Analysis of Machine Elements Using SOLIDWORKS Simulation CHAPTER #8, DESIGN OPTIMIZATION In keeping with demands for faster, lighter, more sustainable, and efficient designs, the Optimization Design feature within SOLIDWORKS Simulation’ should be a standard tool applied to all designs. Although the Optimization Design process performs much of the grunt work by iteratively seeking an optimum solution, control of the design process remains in the engineer's hands. This means that the designer still makes decisions regarding what variables of a machine part are allowed to be altered, what constraints are to be applied to the design, and what overall goals the design is to satisfy. Each of these aspects of the optimization design process is explored in the following example. Learning Objectives ‘Upon completion of this example, users should be able to: * Select and define variables to be optimized during the design process. ‘© Specify and limit constraints (sensors) applied to the optimization process. ‘© Define desired goals (sensors) for the optimization process. * Set-up, run, and interpret results of the optimization design proces. © Plot and interpret Local Trend Graphs. Problem Statement An Alloy Steel part is comprised of a 180 mm long cylindrical rod joined perpendicular toa rectangular bar of length 100 mm. Except for a 2 mm fillet between the cylinder and rectangle, additional dimensions of this part are shown in Fig. 1. This part might be viewed as an “L” shaped cantilever beam fixed at its right end. The goal of this example is to minimize weight of the part while subject to restraints and loads shown in Fig. 2. Fixed end of L-shaped cantilever beam 2 4 Figure 1 — Dimensioned view of the machine component named L-Part. ! The Optimization Design capability is available only in SOLIDWORKS Simulation Professional and SOLIDWORKS Simulation Premium. It is not included in basic SOLIDWORKS Simulation, 8Analysis of Machine Elements Using SOLIDWORKS Simulation A SOLIDWORKS Simulation model of the L-Part and a portion of its Simulation Study are shown in Fig. 2. This example begins with a partially completed finite element model for two reasons. First, an Initial Study is required prior to initiating the optimization design process. And, second, beginning with a partially completed model allows us to focus attention on new topics rather than repeating topics mastered in previous chapters. Figure 2 shows a Fixed restraint applied on end A of cylindrical rod AB and a downward force of 775 N acting on the surface at end C of rectangular segment BC. Other information to be satisfied by the optimization design is that stress in the part must not exceed one-half of the material yield strength (Sy = 620.422e+6 N/m?) and the maximum allowable part deflection must not exceed 2.50 mm. i Sy Fan Osta c B B.4 LPart (Alloy Steet-) i comecone = Shines Saco ~ A stera nds Ab Force (Per iter: -775 N) ten {Ehret Opson Figure 2 Finite element model of the L-Part showing Fixtures, External Loads and the Simulation manager tree. 1. Open SOLIDWORKS by making the following selections. (NOTE: “>” is used to separate successive menu selections.) Start>Alll Programs>SOLIDWORKS 2021 (or) Click the SOLIDWORKS icon ‘on your screen, 2. Within SOLIDWORKS, select File > Open... Then use procedures common to your computer environment to open the file named “L-Part,” (not: “L-Part 1-3"). Complete and Run the Initial Study Begin by completing the Jnitial Study. An initial study serves as the basis, or starting point, for a subsequent design optimization study. It does this by calculating finite element results for the current part “as is” before any changes are made. Open the initial Simulation Study as follows. 1. On the Simulation Study tab, located beneath the graphics area, click the tab labeled Initial Study L-Part. This opens the partially completed Simulation Study. ‘The model and Simulation manager tree should look similar to Fig. 2 2. Inthe Simulation manager tree, verify that (a) the L-Part Material is specified as (G.L-Pare(Aloy See), (b) the Fixtures folder shows @ F*4-1and corresponding restraints appear on end A of the cylinder; and (c) the External Loads folder 82Design Optimization shows Force-1 (Per item: -715 N) and downward vectors appear at end C of the rectangular beam, Design Insight ‘The 775 N External Load is intentionally distributed on the rectangular beam face at location C. A concentrated load applied to the top or bottom edge or to a split line on this face would cause a localized high stress region. If that stress exceeds one-half of the material yield strength, it might cause the design optimization solver to focus on it as a “false” upper stress value in the model. A possible consequence might result in design optimization at that location rather than optimize part dimensions to limit, maximum stress throughout the entire model when the L-Part is taken as a whole. s 3. On the Simulation tab near top of the screen, click the Run This Study "5" icon Upon completion of the run, the Results folder should list the three default plots [Stress1 (CvonMises-), Displacement (-Res disp-), and Strain (-Equivalent-)]. Before proceeding, a few alterations are made to the stress and displacement plots to set units and other display settings desired for these and future plots. Proceed on your own to incorporate SI units, discrete fringes, un-deformed model plots, label maximum stress, maximum displacement, and display legend values in scientific notation with three digits. If you make these changes on your own, skip to the Observations- Design Optimization Considerations text box (on page 8-5), otherwise follow the abbreviated steps below. 