature
Any CAD body can be used as a Keep In Optimization Feature.

This ensures the Keep In feature’s space will be included in the
final optimized model. Unless it is cut by other optimization
features.
Used to maintain connections to surrounding components, to
limit the optimizers freedom, etc.
Keep In Green
Optimization
Features
These CounterBore Optimization

Features cut through the Keep In
features

Keep Out Optimization Feature
Any CAD body can be used as a Keep Out Optimization

Feature.
A Keep Out Optimization Feature tells the optimizer that no
material can be placed in this space.
Some Optimization Features are pre-defined as Keep Out
features, these include:
• SimpleHole Keep Out
CounterBore
• CounterBore Hole Holes
Keep Out
Block

Shell Optimization Feature
A Shell Optimization Feature is similar to the NX CAD Shell command creating a

uniformly thick offset of the body.
Offset Thickness value defines the wall thickness of the Shell.

Optimization Feature – Properties
• Offset Thickness
• To define a hole it must have material around the
Offset Thickness on a
hole. This is the Offset Thickness on a Hole feature.
CopyFace feature
• Offset of a solid Keep-Out body.
• Offset of Copy Face features (similar to an NX
Thicken feature).
Offset Thickness
around a solid
Keep-Out body
Offset Thickness on
a Hole feature

Design Constraints
Rules to guide the geometry shape during the optimization.
Design Constraints available

• Planar Symmetry
• Rotational Symmetry
• Extrude Along a Vector
• Draft
• Void Fill
• Material Spreading
• Overhand Prevention
• Self-Supporting

Design Constraints – Planar Symmetry
Planar Symmetry
• Single or dual symmetry planes.
• Only half (or quarter) Design Space required.
• Whole model returned with blending across the symmetry plane(s).
Two Symmetry Planes
Single Symmetry Plane

Design Constraints – Rotational Symmetry
Rotational Symmetry
• Only a segment is required for the Design Space.
• Whole model returned with blending between the segments.
Stress Results

Design Constraints – Extrude Along a Vector
Extrude Along a Vector

• Where possible the optimized shape will be a constant cross-section normal to the
specified vector.
• Useful for a part to be made using 2.5 axis machine tool.

Design Constraints – Draft
• Draft is applied to the model relative to an automatically located neutral

surface, relative to a plane or a collection of surfaces.
• Significant amount of time saved compared to manually creating the draft
effects.
• Repeatable allowing the user to tweak, for example, the Parting Surfaces
to get the result they need.
Surface Type = Auto Surface Type = Surfaces

Draft vector = Hole axis Surface Type = Plane Draft vector = Hole axis
Draft vector = Normal to Parting Plane
Design Constraints – Draft Example
Surface Type = Auto

Draft vector = Z

Design Constraints – Void Fill
Void Fill
• Parts with interior voids will have the voids filled with wasted expensive metal powder.
• This Design Constraint prevents internal Voids will being created or other surfaces not
directly accessible from outside the part.
Voids

Design Constraints – Material Spreading
Material Spreading
• This controls how the material is “pushed apart”.
• Have the model tend towards a hollowed out model, a thing walled model or a
strut like model.
Material
Spreading = 100%
Struts
Material
Spreading = 60%
Thin Walls
Material
Spreading = 30%
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Design Constraints – Overhang Prevention
Overhang Prevention
• Prevents overhanging geometry along the specified vector.
• This is important for parts built using a powder bed additive manufacturing method.
Overhanging geometry often requires supports to hold it up during the manufacturing
process. Reducing or removing the need for supports reduces time and cost to make the
part.
No Constraint
Overhang Prevention Constraint

Design Constraints – Self-Supporting
Self-Supporting
• The angle wrt to the base plate plane, beyond which that the geometry can
not support its self as each layer is created during the AM process. This
Constraint ensures the resultant model is not smaller than the angle.
Build
Direction
Self-Supporting &
Overhang Prevention Build
Constraint Direction
Part
Self-Supporting
Angle
No Constraint
Base Plate

Design Constraints – Multiple Design Constraints
• Applying multiple Design Constraints can produce interesting and

impressive results. And the order they are applied and also change
the result
• In the example shown, the Design Space will have the Planar
Symmetry applied, followed by Extrude Along a Vector. This
implies that Extrude Along a Vector takes precedence over Planar
Symmetry in the case that both cannot be satisfied.
• By selecting a Design Constraint it can be moved Up of Down thus
changing the order the Design Constraints are applied and the
resultant geometry.

Design Constraints – Per Design Space
Each Design Space can have it’s

own set of Design Constraints.
Material Spreading
Fill Void
Draft

Displacement Constraint
Displacement Constraint can be added to a Optimization

Feature in a Design Space or Scenery Body.
• Magnitude in any direction.
• Magnitude in a specific direction.
Can be used to constrain deformation of the of the model.
Max Displacement in -Z

Load Cases
• Different combination of loads can be applied using Load Cases. For example,
front loads, side loads, top loads, etc. The solution will take all these different
load cases into account.
4x Load case examples

FE Loads
Loads are applied to Optimization Features

per Design Space and Scenery Body.
Load types available:
• Force
• In single direction
• Pressure
• Normal to commonly applied CopyFace
• Torque
• On a revolved feature
• Bearing Load
• On a resolved feature
• Enforced Displacement
• Along a vector

FE Constraints
Constrain to Ground are applied to

Optimization Features per Design Space
and Design Space.
Constraints available:
• Fixed
• In all directions
• Pinned
• Allowed to rotate about a vector
• Linear Slider
• Allowed to slide in one vector
• Planar Slider
• Allowed to slide in any direction
within a plane

Global Loads
Global loads are applied to the whole model.
Global Loads available:

• Acceleration
• Most commonly used to add a Gravity load for geometry that as a
significant mass that can affect the results.
• Temperature
• Used when the part will operate in a area where the temperature is
higher than the normal 20degC and the material has temperature
varying properties.

