PART A : Problem No 2 : Control Arm TOPOLOGY OPTIMIZATION

This tutorial uses OptiStruct's topology optimization functionality to create a design concept for an automotive control arm required to meet performance specifications. The finite element mesh containing designable (blue) and non-designable regions (yellow) is shown in the figure below. The optimal design would use as little material as possible.

A finite element model representing the designable and non-designable material (shown in figure) is imported into HyperMesh. Appropriate properties, boundary conditions, loads, and optimization parameters are defined and the OptiStruct software is used to determine the optimal material distribution. The results (the material layout) are viewed as contours of a normalized density value ranging from 0.0 to 1.0 in the design space. Isosurfaces are also used to view the density results. Areas that need reinforcement will tend towards a density of 1.0.

The following exercises are included: Setting up the FE model in HyperMesh. Setting up the optimization in HyperMesh. Post-processing the results in HyperView.

Exercise
Setting Up the FE Model in HyperMesh Step 1: Launch HyperMesh, Set the User Profile and Retrieve the File
1. 2. Launch HyperMesh student edition. Choose the OptiStruct User Profile and click OK. This loads the user profile. It includes the appropriate template, macro menu, and import reader, paring down the functionality of HyperMesh to what is relevant for generating models in Bulk Data Format for RADIOSS and OptiStruct. The User Profiles GUI can also be accessed from the Preferences pull-down menu on the toolbar. From the File pull-down menu on the toolbar, select Open. Select the PartA_Problem2_Control_Arm.hm file, Click Open.

3. 4.

Step 2: View the surface and make the geometry Mappable for the Hexa-Meshing.
1. 2. Click on Shaded Geometry and Surface Edge icon as show Then click on Geometry colour mode and select Mappable from the drop down list.

3.

Go to Geom page and click on quick edit panel or press F11 from your Keyboard.

4.

If you are not able to view the fixed point, then click on display fixed point icon

5.

Now select the XZ Left Panel View, an zoom in to the location as shown in the image.

6.

Now on replace point: option select point(s). and replace the two point with the point on the line, the geometry will become mappable automatically.

Step 3: Create a Hexa Mesh.

1. Go to 3D page and select solid map panel.

2. 3.

Select multi solids from the radio button. Click on solids and select all. Enter 4 in elem size and in source shells: select quards from the drop down list, click on mesh.

4.

It will generate a 2D mesh showning the mesh pattern it will generate for the hexa-mesh you can chage number of elements along the length of the component by clicking on the edge as shown in figure a number will appear and then when you left click on number it will increase the number of elements ..

5.

Now again click on mesh. And then click on return twice to exit the hexa mesh panel.

Step 4: update the components, create property, and create rigid elements.
1. 2. Click on Component (3) to expand the list of components. Right click on Non_design component and click on rename and type rigids. Now right click on control arm component, click on rename & type Non_design.

3.

Click on propert collector icon

4.

Enter Design in prop name =, select a different colour, select 3D in type =, Select PSOLID in card image, Select the material as steel. Then click on create.

5.

Enter Non_Design in prop name =, select a different colour, select 3D in type =, Select PSOLID in card image, Select the material as steel. Then click on create.

6. 7.

Now click on component collector icon Select update from the radio button on the bottom left side of your screen

8.

Click on comps, check the box next to Non_design and click select.toggle the no property option to property, click on blank space in front property a list of properties will appear. There select Non_design. Click on Update.

9.

Click on comps, check the box next to design and click select.toggle the no property option to property, click on blank space in front property a list of properties will appear. There select design. Click on Update.

10. Click return. 11. Go to 1D page and select Rigids.

12. Make sure the radio button is on create, now click on node infront of independent, and select the node where forces or constraints are applied. Now click on small drop down arrow in front of dependent and select multiple nodes option and the select all the nodes on the inner surface of the hole as show in figure. Keep all the other parameters as shown in the image below. Then click create.

13. Similarly create rigids for the other two holes.

14. Click return.

Step 5: Create load step, as breake, corner and pothole.

As there are three forces applied on the model and we have to restrict the displacement due to all the three forces seperately therefore we will create three different load steps. 1. Go to Analysis page and clink on Loadstep panel.

2.

Enter Brake in name = , Select linear statics as type, check the box next to SPC and LOAD. Click on blank space in front of SPC and select SPC. Now click on blank space in front of LOAD and select Brake. Click create.

3.

Similarly create two more loadsteps as Corner (SPC as SPC & LOAD as Corner) and Pothole (SPC as SPC & LOAD as Pothole). And type as liner static.

4.

Click return.

Step 6: Create one more Constraints on the model.

Here we will create one more constraint on the model because there is no reaction force is applied on the model for the force acting on Z-direction, so to provide the reaction force we will restrict the translation along Z-axis (dof3) along the line of action of Zdirection force. 1. Expand the Load Collector (4) on the model browser. Right click on SPC and select Make Current.