4. Right-click Stress1 (-vonMises-), and from the pull-down menu select Edit Definition... The Stress plot property manager opens. 5. Inthe Display dialogue box change E] Units to N/m’2 and remove the check “¥” from the CI Deformed Shape dialogue box. 6. Click to open the Chart Options tab. 7. In the Display Options dialogue box, check © Show max annotation. 8. In the Position/Format dialogue box, click to open the ¥ Number Format tic! box and select 3 Gxt scientific notation as the desired number format. 9. Immediately beneath the Number Format box, set the No of Decimals to 3. 10, Click to open the Settings tab. 11, Change the Fringe Options dialogue box to Diserete (if not already selected). 12, Click [OK] ¥ to close the Stress plot property manager. ‘The von Mises stress plot should now look like that shown in Fig. 3. 83Analysis of Machine Elements Using SOLIDWORKS Simulation von Mises (m2) s6seso0e Ls02e+ 008 (ise Lnaeeeom} .638e+ 008 arses 08 aise o0e adresooe s.835e0007 asses 007 es61e6007 4 924e+007 a2eres007 sLesves 007 airesoos —p ied stvengt 620468008 Figure 3 - Von Mises stress plot showing maximum stress occurs on the top ‘surface near the fixed end. Results from the Initial Study. The following steps are used to alter display of the displacement plot. 13, In the Simulation manager tree, right-click Displacement (-Res disp-), and from the pull-down menu select Show. 14, Right-click Displacementi (-Res disp-) again, and from the pull-down menu select Edit Definition... The Displacement plot property manager opens. 15. In the Display dialogue box change El Units to mm and clear the check “Y” to tum off O Deformed Shape. 16. Click to open the Chart Options tab. 17. In the Display Options dialogue box, check @ Show max annotation. Also, in the Position/Format dialogue box, verify that seientifie notation with No of Decimals is set to 3; if not, change them. 18, Click to open the Settings tab. 19. Change the Fringe Options dialogue box to Diserete (if not already selected). 20, Click [OK] ¥ to close the Displacement plot property manager. The displacement plot should now appear as shown in Fig. 4. 84Design Optimization RES fm ssresom \ a raison sme: o00e a0 Figure 4 ~ Displacement plot results for the Initial Study of the L-Part. Observations ~ Design Optimization Considerations 1. Figure 3 reveals a maximum von Mises stress in the part of 196.6 MPa. This stress value is only about 31.7% of the material yield strength. This magnitude indicates that the part may be overdesigned relative to stress magnitude. 2. The maximum displacement shown in Fig. 4 is 1.916 mm. Although this displacement might be excessive in some situations, the problem statement indicates that a 2.50 mm maximum displacement is permissible in this case This observation also leads to the conclusion that part size may be reduced, thereby resulting in an increased deflection (displacement). 3. For simplicity, this example examines only the magnitude of URES (the maximum resultant displacement). However, in an actual machine application, specific displacements in the X, Y, and/or Z. directions would probably be more meaningful to examine. As stated earlier, an Initial Study serves as the basis for an Optimization Design Study by providing a starting point (ie., an estimate of initial values) for the iterative design process. Because magnitudes of both stress and displacement are found in the Study completed above, itis the only Initial Study needed. However, if thermal and vibration effects also influence the outcome of this part design, then two additional Initial Studies are needed. One study would be needed to establish initial thermal effects on the part (because expansion or contraction influence part displacement) and a second Initial Study is needed to determine a baseline natural frequency (fr) for the part (because fn would affect part displacement), and hence part dimensions and mass may also change. 