Topology Optimization

Extension for ANSYS Mechanical

Hong Dong, Juan Pablo Leiva and Phani Adduri

Vanderplaats R&D, Inc
gtam.support@vrand.com

1 © 2014 ANSYS, Inc. June 6, 2014 ANSYS Confidential

 Outline

1. Brief Introduction to VR&D

2. GENESIS Structural Optimization
3. What is Topology Optimization
4. GENESIS Topology for ANSYS Mechanical (GTAM)
5. GTAM Functionality
6. Examples
7. Summary

2 © 2014 ANSYS, Inc. June 6, 2014 ANSYS Confidential

 Brief Introduction to VR&D

Company Profile
• Vanderplaats Research and Development, Inc
(VR&D) was founded by Dr. Gary Vanderplaats in
1984
• In the 70s and early 80s Dr. Vanderplaats wrote
optimizers that became very popular. The users
strongly requested our founder to start our
company to support and enhance the optimizers
• The company since then has devoted itself to
develop best in class optimization software and
technologies

3 © 2014 ANSYS, Inc. June 6, 2014 ANSYS Confidential

 Brief Introduction to VR&D

VR&D Offering
• GENESIS – Structural Optimization
• Design Studio – Pre-Post for GENESIS
• GTAM – GENESIS Topology for ANSYS Mechanical
• VisualDOC – MDO
• DOT – Optimizer
• BIGDOT – Large Scale Optimizer
• SMS – Fast Eigensolver

4 © 2014 ANSYS, Inc. June 6, 2014 ANSYS Confidential

 GENESIS Structural Optimization

Analysis Options • Optimization Options

− Linear Statics − Topology
− Inertia relief − Sizing
− Normal modes − Topometry
− Frequency response − Shape
− Heat transfer − Topography
− Buckling − Freeform
− Random
− Nonlinear Contact

5 © 2014 ANSYS, Inc. June 6, 2014 ANSYS Confidential

 Topology Optimization

What is Topology Optimization?

• Topology optimization is a type of optimization
that allows to carve out a structure from a block
of material

6 © 2014 ANSYS, Inc. June 6, 2014 ANSYS Confidential

 Topology Optimization Examples

7 © 2014 ANSYS, Inc. June 6, 2014 ANSYS Confidential

 Topology Optimization Examples
Wing Frame Structure designed by topological optimization

2012 Corvette
Daytona Prototype

8 © 2014 ANSYS, Inc. June 6, 2014 ANSYS Confidential

 GENESIS Topology for ANSYS Mechanical
(GTAM)
An integrated extension that adds Topology
optimization to the ANSYS® environment
• Developed based on ACT (ANSYS Customization
Toolkit)
• Easily add Topology optimization to existing
ANSYS Workbench workflow
• Easy and fast to create Topology optimization
data
• Easy and fast to post-process Topology
optimization results
• Export optimized geometry in STL or IGES format

9 © 2014 ANSYS, Inc. June 6, 2014 ANSYS Confidential

 GTAM Workflow
Pre-processing

• Add GENESIS • Meshing

Extension to • Load
Workflow • Boundary
Conditions

Import Optimized Geometry

• STL or IGES Topology Design via ACT

• Topology Region
• Objective
• Constraints
• Solve

Post-processing via ACT

• Element Density
• Density Isosurface
• Deformation
• Stress
• Strain Run GENESIS
(in the background)
10 © 2014 ANSYS, Inc. June 6, 2014 ANSYS Confidential
 GTAM Functionality

Highlights
• Multiple Analysis Systems
− Supports different analysis systems such as Static,
Modal, Linear Buckling and multiple loading
conditions
• Built-in Responses for Objectives and Constraints
− Several built-in responses for objectives and
constraints such as strain energies, frequencies,
mass, displacement, etc.
• Built-in Manufacturing Constraints
− Several built-in manufacturing constraints for the
designable region such as symmetries, casting,
extrusion, etc.