2.

Now go to Analysis page and select constraints

3.

Select the node as shown in figure and make sure the check box next to dof3 is marked, uncheck other (dof1, dof2, dof4, dof5, dof6). Make sure all the other parameters will be same as given in the image below.

4. 5.

Click create. Click return.

Step 7: Save the file and run the Analysis.

1. 2. 3. 4. 5. 6. 7. 8. Click on File pull down menu on tool bar, go to Save As and select Model. Create a new folder in different location and save the file. Go to Analysis and select Radioss. Set export option: all Set run options: analysis Set memory options: memory default Click on save as and save the .fem file and then click on Radioss. Once you see ANALYSIS COMPLETED. Message on the solver window, close the solver window.

Step 8: View the displacement contour plot using HyperMesh.

1. Click on the drop down arrow, of Page Window Layout. And select the two window layout. From the list.

2.

Click on 2 Window.

nd

3. 4.

Go to File pull down menu on the tool bar, select open and then click on model. Now on the bottom of your window click on the folder icon in front of Load model. Select the folder where you have saved your file before Analysis. In that folder select the .h3d or Altair hyperview Player file, click Open, and then click on Apply. To Load the results.

5.

Now click on contour and the click on Apply.

6.

This is the displacement due to load step Brake. To view the displacement due to the other two load cases, change the subcase as shown in the image below.

7.

Click on the 1 window and click on Expand/reduce window. To enlarge the 1 window.

st

st

Setting up the Topology Optimization Step 9: Create Topology Design variable.

1. Go to Analysis page and select Optimization panel.

2.

In optimization panel select topology.

3.

Enter Design in desvar = , click on props and select Design from the list of properties, select type: as PSOLID. Click create.

4.

Go to draw by selecting the radio button. Click on desvar and select design. In draw type: select single, check the box next to no hole and stamp, enter 3 in thickness =, select the anchor node and first node as shown in the image. Click update.

5.

Click return.

Step 10: Create responses as volume, disp_x, disp_y, disp_z.

1. Click on responses panel.

2.

Enter Volume in response = , select volume as response type , make sure the toggle is set to total and no regionid. Click create.

3.

Enter disp_x in response = , select static displacement as response type, click on nodes and select the node where forces are applied, select the radio button in front of total disp, click create.

4.

Enter disp_y in response = , select static displacement as response type, click on nodes and select the node where forces are applied, select the radio button in front of total disp, click create.

5.

Enter disp_z in response = , select static displacement as response type, click on nodes and select the node where forces are applied, select the radio button in front of total disp, click create.

6.

Click return.

Step 11: Create Constraints for the topology Optimization Setup.

1. Click on dconstraints panel.

2.

Enter x_disp in constraints =, click on response = and select disp_x from the list of responses. Click on loadsteps and select brake from the list of loadsteps. Now check the box next to upper bound and enter the value 0.05. Click create.

3.

Enter y_disp in constraints =, click on response = and select disp_y from the list of responses. Click on loadsteps and select corner from the list of loadsteps. Now check the box next to upper bound and enter the value 0.02. Click create.

4.

Enter z_disp in constraints =, click on response = and select disp_z from the list of responses. Click on loadsteps and select pothole from the list of loadsteps. Now check the box next to upper bound and enter the value 0.04. Click create.

5.

Click return.

Step 12: Create Objective Function.

1. Click on Objective panel.

2.

Select min from the drop down list, click on response = and select volume from the list of responses.

3. 4.

Click create. Click return.

Step 13: Save the file and run the optimization analysis.
1. 2. 3. 4. 5. 6. 7. 8. Click on File pull down menu on tool bar, go to Save As and select Model. Create a new folder in different location and save the file. Go to Analysis and select OptiStruct. Set export option: all. Set run options: optimization. Set memory options: memory default. Click on save as and save the .fem file and then click on OptiStruct. Once you see OPTIMIZATION HAS CONVERGED.. FEASIBLE DESIGN <ALL CONSTRAINTS SATISFIED> Message on the solver window, close the solver window.

Step 14: View the shape change due to topology optimization, and changes in displacement after optimization process.
1. Click on Page Window Layout and split the window into 4.

2. 3.

Click on 3 window and click on open folder Click on the folder icon in front of Load Model: and open the folder where you have saved the file before optimization. There select the _des.h3d file, this file contains the design history after the Optimization Process. Click on Apply.

rd

4.

Select the last ittration as shown in the figure.

5.

Click on contour icon, in Result type: select Element Densities (s), and in Averaging Method: select Simple. And then click Apply.

6.

Click on Iso icon, click Apply. on current value: enter 3. Check the box next to Features and Transparent.

This is the final optimized shape which we have received