85Analysis of Machine Elements Using SOLIDWORKS Simulation Because neither thermal nor vibration aspects are investigated in this text, they are not included in the current example. However, be aware that depending upon optimization goals, additional initial studies might be required. ‘After the Initial Study has been run, the next step is to set up an optimization Study. The following section introduces steps unique to the Optimization Design process. Creating an Optimization Design Study Because of its importance when determining the Variables, Constraints, and Goals needed to set up this problem, the optimization design goal is restated here. DESIGN GOAL: To minimize weight of the L-Part. 1. Beneath the graphics area, right-click the Simulation Study rab labeled Initial Study L-Part, and from the pop-up menu select Create New Design Study. The lower portion of the graphics area changes to that shown in Fig. 5. The Variable View tab is intially active, Design Study Options ve ool Bens an agh ER ain Ta EPO] Mma etme at | tax |2 Sen intial Study LE >] Glick here fo 038 Constraints Figure 15 — Completed Constraint table for the L-Part Optimum Design example, Near the top of the SOLIDWORKS feature @ Bl }|/@|> ‘manager tree, click the “>” symbol adjacent to Sensors. In Fig. 16 and on your V screen, note the values listed adjacent to the @ L-Part (Default< Display Ste Sensors for Stress and Displacement1. (5) History ‘These values were computed during the > 5) Sensors Initial Study. (Values may vary slightly.) © seme s67—-t08 v2 Displacement 91602 mm) In the event these values do not appear and an information symbol © appears instead,” (A) Amotations “not to worry.” This is due to an occasional Sy Material glitch observed when this information is NM Front Plane accessed for the first time. ‘These values NX Top Piane will be revisited later in this example when X, gight Plane they appear elsewhere in the display. L ote > B0ss-berude > Gl Boss-Eetruded Brite Figure 16 - Sensors and their origi values calculated during the Initial Study. that values from the Jnitial Study form the starting point from which to run and track sensor values during subsequent optimization design studies. » Yield Strength shown is that for Alloy Steel as listed in the Material window when the Initial Study was defined. 8-16Design Optimization Define a Goal and its Sensor Although only a single Goal is specified in this example, it is important to note that multiple goals can be specified. When multiple goals are used, itis also possible to apply “weights” for each goal, where a higher weight assigns more importance to that goal The optimization design goal, namely to minimize part volume, has been stated several times throughout this example. Implementation of this step is outlined next. 1. Scroll down to the Goals section at bottom of the [STS [RLOlS design optimization table, and select Click here to add Goals ¥ and from the pull-down menu select Add Sensor... The Sensor property manager opens as shown in Fig. 17. Sensor te 1G [Mass Properties Sensor @ vxw 2. Inthe Sensor Type dialogue box, select Mass Properties from the pull-down menu (if not already selected). 3. Next, within the Properties dialogue box, select ‘Volume from the pull-down menu. In this example, part volume is synonymous with its ae e weight. Figure 17 — Defining the design ‘optimization Goal and its sensor. 4, Finally, observe the Entities to Monitor field (highlighted light blue). // Fillet does not appear there, then move the cursor anywhere on the L-Part model and click to select it as the item to be monitored for minimum volume. It may seem ridiculous that Fillet1 appears in the Entities to Monitor field. But, in this case, Fillet! is selected by the software because it was the last feature added when the model was built in SOLIDWORKS. Verify this by referring to the bottom of the SOLIDWORKS feature manager tree, or flyout menu, where Filletl is listed. This entry does not imply that only volume of the fillet will be monitored and/or minimized, 5. Click [OK] v to close the Sensor property manager and Volumel is listed beneath the Goals section of the design optimization table. 6. Also, beneath the Goals section, verify that Minimize appears next to Volumel. Ifnot, click ¥ to open the pull-down menu and select Minimize. Briefly examine other optimization criteria available in this drop-down menu. 7. Within the SOLIDWORKS feature manager, observe that the total volume of the original (initial) L-Part appearing as 101.605013 cm’3 is now listed beneath the Sensors folder. Clearly this is the entire part volume, not just the fillet volume. 817Analysis of Machine Elements Using SOLIDWORKS Simulation ov | natevow | sens ew | fee Figure 18 — Select the [Run] button to begin the Optimization Design study. ‘The Optimization Design Study is completely defined and ready to execute. The [Run] button, located just beneath the Variable View tab, is now active (no longer grayed-out). 8. Click to select the [Run] button circled in Fig. 18. As the Design Optimization process executes, direct your attention to model images displayed on the screen. Then, continue reading below. The optimization process steps through 13 iterations (15 iterations if the Initial Study and the final Optimal design scenario are included). The number of iterations is proportional to the number of design Variables. As the optimization proceeds, Iteration columns are added to tabulated results beneath the graphics screen while images of each model are briefly displayed in the graphics area. Notice that part geometry associated with some iterations is undesirable or invalid based on the practical desire to have a complete fillet between ‘mating parts; see circled area in Fig. 19. Figure 19 - Undesirable results due to mis- match of sizes. (Iteration 2) Results are reviewed below to gain further insight into the findings. Overview of Results We begin by making some general observations applicable to all results displayed on the final screen and in the Optimization Design table (located beneath the graphics area). First, notice that results are displayed in the Results View tab rather than the Variable View tab where this study was defined. Also, it is assumed that most monitors are not, wide enough to display all 13 iterations simultaneously. Therefore, results only up to Iteration 6 are shown in Fig. 20 (more are displayed on wide screen monitors). To see additional iterations, click-and-drag the horizontal scroll bar located beneath the table. 