Materials
• All Design Space and Scenery bodies must have a

Material assigned before Optimization.
• Any mix of Isotropic & Orthotropic material types are
supported.
• Isotropic
• Material properties are the same in all
directions. Most commonly used and properties
available.
• Orthotropic
• Material properties vary in X, Y, Z axis.
• Can be used to simulate parts where the
properties in the Build Direction are different to
the in-layer plane.
• Orthotropic axis align with the global axis.

Optimization Types
One combination of optimization Objective and Constraint.

• Minimize strain energy subject to mass target.
• Maximize the parts stiffness whilst reducing the mass to a
target value.
• Each Design Space has it’s own Mass Target.
Top Design Space

Mass Target = 0.15kg
Btm Rgt Design Space

Btm Lft Design Space


Resolution & Estimating Optimization Parameters
Resolution
• A slider bar is presented to enable the user to choose a Resolution
between “Fast & Coarse” or “Slow & Fine”.
• The value chosen by the user is important to the results as it
dictates how much detail is “carved” out of the model.
• During exploration, leaving the slider towards the Fast/Coarse end
will give good indication of what the Topology Optimization is doing.
Enabling the user to adjust/change the model setup as required.
• Once the user is happy with the model setup, then moving the
slider more to the right will generate the detail in the model.
Estimate Optimization Parameters
• Based on the Resolution selected this option calculates the following
for each Design Space to guide the user:
• Approximate Design Space Mass
• Minimum Mass Target

Running the Topology Optimization
• During the Topology Optimization a first rough pass

is performed to size the problem, followed by a
second pass. This better ensures a good result.
• The Topology Optimization performance is shown
in the bar chart diagram.
• After the Optimization run the Status changes to
Meshing. This indicates the Optimization has
completed and the result (mesh) models are being
created.
• The log window reports the Optimization results per
Design Space and Scenery body.

Geometry Results
For each Design Space and Scenery body there will be 3 faceted models.
User can use the normal NX display options to control what they want to view.
Optimization results are stored as Attributes on the body.
Geometry Displacement Von Mises Stress

Topology Geometry Results
• Highly smooth organic results with sharp edges were required.

• For many models no further modelling is required.
• Auto Blend can be turned off and specific Blend radii used to
tighten or smooth out connections to a Feature.

Displacement Results
The Displacement (magnitude) results are available for each Design

Space and Scenery body.
The results shown are the max values envelope across all the load cases.
The results are quantitatively good and can confidently be used to guide
design decisions.

Stress Results
The Von Mises stress results are available for each Design Space and Scenery
body.
The results shown are the max values envelope across all the load cases.
The results are quantitatively good and can confidently be used to guide design
decisions.

Uses for Topology Optimization Results
Topology Optimization is not the finish, for many parts it’s

just the start. Many opportunities exist to use the Topology
Optimization results.
1. Direct to AM machine for printing.
2. Direct to cast, mold or multi-axis machining.
3. Direct use in Design or Simulation using Convergent
models.
• Convergent model is a new Parasolid data format
introduced in NX 11.
• Single data format for both/either NURBS and Facet
geometry. Existing modelling functionality will work
on both in the same CAD body.
4. Guidance for re-modelling using traditional CAD tools.
Holes cut into Convergent Facet model

Summary
• New approach to optimizing the topology within the given design

space.
• Designer for CAD users and does not require deep CAE
expertise.
• Focuses on the Functional Requirements of the design.
• Results are returned quickly.
• Highly smoothed Convergent model results
ready for AM printing, or guidance for re-design.

Guy Wills
Product Manager
Simcenter 3D Engineering Desktop
E-mail:
guy.wills@siemens.com
Realize innovation.

Topology Optimization For Designers

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NX 12 Topology Optimization for

Restricted © Siemens AG 2017 Realize innovation.

Page 2 20YY.MM.DD Restricted © Siemens AG 2017 Siemens PLM Software

• Uses a different workflow than traditional Topology Optimization solutions.

Page 3 20YY.MM.DD Restricted © Siemens AG 2017 Siemens PLM Software

Topology Optimization is not the finish, for many parts it’s

Holes cut into Convergent Facet model

Page 4 20YY.MM.DD Restricted © Siemens AG 2017 Siemens PLM Software

Workflow is centred around the

Assign Materials Design

Setup & Run Load Cases

Page 5 20YY.MM.DD Restricted © Siemens AG 2017 Siemens PLM Software

• Works in the NX CAD Work part in the context

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• Single Design Space or the ability to solve

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Bodies that are to be used as a Design

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Use Case 1 Use Case 2 Connection types:

Scenery Design Scenery

Connection Region Pair of bodies

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Selecting two bodies enables the user to create

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• Design Spaces and Scenery Body can have Optimization Features.

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If the Optimization Features don’t intersect, Red block moved to

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Any CAD body can be used as a Keep In Optimization Feature.

These CounterBore Optimization

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Any CAD body can be used as a Keep Out Optimization

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A Shell Optimization Feature is similar to the NX CAD Shell command creating a

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Rules to guide the geometry shape during the optimization.

Design Constraints available

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Two Symmetry Planes

Single Symmetry Plane

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Extrude Along a Vector

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• Draft is applied to the model relative to an automatically located neutral

Surface Type = Auto Surface Type = Surfaces

Surface Type = Auto

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Overhang Prevention Constraint

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• Applying multiple Design Constraints can produce interesting and

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Each Design Space can have it’s

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Displacement Constraint can be added to a Optimization

Can be used to constrain deformation of the of the model.

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