AOC 2012 : Oops

Innovation Intelligence
August 17, 2012
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Winch Base Frame Optimization

Innovation Intelligence

Copyright 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

Contents

1. Intro

Winch base frame

2. Optimization

Topology + Shape + Size

3. Result

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Intro
Winch Base Frame line Base .

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Model Property

Extract
Y

Z
X

< Initial Model >

< Mid Surface Model >

DH36 (/2 ) ( 2 /4 ) 2.1e+05 0.266 7.8e-09 Node Element Number 9191 8290

< Material Property >

< Material Property >

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Model Property

< Design & Non_Design >

Color Blue Orange Area Design Non_design

< Thickness >

Color Red(mm) Blue(mm) Green(mm) Thickness 100 30 50

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Boundary & Load Condition

All DOF 0

< Boundary Condition >

< All connect Weld point using RBE2>

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Boundary & Load Condition

Fy2
Fy1 Fz3

Fz2

Z X Y

Fy3

Brake holding & Tension

Brake holding (Fy1) Driving Shaft (Fy2) 727 ton 8.38 ton

Driving Shaft (Fz2)

Tension (Fy3) Tension (Fz3)

3.05 ton
-203.428 ton 64.1405 ton

< Load Condition >

Driving Shaft

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Optimization Process

1 2 3

Objective

Minimize Volume

Design Variable

Density in the design space

Design Constraint

The resultant Von Mises stress is less than 355MPa

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Topology Optimization Process

Re-modeling

Extrude Surface

Topology Opt

Initial Model

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Production Process
Apply Pattern

Anchor point 2-pln

2-pln sym

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Iteration

Iteration 1

Iteration 7

Iteration 13

Iteration 32

Iteration 25

Iteration 19

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Topology Optimization Result

tendency Re-modeling Mesh

Re-modeling & Mesh generation

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Topology Optimization Result

Max von-Mises Stress = 286.6MPa Topology Optimization Re-modeling Von mises stress 355MPa .

Copyright 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

Shape - Morph Optimization

Initial Shape

Shape_1 Apply both shape

Shape_2

Shape_3

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Shape - Morph Result

Optimization
Max stress =286.6MPa Max stress =291MPa

Shape

Main Frame.

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Size Optimization

Condition

Main Frame

Initial value(mm) Lower bound(mm)

Upper bound(mm) Stress Constrain

100 10
110 350Mpa

< Main Frame>

Condition Initial value(mm) Lower bound(mm) Upper bound(mm) Side Frame Stress Constrain 30 10 50 350Mpa

< Side Frame>

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Size Optimization Result

Main Frame

Side Frame

Main Frame Initial T(mm) 100

Side Frame 30

Result T(mm)
Final T (mm)

50.047
50

38.52
39

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Size Optimization Stress Result

Max von-Mises Stress = 293.8MPa Topology Optimization Re-modeling Von mises stress 355MPa .

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Optimization Result
Initial Topology Shape Size

Model

Initial Model

Topology

Shape

Size

Mass(Kg)
Volume(mm^3) Max. Stress(MPa)

5750
7.279e+08 263

3881
4.913e+08 286.6

3458
4.377e+08 291

2897
3.667e+08 293.8

Copyright 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

Optimization Result

49.6%

49.6%

355MPa

Stress Mass volume 39.8% .

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Result

Mass volume 49.6% .

Objective Function

Min volume

Initial Model

Topology

Shape

Size Model

Constraint Condition

Max st. < 355MPa

Copyright 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.