8-18Design Optimization General Observations 1. To display results of a particular iteration, click the Iteration name located at the top of each column, Example: Iteration 1, Iteration 2, ... etc. The image shown in Fig. 20 is that of the Optimal solution. Its name is circled in Fig. 20, The Optimal solution column is highlighted light green. Final results are displayed on the Results Viow tab. Figure 20 - Table summarizing results of the first six iterations of the optimization design process for the L-Part. 2. To the left of the Optimal column are listed results of the Initial Study and the Current column. As implied by its name, the Current column contains the same results as those in the currently selected column. 3. At the far left of the optimization table, part dimensions (Width, Height, and Diameter) are displayed as sliders showing current sizes relative to the design Range. These sliders can be moved to update the model (not recommended until you become proficient using optimization studies). Also shown are the original Constraints (Stress1 and Displacement!) and the optimization Goal (Volumel). 4. Design constraint plots for Stress1 and Displacement can be displayed in the graphics area by clicking “>” to open the Results and Graphs folder (see arrow at lower left of Fig. 20). Then, double click the desired plot name. For example: Fig. 20 shows the von Mises stress plot corresponding to the Optimal solution. 5. Sensors, shown boxed in the SOLIDWORKS feature manager at the top left of Fig. 20, are updated to show the currently displayed Volumel. Note that Stresst and Displacement Sensors are indicated by an information Osymbol only. Refer to the optimization table for current values of these two Variables. 819Analysis of Machine Elements Using SOLIDWORKS Simulation 6. All columns highlighted in light red (or “pink”) indicate cases where one or both of the design Constraints is violated. ‘The darker red cells in these columns indicate the specific Constraint(s) violated. For example, in Iteration 2 the Stress1 Constraint is violated (because actual Stress1 > *Yield Strength). The maximum stress is also exceeded in several other iterations, However, in Iterations 4, 6, 8, 10, and 12 both the Stress1 and Displacement! Constraints are violated because actual Stressi > '4*Yield Strength > (3.102e+008 N/m?) and Displacement > 2.50 mm. Scroll to the right in the optimization table and examine Iterations that violate one or both Constraints. 7. Click the Iteration name at top of any of the red columns to display the model and corresponding Stress1 or Displacement plots. 8, Iteration columns highlighted in light gray satisfy all Constraints. However, those solutions do not satisfy the design Goal which results in minimum volume for the L-Part. Local Trend Graphs A series of Trend Graphs can be plotted at the conclusion of an Optimization Design Study. A trend graph displays either the Goal or a Constraint with respect to a design Variable. Alternatively, a trend graph can display variation of a Constraint relative to a selected design Variable. Examples of each are illustrated on the following pages. NOTE: Local Trend Graphs are not available when discrete variables and a High Quality study are selected. Local Trend Graph of the Design Goal versus a Design Variable Begin by examining a typical graph showing the relationship between a design Variable, in this case cylindrical rod diameter, and the design Goal (the “Objective”) which is to imize part volume. Proceed as follows. 1. To the left of the tabulated results, right-click Results and Graphs, and from the pull-down menu select Define Local Trend Graph... The Local Trend Graph property manager opens as shown in Fig. 21(a). 2. In the Design variables (X-Axis) dialogue box, select Diameter from the pull- down menu as the variable to be displayed on the graph X-axis. 3. Inthe Y-Axis dialogue box, select © Objective, then from the pull-down menu select Volumel Notice that Volumel is the only choice available. This is because, in SOLIDWORKS ‘Simulation jargon, the design Goal (in this case minimum volume) is also named the “Objective” of the design optimization process. The Local trend at dialogue box should show the Optimal solution as currently selected; if not, change it. 8-20Design Optimization 4. Click [OK] ¥ to close the Local Trend Graph property manager and the graph shown in Fig. 21(b) appears. Local Trend Graph (@ () Figure 21 - Definition of a Local Trend Graph showing the relationship between cylinder diameter (a Variable) and part volume (the Objective or Goal) ofthis optimization study. Observations a. Figure 21(b) reveals the full Range of possible rod diameters [10mm < Range < 30mm (approx.)]