2 - MF and Examples

modeFRONTIER
is a registered product
of ESTECO srl
Copyright ESTECO srl 1999-2007
For more information visit:
www.esteco.com or send an e-mail to:
modeFRONTIER@esteco.com
The concept behind modeFRONTIER
Some conceptual fundaments for introducing the modeFRONTIER design environment
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of ESTECO srl
2
Defining modeFRONTIER
modeFRONTIER is a multi-objective optimization and design environment,
written to allow easy coupling to almost any computer aided engineering
(CAE) tool, whether commercial or in-house.
modeFRONTIER
of ESTECO srl
The concept behind modeFRONTIER
Input Variables:
Entities that define the
design space.
Output Variables:
Measures from the system
The Black Box:
Generates the outputs
accordingly to the inputs
modeFRONTIER
of ESTECO srl
The input variables
Variables:
Variables are the free parameters, i.e. the quantities
that the designer can vary or the choices the designer
can make.
Continuous variables:
point coordinates
process variables
Discrete variables:
components from a catalogue
number of components
modeFRONTIER
of ESTECO srl
The Black Box
The black box can be:
A set of solvers that models and solves in a numerical
manner the design problem (e.g. CAD/CAE tools)
A set of experiments that produces some data
CAD
(CATIA, UGS,
PROE)
CFD
(StarCD,
Fluent, CFX)
FEM
(Nastran, Ansys,
Madymo, etc)
Others
(In-House codes,
MATLAB, Excel)
Multi-disciplinary Scenario
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6
The output variables are a measure of the system response and/or performance, i.e.:
acceleration, speed, consumption, confort,
deformation, stress, mass, volume,
lift, drag,
defects, number of failures, cost,
.
The output variables
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of ESTECO srl
7
Input Variables:
Entities defining
the design space.
Output Variables:
Measures from the
system
The Black Box:
(ANSYS, FLUENT, Workbench,
MatLab, etc)
Optimization means to find a set of system configurations (input
variables) that meets the objectives and satisfy the constraints
Objectives Constraints
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of ESTECO srl
8
The optimization can be
multiobjectives
Many softwares can be
used to describe the
behavior of the system
under exam
CAE1
INPUT
OBJECTIVES
CONSTRAINTS
CAE2
OUTPUT
OPTIMIZER
Black box
modeFRONTIER
of ESTECO srl
Multidisciplinary Optimization - MDO
Discipline
1
Discipline
2
Discipline
3
Discipline
4
Discipline
5
Discipline
x1
x2
xn
Objective 1
Objective 2
Objective k
Multiobjective optimization, Approximation methods, Sensitivity Analysis, Space
exploration, Multivariate Analysis
modeFRONTIER
of ESTECO srl
EMO and its fields*
aerospace & defence
appliance
automotive
chemical
construction
electronics
healthcare equipment
industrial equipment
marine & offshore
materials & processes
others
Leisure &
Sport
*On a database of 148 real world applications
modeFRONTIER
of ESTECO srl
Leisure & Sport Applications
Study of innovative solutions of a cycle wear crotch pad for Campagnolo
The optimization considered the ergonomic level of the crotch pad function
of both geometry and materials.
modeFRONTIER
of ESTECO srl
Simplified product analysis Decrease in cost
Alternative materials Stiffness and energetic absorption
Ergonomic/Marketing Independence by anthropomorphic features
Ergonomic improvement Shape and thickness modification
Objective: Product innovation for high performances
Innovation HOW ?
Technologic issue (cost) appearance/ Marketing performances
modeFRONTIER
of ESTECO srl
A
B
C
Parametric models carrying out
Objective : Ergonomic improvement Shape change, thickness, material
Assessment of the critical zone
modeFRONTIER
of ESTECO srl
Parametric models carrying out
Objective: Ergonomic improvement Shape, thickness, weight change
modeFRONTIER
of ESTECO srl
Geometric parameters
Simulation CAD parameters. These parameters have been implemented in modeFRONTIER.
modeFRONTIER
of ESTECO srl
Optimization process
Workflow
Ansys node - WorkBench
Independent variables
Excel node
Dependent variables
Objectives
modeFRONTIER
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The optimization process:
Input variables: Geometry, materials mechanical properties
Objectives: Minimization of back and front cushions volume, minimization
of pressure distribution and its maximum value.
