Professional Documents
Culture Documents
com/tosca
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
SIMULIA
Tosca Structure
This work is protected by copyright. All rights are reserved. This especially
applies to the translation, reproduction, presentation, use of illustrations and
tables, electronic broadcast, transfer to microfilm or any other kind of duplication or stored in an information retrieval system, even as excerpts. Reproduction of this work in part or whole for personal use is also only allowed as
specified in the legal context of the current copyright laws of the Federal
Republic of Germany from September 9, 1965. Reproduction is always subject to compensation. The guidelines set by the Council of the European community from May 14, 1991 regarding the protection of computer programs are
applicable. Violations will be prosecuted under the conditions of the copyright
law.
Copyright 2014 by FE-DESIGN GmbH, a Dassault Systmes company,
all rights reserved
Tosca Structure is a registered trademark of FE-DESIGN GmbH. All other
products and product names are the property of their respective owners.
www.3ds.com/tosca
FE-DESIGN GmbH
Albert-Nestler-Strae 17
76131 Karlsruhe
+49 (0) 721-96467-250
support@fe-design.com
www.fe-design.com
SIMULIA
Tosca Structure
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
The contents of GLview Reporter and/or its documentation may not be disclosed to third parties, copied or duplicated in any form, in whole or in part,
without the prior written permission of Ceetron AS.
GLview Reporter is protected by copyright law and international treaties.
Unauthorized reproduction or distribution of GLview Reporter, or any portion
of it, may result in severe civil and criminal penalties, and will be prosecuted
to the maximum extent possible under law.
SIMULIA
Tosca Structure
Table of Contents
SIMULIA Tosca Structure Documentation 8.1
General Remarks
0-i
Volume I
Start Manual
Preface
1-3
1-5
www.3ds.com/tosca
1-8
1-9
1-10
1-11
1-13
1-14
1-15
1-15
1-18
1-19
1-20
1-20
1-21
1-21
1-22
1-23
1-23
1-24
1-24
1-24
1-25
1-25
0-v
SIMULIA
Tosca Structure
1-26
1-26
1-27
1-30
1-31
1.2.1
1.2.2
1.2.3
1.2.4
1.2.5
1.2.6
1.2.7
1.2.8
1.2.9
1.2.10
1-33
1-34
1-37
1-37
1-38
1-38
1-39
1-40
1-43
1-45
1-46
1-47
1-48
1-48
1-48
1-48
1-50
1-55
1-55
1-57
1-58
1-59
1-60
1-60
1-61
1-61
0 - vi
1-67
1-68
1-70
1-71
1-72
1-72
1-73
1-74
1-78
1-82
1-84
1-87
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
1-87
1-91
1-91
1-91
1-91
1-91
1-94
1-100
1-100
1-104
1-104
1-104
1-107
1-108
1-108
1-110
1-110
www.3ds.com/tosca
1-113
1-115
1-115
1-117
1-117
1-118
1-118
1-119
1-120
1-123
1-124
1-126
1-126
1-127
1-130
1-130
1-131
1-131
1-131
1-134
1-140
1-140
1-143
1-145
0 - vii
SIMULIA
Tosca Structure
1.5.2
1.5.3
1.5.4
1.5.5
1.5.6
1.5.7
1.5.8
1.5.9
Model
1-146
Optimization Task
1-148
Step by Step Manual: Summary
1-149
Preprocessing
1-150
1.5.5.1 Choice of the optimization type
1-150
1.5.5.2 Loading the input model file
1-151
1.5.5.3 Choice of design area
1-152
1.5.5.4 Choice of thickness bounds (design variable constraint)1-155
1.5.5.5 Optional: Cluster groups
1-157
1.5.5.6 Choice of the objective function
1-157
1.5.5.7 Choice of the constraint
1-159
1.5.5.8 Saving Tosca Structure parameter file
1-159
Start Optimization
1-160
1.5.6.1 Start Tosca Structure
1-160
1.5.6.2 Logging and monitoring
1-160
Postprocessing
1-161
Report Generation
1-162
Result Discussion
1-167
1-171
1-171
1-172
1-173
1-174
1-177
1-180
1-183
1-185
1-186
1-186
0 - viii
1-189
1-190
1-193
1-193
1-194
