6.

Generating Topology optimization for 2 Geometries with 2 Different materials (Concrete

and Structural Steel.

First of all, we need to carry out topology optimization choosing single material at one time.
Hence, firstly we have selected Concrete material. And done Topology Optimization with 25
% and 10 % Retention of mass. Geometry 1 Topology Optimization is done first and then
followed by Geometry 2.
Process of topology optimization:
1. First of all, select choose topology optimization component from the analysis
component.
2. Then drag the component to the solution tab of static structural component.
3. Then right click on modal tab, this will create the new topology optimization
interface shown in the left side flow diagram.
4. In topology optimization component there are some options available like
optimization region, objective, and constrain.
5. First of all, we have to choose the design region which is overall 3D component and
we have to select the complete component in that tab.
6. Next, we have to select exclusion region, for that we need to select the upper face
portion on which we have applied force and the bottom support portion which we
made fixed.
7. Exclusion region is very important to select. Once this region is selected then
during solving the software is going to exclude this region for optimisation of mass.
However, it will consider some region adjacent to the exclusion region for better
stability of geometry.
8. The next step is we have to click on response constraint, in that there is a response
type where we have chosen mass as a constraint. And we have to select the
percentage of retention, according to the problem description we have to retain
25% and 10% of mass during entire design.
9. First of all, we have to select 25% attention and then we have to right click on
solution tab and then clicking on solve.
10. After sometime the follower is going to process the topology model and generate
the best possible solution of 3D geometry by decreasing the mass.
11. Further we need to again select topology optimisation component and carry
forward same process for percentage to retain 50%. And generate the optimised
3D geometry.
 Following are the Screenshot Images of Topology Optimization for Concrete Material.

25 % Mass Retention:

10% Mass Retention:

Similarly for Geometry 2:
25 % Mass Retention:

10% Mass Retention:

With another Static Structure Analysis System, we had assigned Structural Steel as new
material to both the geometries and then again carried out same process for Topology
Analysis.
Following are the Screenshot Images of Topology Optimization for Structural Steel Material.
Geometry 1 :
25 % Mass Retention:

10% Mass Retention:

Geometry 2:
25 % Mass Retention:

10% Mass Retention:

Results for Concrete material:
Topology Optimization with 25% of retention of Mass of Concrete material

Support Initial Mass Final mass Reduction in %Mass

Structure mass Reduction
GEOMETRY 1 1323.1 kg 417.27 kg 905.83 kg 68.46 %
GEOMETRY 2 1363.1 kg 445.67 kg 917.43 kg 67.30 %

Topology Optimization with 10% of retention of Mass of Concrete material

Support Initial Mass Final mass Reduction in %Mass

Structure mass Reduction
GEOMETRY 1 1323.1 kg 231.14 kg 1091.96 kg 82.53 %
GEOMETRY 2 1363.1 kg 254.36 kg 1108.74 kg 81.33%

Result for Structural Steel Material

Topology Optimization with 25% of retention of Mass of Structural Steel material

Support Initial Mass Final mass Reduction in %Mass

Structure mass Reduction
GEOMETRY 1 4515.6 kg 1423.4 kg 3092.2 kg 68.47 %
GEOMETRY 2 4652.2 kg 1520.1 kg 3132.1 kg 67.32 %

Topology Optimization with 10% of retention of Mass of Structural Steel material

Support Initial Mass Final mass Reduction in %Mass

Structure mass Reduction
GEOMETRY 1 4515.6 kg 789.99 kg 3725.61 kg 82.50 %
GEOMETRY 2 4652.2 kg 879.02 kg 3773.18 kg 81.10 %
Conclusion:

In this way we have successfully optimized the Support Structure with Help of TOPOLOGY
Optimization Analysis Systems with 25 % and 10% retention of mass of concrete material. We found
the best 3D design develop by Topology optimization tool (Mentioned in above Screenshots in
ANSYS Software) and we can use that design for further manufacturing process to produce and make
in use.

The report has also made to learn about various tools and commands in ANSYS Software like
generating Hex – Dominant mesh, Mesh element size, Design Modular, Linking the Topology
optimization to Static Structural Analysis. Concepts of Exclusion region, Design region and
Constraints in Topology optimization Analysis System

REFERENCES:

[1] ANSYS Workbench Software R1 2020.

[2] Reference book: Topology Optimization Theory, Methods, and Applications by Martin
Philip Bendsoe and O. Sigmund.