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The CAE Driven Design Process. Topology Optimization – Conceptual Design. Setup of optimization problem, definition of design constraints. Mesh generation, definition of loads and boundary conditions. Computation. Interpretation of results. CAD Design.

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The CAE Driven Design Process

Topology Optimization – Conceptual Design

Setup of optimization problem, definition of design constraints

Mesh generation, definition of loads and boundary conditions

Computation

Interpretation of results

CAD Design

Definition of available package space


Case study – Bracket Redesign

Engine Mount Bracket - Material saving

Design Proposal (1997)

Design Space

7 Loadcases

Objective: Minimize the Mass

Stiffness should be the same

Annual Cost Savings

Weight reduction per part = 0,22 kg

Annual Prodution Volume = 200,000 pcs

Total Mass Reduction = 44,000 kg

Nominal Material Cost = $0.80/kg (1997)

Total cost Savings in Material = $35,200/yr

Initial Design

Mass: 950g

Design

Mass: -20%


Case study bracket redesign
Case Study – Bracket Redesign

New Design

Multivan V6 3,2l 173 KW

Old Design

Altair OptiStructProposal

Mass Reduction: 23%


Case study bracket redesign1
Case Study – Bracket Redesign

Stress Anal.Des. Adj.

Topology Optimization

Test

CAD

Topology Result

Design Development Bracket VW Multivan

Design space

CAD

Stress check

Entwicklung Aggregate, Volkswagen


Case study bracket redesign2
Case Study – Bracket Redesign

Base Design

2.000g

New Design

1.550g

Mass Reduction 23%

<<

Entwicklung Aggregate, Volkswagen


Case study topology optimization process
Case Study - Topology Optimization Process

Fairchild Dornier 728 – door support arm

Design Problem

  • Connector element between door and fuselage

  • Three static load cases

    • Door blocking

    • Emergency opening

    • Hit of damper mechanism on door

      Optimization Statement

  • Minimize Mass

  • Stress Constrains

    Methodology

  • Topology Optimization followed by Size&Shape Optimization


Case study topology optimization process1
Case Study - Topology Optimization Process

Meshing of Design Space

Determination of Design Space

Topology Optimization

Export of Geometry with OSSmooth

Fairchild Dornier 728 – door support arm

Analysis of OriginalDesign


Case study topology optimization process2
Case Study - Topology Optimization Process

Drafting of Design Proposal

DV

Analysis of Design Proposal

Size&Shape Optimization

Export of final Geometry from HyperMesh

Fairchild Dornier 728 – door support arm


Case Study - Topology Optimization Process

Fairchild Dornier 728 – door support arm

-14%

-19%

m = 9.15 kg

m = 7.90 kg

m = 7.5 kg

Original Design

After Topology Optimization

After Shape Optimization


Optimization in the design process
Optimization In The Design Process

topoGRAPHYoptimization

(Conceptual Design)


Topography optimization conceptual design
Topography Optimization – Conceptual Design

Definition of desired bead dimensions and optimization targets

OptiStruct proposal of optimized bead pattern

Interpretation of proposed bead pattern


Case study topography optimization muffler
Case Study – Topography Optimization Muffler

-10 dB sound emission

<<


Case study reducing heating boiler sound emission
Case Study -Reducing Heating Boiler Sound Emission

  • Challenge

    • Reduce noise emission of heating boiler

    • Increase stiffness of cover through innovative bead pattern

  • Solution

    • OptiStruct topography optimizationfor initial bead pattern layout

    • Shape optimization for further optimization of bead width

  • Results

    • 20% stiffness improvement

    • 30% reduction of parts (needed to stiffen the old design)

“Thanks to OptiStruct, the stiffness of the boiler was significantly improved leading to a accoustically superior heating boiler.”

Andreas SchubertCAE Manager VIESMANN GmbH, Germany


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