2011 ALTAIR

( 2) ( 4) :

School of Mechanical and Automotive Engineering KUNSAN NATIONAL UNIVERSITY Kunsan, Jeonbuk

Contents
1.

2.

3.

1.
:

: 2

: 4

2. B Transmission center mounting bracket optimization

Material and mesh properties

PIPE
material (steel)
E = 2.1x10^5 MPA = 0.29 = 7.9x10-9 ton/mm3

input thickness

PNL

PNL = 4 mm PIPE = 3 mm

mesh property
type = mixed size = 2.5 mm

Base analysis : initial model

* mounting bracket model design region non-design region

design region

initial design model non design region

Base analysis : initial model

rigid element
mounting bracket model A

constraints D.O.F 1 ~ 6

A load Fz = 19,620(N), Fx = 19,620(N)

Optimization problem

* (object function) : * (constraint) 1) Z B > F = 272.22 * Z() + 14301 X B > F = -26.651 * X()^2 +1151.3*(X) 2375.4 2) Z1G*3.5G >1E6[1G=784.8(N)] (1Gstatic ,3.5G sin)

3) free-free normal mode 1st Hz>300Hz

Base analysis result ( X-load)

uper PNL
max. stress ( MPA ) max. displacement ( mm )

lower PNL 177.402 0.282 2965.625

608.990 0.281

compliance ( N.mm )

von mises stress

displacement

Base analysis result ( Z-load )

uper PNL
max. stress ( MPA ) max. displacement ( mm )

lower PNL 311.534 0.477 4191.303

529.016 0.477

compliance ( N.mm )

von mises stress

displacement

1-D
response 1-D element
base model 1-D model base X (N) Y (N) -280.812 -10914.089 1-D -280.9 -10920 dif 0.092 6.089

Z (N)
MAG (N)

5706.986
12319.330

5707
12324.57

0.014
5.25

ZOOM

Base analysis result

(free-free- normal mode)

mode 7 = 5.190383E+02 Hz

mode 8 = 7.437028E+02 Hz

mode 9 = 9.837320E+02 Hz

mode 10 = 1.144471E+03 Hz

1-D base analysis result

(free-free- normal mode)

Mode 7 = 5.190147E+02 Hz

Mode 8 = 7.436957E+02 Hz

Mode 9 = 9.837346E+02 Hz

Mode 10 = 1.144475E+03 Hz

Free-free- normal mode result

mode 1 2 3 4 5 6 base (Hz) 0.000000E+00 4.947790E-03 5.381941E-03 6.433990E-03 6.578498E-03 6.684623E-03 1 D base (Hz) 0.000000E+00 6.057863E-03 1.780081E-02 1.314566E-01 2.301689E-01 5.394379E-01

7
8 9 10

5.190341E+02
7.437028E+02 9.837320E+02 1.144471E+03

5.190147E+02
7.436957E+02 9.837346E+02 1.144475E+03

mode 7

Optimization

design variables topology topography size

Topology
objective function : min. mass

design variable
parameters fatigue constraints > 1 E6

pattern grouping

pattern type = 2 Pln sym

objective

minimize mass

Optimization result : objective value

( topology )
iteration 3

iteration 19

iteration 52

iteration 96

Topograhy
objective function : min. mass

design variable
bead parameters
3.0

8.0 60

minimum bead width = 8 draw angle = 60 draw height = 3 boundary skip = load&spc
up_PNL = Upper Lower low_PNL= Upper Lower Bound Bound Bound Bound 1 0 0 -1

bounds

objective

minimize mass

Optimization result : objective value

( topograhy )
iteration 3

iteration 19

iteration 52

iteration 96

Size optimization
objective function : min. mass

design variable
desvar initial value = 4 upper bound = 8 lower bound =1

genric relationship

objective

minimize mass

Optimization result : objective value

( Size )
iteration 3

iteration 19

iteration 52

iteration 96

Optimization process

base analysis Model

topology optimization

topography optimization

final model

size optimization

Final model analysis result

( reaction force & displacement )
base model
B

final model
B

B 4181.135 N
B

B 17219.168 N
B

B 12319.330 N
A

B 15089.945 N
A

A 0.302 mm
A

A 1.243 mm
A

A 0.427 mm

A 0.842 mm

Final model analysis result

( fatigue )

maximum fatigue = 1.0E20

minimum fatigue = 1.13E6

Final model analysis result

(free-free- normal mode)

mode 7 = 4.882127E+02 Hz

mode 8 = 4.960924E+02 Hz

mode 9 = 7.508431E+02 Hz

mode 10 = 8.474523E+02 Hz

Constraint result
B (constraint)
1 1) B >
( 15089.945 N > F = 272.22 * Z() + 14301 = 272.22 * ( 0.842 ) + 14301 = 14530.21 N )