. In Fig. 21(b), the cursor was moved into the graph and intersecting horizontal and vertical dashed lines automatically appear. b. Atthe intersection point, approximate values of the optimum cylinder Diameter (19.31 mm, rounded value) and minimum part Volume (65500 mm’3, also a rounded value) occur. See circled values beneath the graph. c. Similar graphs of Height vs Volume or Width vs Volume can be made. 4. Software default captions appear for the graph title and axis labels in Fig. 21(b). Titles can be altered as outlined in Chapter 1. 5. Click I to close the current graph. Notice that Graph is now listed beneath the Results and Graphs folder in the Simulation manager tree. Local Trend Graph of a Constraint versus a Design Variable ‘Next examine a typical graph showing the relationship between a design Variable and a design Constraint, The design Variables remain the same as above (Height, Width, 8.21Analysis of Machine Elements Using SOLIDWORKS Simulation and Diameter). However, the Constraints applied to the model include a maximum Stressl value and a maximum Displacement value. Proceed as follows to examine one of these graphs. 1. Right-click Results and Graphs, and from the pull-down menu select Define Local Trend Graph... The Local Trend Graph property manager opens as shown in Fig. 22(a) 2. In the Design variables (X-Axis) dialogue box, select Height from the pull-down menu, Note that either of the remaining two variables (Width, or Diameter) also could be selected. 3. In the Y-Axis dialogue box, select © Constraint, then from the pull-down menu select Displacementl. It is also possible to select Stress1 if it is of primary interest. 4, The Local Trend at dialogue box should show the Optimal solution as currently selected; if not, change it. 5. Click [OK] ¥ to close the property manager and the graph shown in Fig. 22(b) appears. tocalTrend Graph @® vx Design varabies 0 A) “ cK 7 vans “ oe: (Mormalized to intial value tet Pean n —Ee— toca rend at a Optima Close followed by selecting Don’t Save as shown in Fig. 23. 9 Sweat Figure 23 — Close the Study without saving results. Closing Observations The above Optimization Design Study introduces only some of the more important and frequently used capabilities available within the design optimization module of SOLIDWORKS Simulation Premium. This capability is not available in the Standard version of SOLIDWORKS Simulation and is available to a more limited extent within the 8.23Analysis of Machine Elements Using SOLIDWORKS Simulation Simulation Professional version, Beyond this basic example, it is possible to optimize designs based on other parameters such as shape, safety factor, mass, weight, and others. The optimization search scheme is based on the “design of experiments” approach to find an optimum solution using a minimum number of iterations. When should the optimization process be applied? It is highly recommended to run a design optimization near the beginning of the design process. This approach allows the designer to benefit from software recommended changes to model geometry early in the design process when the influence of those changes can be factored into the design of related components, sub-components, and assemblies. ‘Also, the user should not consider completion of a single design optimization study to be the “best” solution. For example, in the current example a value of 4.0 mm was arbitrarily specified for the lower range of Width for the rectangular beam cross-section. However, the Optimal solution converged to a value just slightly greater than 4.0 mm. (4.04037 mm to be exact). This observation, combined with the fact that both the optimal Stress and optimal Displacement are lower than the maximums specified for these Constraints, leads one to believe that a more optimal design might be possible. Thus, further investigations are warranted. The interested reader should also access the available SOLIDWORKS Simulation Design Optimization tutorials found under Help > SOLIDWORKS Simulation > Tutorials > Design Studies. CAUTION: Use caution when specifying and/or accepting software suggested estimates for Min: and Max: values specified in the Range fields. Incorrect values, that is out-of-bound values or values that cause segments of the model to “self-intersect,” may cause the design optimization process to fail. In these cases, the error message shown in Fig. 24 results. Therefore, use caution when applying values to Variables, Constraints, and Goals to ensure selected values are realistic. Ay viezaton tea Figure 24 ~Error received when “incorrect” estimates for Range values are used or if software suggested Min: and Max: values cause unrealistic events such as segments of ‘a model “setf-ntersecting” with one another. This concludes discussion for the current chapter. 8.24