DOE: Sobol (50 designs initial population )
Optimisation algorithm: MOGA II
modeFRONTIER
of ESTECO srl
1810
modeFRONTIER
of ESTECO srl
Assos F13
Optimization Assos F13
Des. 1810
Comparison
between initial
configuration and
optimal points
http://www.campagnolosportswear.com/
modeFRONTIER
of ESTECO srl
Graph of relative drag difference between a
cyclist using a rear wheel with and without a
disk in a range of crosswinds
Example of Applications: Biomechanics
modeFRONTIER
of ESTECO srl
Example of Applications: Biomechanics
modeFRONTIER
of ESTECO srl
Bozen
Verona
Mnchen
Innsbruck
Two single track railway tunnels connecting Fortezza (Italy)
and Innsbruck (Austria).
Tunnel section: 72,4 m2
Length: 56 km
Up to 1650 m under the Alps
Tunnels about 70 apart, connecting galleries every 330
meters
The problem:
Uncertainities of data on the mechanical behaviour of
the rock mass
Passing from south to north, the tunnel will be drilled throug
granite, paragneiss, schist, gneiss, marble, phylite.
It also crosses the Periadriatic Seam, caused by the collision
of the African plate and the European Continent
Constructions - Brenner Railway Base Tunnel
modeFRONTIER
of ESTECO srl
Time and Cost Reduction
modeFRONTIER tasks
Reliability analysis (general) and
documentation
Reliability analysis with respect to rock
models (behaviour of the mass during
borging)
Senario and decion on the best excavation
method.
Examples Constructions - Transportation
modeFRONTIER
of ESTECO srl
Automotive Application
The aim of this activity is to OPTIMIZE CONFLICTING ASPECTS in terms of
Handling performances as well as Ride&Comfort performances.
The study results in a set of vehicle set-up, concerning suspension vertical and longitudinal
stiffness, elasto-cinematic behavior, optimizing both aspects without forgetting the robustness of
the solution.
Stability and response of the vehicle
Understeer
Side-slip angle
Rolling
Yaw speed
Comfort for driver and passengers
Peak accelerations
Time of dissipation after impact
RMS of low frequency accelerations
on uneven road, highway, obstacles
Courtesy of Fiat
modeFRONTIER
of ESTECO srl
Full-vehicle MSC.ADAMS/Car Models
Rear Suspension
Front Suspension
Assembly Comfort
Front Suspension (incl. flexible
subframe)
Rear Suspension
Steering
Antirollbar
Engine
Front&Rear Tires
Rigid Body
Assembly Handling
Front Suspension (incl. flexible
subframe)
Rear Suspension
Steering
Antirollbar
Conceptual Driveline
Front&Rear Tires
Rigid Body
modeFRONTIER
of ESTECO srl
Definition of Input variables
Input variables:
Spring Stiffness and preload
Bumpstop clearance and characteristics
Anti-roll-bar diameter
Damper characteristics
Bushing characteristics
Vehicle parameters able to influence both the Ride-Comfort and Handling performance
VERTICAL STIFFNESS AND
ROLLING STIFFNESS
VERTICAL DAMPING
ELASTO-CINEMATIC
CHARACTERISTICS
LONGITUDINAL
STIFFNESS AND DAMPING
modeFRONTIER
of ESTECO srl
Objectives:
- Key synthesis Handling parameters
(understeer, sideslip curve, yaw, rolling - gains, time
delays)
- Key synthesis Comfort parameters (peak
accelerations, time dissipations, RMS/RMF)
Objectives and Constraints
Constraints:
- Ride height in various load conditions
- Feasibility of the components for
.ex. rate between axial and radial bushing
stiffness, damper characteristics, bumpstop
length and characteristics etc.
- Top mount stiffness for damper
efficiency
- Performance constraints
StdA
P.C.