B ( 15089.945 N ) > ( 14530.21 N ) -2) B >

(17219.168 N > F = -26.651 * X()^2 +1151.3*(X) 2375.4 = -0.09855 N)

B ( 17219.168 N ) > ( - 0.09855 N ) 2) Z1G*3.5G >1E6 Z1G*3.5G ( 1.133 * 1E6 ) > 1E6 3) FREE-FREE NORMAL MODE 1st HZ>300Hz FREE-FREE NORMAL MODE 1st HZ ( 488 HZ ) > 300Hz

Optimization result
base model mass (kg) free free normal 1ST (Hz) thickness (mm) 6.62807 519.03 4 final model 4.03392 488.21 3 - 39.138 % - 5.94 % - 25 %

base model

final model

3.
car side door inner-panel optimization

Material and mesh properties

material (steel)
E = 2.1x10^5 N/mm2 = 0.29 = 7.9x10-9 ton/mm3

input thickness
inner_panel = 2 mm outer_panel = 1mm

mesh property
type = mixed size = 10 mm

inner_panel

Base analysis : initial model

* inner_panel model design region non-design region

initial design model

non design region

design region

Base analysis : initial model

load case 1

load Fy = 98(N)

Z Y

D.O.F =1~ 6 D.O.F =1~5

Base analysis : initial model

load case 2 load case 3

B
load Fz = -198(N)

D.O.F =1~5 D.O.F =1~5

Z Y

normal mode

Optimization problem

* (object function) : min compliance

(constraint) mass 60% - A Y < 1mm - B Z > -2.5mm frequency 1st mode > 4.5 Hz
*(design variables) : inner_panel (topology&topography)

Base analysis result (load case 1)

inner_Panel
max. stress ( MPA) max. displacement ( mm )

92.479 1.390 1.010705E+02

compliance ( N.mm )

von mises stress

displacement

Base analysis result ( load Case 2 )

inner_panel
max. stress (MPA) max. displacement ( mm )

170.7 4.11 2.106943E+02

compliance ( N.mm )

von mises stress

displacement

Final model analysis result

(displacement)
load case 1 load case 2

A B

Y_disp = 1.358mm

Z_disp = -2.197mm

Base analysis result

(normal mode)

horizontal_bending

vertical_bending

torsion

mode 1 = 3.885646E+00 Hz

mode 2 = 1.386578E+01 Hz

mode 3 = 2.247015E+01 Hz

Optimization

design variables topology topography

Topology
design variable
parameters objective function : compliance

mindim = 30

pattern grouping

2-plns-sym

objective

minimize compliance

Optimization process ( topology )

iteration 3

iteration 8

iteration 13

iteration 21

Topograhy
design variable
bead parameters
10

objective function : compliance minimum bead width = 30 draw angle = 60 draw height = 10 boundary skip = load&spc
2-plns sym Inner_panel = upper bound 1 lower bound 0

30 60

pattern grouping bounds

objective

minimize compliance

Optimization process (topograhy )

iteration 3

iteration 8

iteration 13

iteration 21

Optimization process

base analysis model

topology optimization

final model

topography optimization

Final model analysis result

(displacement)
load case 1 load case 2

A B

Y_disp = 0.767mm

Z_disp = - 2.497mm

Final model analysis result

(normal mode)

horizontal_bending

vertical_bending

torsion

mode 1 =4.610384E+00 Hz

mode 2 = 1.365678E+01 Hz

mode 3 = 2.480452E+01 Hz

Constraint result

(constraint)
1 1) A load case1 Y < 1mm 0.767 mm < 1mm -2) B load case 2 Z >-2.5mm -2.497 mm > -2.5mm 2) Frequency 1st mode > 4.5 Hz 4.61 Hz > 4.5Hz

3) Mass 60%

Optimization result
base model
compliance ( N.mm )_load case 1 compliance ( N.mm )_load case 2 mass (kg) disp_a_y (mm) [load case1] disp_b_z (mm) [load case2] normal mode 1st (Hz) normal mode 2nd (Hz) normal mode 3rd (Hz) 1.010705E+02 2.106943E+02 23.97 1.358 1.809 3.88 13.87 22.47

final model
7.407087E+01 2.385864E+02 20.95 0.767 2.497 4.610 13.656 24.804 -26.71% +13.24% - 12.60 % -39.51% +38.03% 18.81% -1.54% +10.37%

base model

final model

References
1) ,,,, ,, 10 1,pp.125-132,2002 2) ,,, ,, 10 2,pp.228-233,2003 3) ,,, , , 2006

Q&A