11 © 2014 ANSYS, Inc. June 6, 2014 ANSYS Confidential

 GTAM Functionality

Manufacturing Constraints
• Fill (casting)
− Directional
− Inside to Out
− Outside to In
Fill vs. Extrude
• Extrude
• Sheet Stamping
− 1 sheet
− 2 sheets
• Uniform
• Mirror Various Constraints in Design of Stadium Bleachers

• Cyclic
12 © 2014 ANSYS, Inc. June 6, 2014 ANSYS Confidential
 Manufacturing Constraints

Design of Steering Knuckle

Casting
direction
Hollow

Cavity

Traditional Topology: New Results :

Answers are not castable Answers are castable

13 © 2014 ANSYS, Inc. June 6, 2014 ANSYS Confidential

 Example: Topology Optimization of a
Connecting Rod
Problem Statement
• To obtain a stiff structure using a limited amount
of mass
− Objective
• Min. Strain Energy
− Constraint
• Mass Fraction < 0.3
− Designable Region
• Connecting rod
− Manufacturing Constraint
• Symmetric

14 © 2014 ANSYS, Inc. June 6, 2014 ANSYS Confidential

 ANSYS Workbench Flow
Add GENESIS extension to workflow

GENESIS Extension

15 © 2014 ANSYS, Inc. June 6, 2014 ANSYS Confidential

 Set up Model in ANSYS
Define geometry in ANSYS Design Modeler
Meshing, define load and boundary conditions in ANSYS
Mechanical

16 © 2014 ANSYS, Inc. June 6, 2014 ANSYS Confidential

 Define Topology Regions
GENESIS Structural
Optimization Toolbar

17 © 2014 ANSYS, Inc. June 6, 2014 ANSYS Confidential

 Define Topology Regions
Details

Specify Design Region Manufacturing Constraints

• Symmetry
• Extrusion
• Filling
• Stamping
• Uniform
• Cyclic
Minimum Member Size

18 © 2014 ANSYS, Inc. June 6, 2014 ANSYS Confidential

 Define Topology Objectives
Details

Response Types

Specify loading cases for this objective

19 © 2014 ANSYS, Inc. June 6, 2014 ANSYS Confidential
 Define Topology Constraints
Details

Response Types

20 © 2014 ANSYS, Inc. June 6, 2014 ANSYS Confidential

 Analysis Settings
Analysis Settings
• Analysis Control
• Design Control
• Output Control
• Coarsened Surface

21 © 2014 ANSYS, Inc. June 6, 2014 ANSYS Confidential

 Solve Topology Optimization

Progress Update in Solution Information Worksheet View

22 © 2014 ANSYS, Inc. June 6, 2014 ANSYS Confidential
 Post-Processing

Topology Element Density

23 © 2014 ANSYS, Inc. June 6, 2014 ANSYS Confidential

 Post-Processing

Topology Density Isosurface

24 © 2014 ANSYS, Inc. June 6, 2014 ANSYS Confidential

 Export Coarsened Surface

Export coarsened surface in STL or IGES format

Import back to CAD

25 © 2014 ANSYS, Inc. June 6, 2014 ANSYS Confidential

 Geometry Clean up using Space Claim
Topology Isosurface STL

Model in ANSYS Mechanical

Space Claim Geometry Clean Up

26 © 2014 ANSYS, Inc. June 6, 2014 ANSYS Confidential

 Validation Run in ANSYS

Initial Deformation Result Optimized Deformation Result

27 © 2014 ANSYS, Inc. June 6, 2014 ANSYS Confidential

 Validation Run in ANSYS

Initial Stress Result Optimized Stress Result

28 © 2014 ANSYS, Inc. June 6, 2014 ANSYS Confidential

 Example: Topology Optimization with
Contact
Problem Statement:
• To obtain a stiff structure using a limited
amount of material
− Objective
• Min. Strain Energy
− Constraint
• Mass Fraction < 0.2
− Designable Region
• Two blocks

Initial Optimized
29 © 2014 ANSYS, Inc. June 6, 2014 ANSYS Confidential
 Example: Topology Design of a Hook
Problem Statement:
• To obtain a stiff structure that satisfies mass
and stress requirements
− Objective
• Min. Strain Energy
− Constraint
• Mass Fraction < 0.3
• Stress < 65 GPa
− Designable Region Initial
• Blue region

Optimized
30 © 2014 ANSYS, Inc. June 6, 2014 ANSYS Confidential
 Optional: Write GENESIS Input File and
Launch Design Studio for GENESIS
Write Genesis Input File
• Mesh
• Materials properties
• Load and boundary conditions
• Topology design data
Launch Design Studio For Genesis
• Model is imported to Design Studio automatically
• Access additional functionality

31 © 2014 ANSYS, Inc. June 6, 2014 ANSYS Confidential

 Summary

• GTAM allows users to setup Topology optimization

problems, optimize, post-process, export optimized
geometries within the ANSYS® environment
• Designers benefit by automatically generating
innovative designs in a reliable, robust and easy-to-
use interface
• No knowledge of the GENESIS data format is needed

32 © 2014 ANSYS, Inc. June 6, 2014 ANSYS Confidential