Tarature ammortizzatore posteriore 263
confronto con tarature X250
-2000
-1500
-1000
-500
0
500
1000
1500
2000
2500
3000
3500
4000
-3000 -2500 -2000 -1500 -1000 -500 0 500 1000 1500 2000 2500 3000
velocit [mm/s^2]
F o r z a [ N ]
REAR_MV
muletto validato CRF
ISO SMORZANTE 223
Minimo realizzabile per 263 con
ammortizzatore attuale
MT104
92
93
94
95
96
97
98
99
100
101
0 200 400 600 800 1000 1200
Rigidezza verticale [N]
E
f f i c
i e
n
z
a
a
m
m
o
r
t i z
z
a
t o
r
e
[ %
]
frequency response - lateral acceleration / steering angle
80 km/h 0.45g
0.0000
0.0020
0.0040
0.0060
0.0080
0.0100
0.0120
0.0140
0.0160
0.0180
0 0.5 1 1.5 2 2.5 3 3.5 4 4.5
frequency (Hz)
A
Y
/ D
V
O
L
- g
a
i n
( g
/ d
e
g
)
263 Muletto calcolo pneumMule (195 "Stilo")
223 sperimpneumMule (195 "Stilo")
263 target
263 7q rev4 pneumMule (195 "Stilo")
-0.25
-0.2
-0.15
-0.1
-0.05
0
0.05
0.1
0.15
0.2
0 0.5 1 1.5 2 2.5 3 3.5 4 4.5
frequency (Hz)
A
Y
/ D
V
O
L
- p
h
a
s
e
( s
)
frequency response - yaw rate / steering angle
80 km/h 0.45g
0.000
0.050
0.100
0.150
0.200
0.250
0.300
0.350
0.400
0.450
0.500
0 0.5 1 1.5 2 2.5 3 3.5 4 4.5
frequency (Hz)
P
S
I P
/ D
V
O
L
- g
a
i n
( 1
/ s
)
263 target
-0.14
-0.12
-0.1
-0.08
-0.06
-0.04
-0.02
0
0 0.5 1 1.5 2 2.5 3 3.5 4 4.5
frequency (Hz)
P
S
I P
/ D
V
O
L
- p
h
a
s
e
( s
)
frequency response - side slip angle / steering angle
80 km/h 0.45g
0.0000
0.0100
0.0200
0.0300
0.0400
0.0500
0.0600
0 0.5 1 1.5 2 2.5 3 3.5 4 4.5
frequency (Hz)
B
E
T
A
/ D
V
O
L
- g
a
i n
( d
e
g
/ d
e
g
)
263 target
-0.4
-0.35
-0.3
-0.25
-0.2
-0.15
-0.1
-0.05
0
0 0.5 1 1.5 2 2.5 3 3.5 4 4.5
frequency (Hz)
B
E
T
A
/ D
V
O
L
- p
h
a
s
e
( s
)
frequency response - lateral acceleration / steering angle
80 km/h 0.45g
0.0000
0.0020
0.0040
0.0060
0.0080
0.0100
0.0120
0.0140
0.0160
0.0180
0 0.5 1 1.5 2 2.5 3 3.5 4 4.5
frequency (Hz)
A
Y
/ D
V
O
L
- g
a
i n
( g
/ d
e
g
)
263 target
-0.25
-0.2
-0.15
-0.1
-0.05
0
0.05
0.1
0.15
0.2
0 0.5 1 1.5 2 2.5 3 3.5 4 4.5
frequency (Hz)
A
Y
/ D
V
O
L
- p
h
a
s
e
( s
)
frequency response - yaw rate / steering angle
80 km/h 0.45g
0.000
0.050
0.100
0.150
0.200
0.250
0.300
0.350
0.400
0.450
0.500
0 0.5 1 1.5 2 2.5 3 3.5 4 4.5
frequency (Hz)
P
S
I P
/ D
V
O
L
- g
a
i n
( 1
/ s
)
263 target
-0.14
-0.12
-0.1
-0.08
-0.06
-0.04
-0.02
0
0 0.5 1 1.5 2 2.5 3 3.5 4 4.5
frequency (Hz)
P
S
I P
/ D
V
O
L
- p
h
a
s
e
( s
)
80 km/h 0.45g
0.0000
0.0100
0.0200
0.0300
0.0400
0.0500
0.0600
0 0.5 1 1.5 2 2.5 3 3.5 4 4.5
frequency (Hz)
B
E
T
A
/ D
V
O
L
- g
a
i n
( d
e
g
/ d
e
g
)
263 target
-0.4
-0.35
-0.3
-0.25
-0.2
-0.15
-0.1
-0.05
0
0 0.5 1 1.5 2 2.5 3 3.5 4 4.5
frequency (Hz)
B
E
T
A
/ D
V
O
L
- p
h
a
s
e
( s
)
100 km/h - 0.4 g
0.0000
0.0100
0.0200
0.0300
0.0400
0.0500
0.0600
0.0700
0 0.5 1 1.5 2 2.5 3 3.5 4 4.5
frequency (Hz)
B
E
T
A
/ D
V
O
L
- g
a
i n
( d
e
g
/ d
e
g
)
Option 1
Option 2
modeFRONTIER
of ESTECO srl
Coupling modeFRONTIER & ADAMS/Car
Example Process includes modifying and launching
3 models (K&C, Assembly Handling e Comfort),
7 analysis (4 K&C, 2 Handling e 1 Comfort).
Every run requires approx. 5min => weekend 2.5ggr = about 800 run
MSC.ADAMS Car modeFRONTIER
INPUTS
CONSTRAINT CHECK
- ANALYSIS, POST-PROCESSING
INPUT MODEL, ANALYSIS,
POST-PROCESSING -
COMMAND FILES ADAMS
OUTPUTS =>
COMPARISONS OBJECTIVES AND
CONSTRAINTS
Model modifications
Results simulation
modeFRONTIER
of ESTECO srl
DOE Study and Optimization Method
Influence Study: 8 Input variables, 4 Targets for example
DOE Study Sobol/Full-factorial => Excluding input variables (and constraints/objectives) + Adapting range of study
Optimization with limited numbers of variables, objectives, constraints - real or virtual response surfaces
Pareto FRONTIER => Selection of optimum solutions related to the particular project vehicle target setting
Verification of optimum solutions belonging to Pareto FRONTIER
modeFRONTIER
of ESTECO srl
The geometric model built-up in Catia V5 has been imported into ANSYS
WorkBench 11.0.
Centine (Ribs)
Superfici Alari (Skins)
Longheroni a C (Spars)
Aerospace Application
Courtesy of Alenia Aeronautica
modeFRONTIER
of ESTECO srl
Subdivision of the wing into 6 parts
In this way it is possible to reduce the number of skins while getting closer
to the tip of the wing (more efficient optimization process)
Different values of skin and caps
structural parameters between the
wing underside and the top surface
With the aim to get the best
material performances
The input variables values (thickness, skins number, ) are constant within every 6
parts
Geometric model set-up
modeFRONTIER
of ESTECO srl
Optimization strategy
The optimization process has been sub-divided into the 2 following phases:
1. Firstly, the whole design space has been explored with the scope to get the
global optimal solution. This initial search exploited the MOGA-II
2. In a second step, the more important input parameters have been further
investigated, while the remaining ones have been fixed to constant values.
This approach enabled to get more accurate solutions. In this phase both
MOGA-II and B-BFGS (hybrid approach) have been used.
modeFRONTIER
of ESTECO srl
Workflow modeFRONTIER
DATA FLOW
17 input variables + 67 constants
29 output variables
1 objectives
30 constraints
CPU TIME
Around 680 analyses
10 per run
around 4.5 days
LOGIC FLOW
DOE: 4 best designs fase 1
Optimizer: B-BFGS
DOE: 16 best designs B-BFGS
Optimizer: MOGA-II
modeFRONTIER
of ESTECO srl
The flexural and the total deformation (torsion and flexural) are depicted. In
both cases (positive and negative nz) the maximum deformation values belong to
the feasibilty domain.
Wing tip deflection (1989.3 mm)
positive nz
Total deformation
(torsion < 7)
Results

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