1-194
1-195
1-196
1-198
1-198
1-200
1-202
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
2.2.6
2.2.7
2.2.8
2.2.9
2.2.10
1-203
1-204
1-206
1-206
1-208
1-210
1-215
1-216
1-217
1-218
www.3ds.com/tosca
2.3.6
2.3.7
2.3.8
2.3.9
2.3.10
2.3.11
2.3.12
2.3.13
1-223
1-224
1-226
1-227
1-229
1-229
1-229
1-231
1-234
1-234
1-236
1-237
1-238
1-238
1-240
1-240
1-241
1-241
1-242
1-242
1-246
1-247
1-249
1-257
1-260
1-260
1-260
1-264
1-266
1-267
1-268
1-269
0 - ix
SIMULIA
Tosca Structure
1-269
1-271
1-273
1-273
1-275
1-275
1-277
1-277
1-277
1-279
1-281
1-281
1-283
1-284
1-284
1-286
1-286
1-287
1-288
1-288
1-290
1-293
1-293
1-296
1-297
1-304
1-304
2.5.1
2.5.2
2.5.3
2.5.4
2.5.5
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
2.5.7 Postprocessing
2.5.8 Report Generation
2.5.9 Result Discussion
1-324
1-326
1-332
1-335
1-337
1-339
The model
Loading the Extension
Example files
Preparing the model
Optimization preprocessing
Postprocessing
3.2.6.1 Optimization result view options
3.2.6.2 Iteration Animation
3.2.7 Validation Run
3.2.8 Troubleshooting
1-347
1-347
1-348
1-349
1-357
1-363
1-363
1-364
1-365
1-368
www.3ds.com/tosca
3.3.1
3.3.2
3.3.3
3.3.4
3.3.5
3.3.6
The model
Loading the extension
Example files
Preparing the model
Optimization preprocessing
Postprocessing
3.3.6.1 Optimization result view options
3.3.6.2 Iteration Animation
3.3.7 Troubleshooting
1-371
1-374
1-374
1-375
1-384
1-391
1-391
1-391
1-392
Volume II
User Manual
Preface
2-3
2-5
2-6
0 - xi
SIMULIA
Tosca Structure
1.1.2
1.1.3
1.1.4
1.1.5
1.1.6
1.1.7
1.1.8
2-6
2-6
2-6
2-7
2-7
2-7
2-7
Planning
Preprocessing: Model generation
Check Run
Optimization Loop
Postprocessing: Evaluation of Optimization results
Result Transfer and Validation Run
2-8
2-8
2-9
2-9
2-10
2-10
2-13
Preprocessing
Check Run
Start Optimization
Postprocessing
Result Transfer and Validation Run
2-14
2-15
2-16
2-16
2-16
2.2.1
2.2.2
2.2.3
2.2.4
2.2.5
Preprocessing
Check Run
Start Optimization
Postprocessing
Result Transfer and Validation Run
2-18
2-19
2-19
2-20
2-21
Preprocessing
Start Optimization
Postprocessing
Result Transfer and Validation Run
2-24
2-24
2-25
2-25
0 - xii
2-27
2-27
2-28
2-28
2-28
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
2.2 Working with the Graphical User Interface Tosca Structure.gui . . 2-17
SIMULIA
Tosca Structure
The Model
2-29
2-31
2-31
2-32
2-32
2-33
2-35
2-35
2-35
2-36
2-36
2-37
2-37
2-37
2-38
2-40
www.3ds.com/tosca
3.4.1
3.4.2
3.4.3
3.4.4
3.4.5
3.4.6
3.4.7
2-42
2-44
2-44
2-44
2-45
2-45
2-46
2-46
2-47
2-48
2-48
2-49
2-49
2-50
2-60
0 - xiii
SIMULIA
Tosca Structure
2-63
2-66
2-67
2-68
2-69
2-71
2-72
2-73
2-75
2-76
2-87
2-88
2-92
2-95
2-97
2-98
2-102
2-103
2-105
2-107
2-109
2-111
2-114
2-114
2-118
2-123
2-125
2-127
2-131
2-135
2-135
2-137
2-137
2-139
2-142
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Topology Optimization
2-179
2-181
2-183
www.3ds.com/tosca
2-217
2-217
2-219
2-223
0 - xv
SIMULIA
Tosca Structure
2-226
2-228
2-235
2-240
2-250
2-254
2-256
2-258
2-262
2-267
2-270
2-273
2-273
2-274
2-274
2-274
2-276
2-276
2-278
2-279
2-285
2-286
2-287
2-288
2-289
2-292
2-293
2-293
2-294
2-294
Shape Optimization
2-297
2-298
2-298
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
www.3ds.com/tosca
SIMULIA
Tosca Structure
0 - xvii
SIMULIA
Tosca Structure
2-353
2-354
2-354
2-357
2-358
2-359
2-360
2-362
2-364
2-364
2-367
2-369
2-371
2-373
2-377
2-378
2-379
2-380
2-382
2-383
6.9.1
6.9.2
6.9.3
6.9.4
General
Test run (CHECK_INPUTS) in Tosca ANSA environment
Test run in Tosca Structure.gui
Command syntax
2-383
2-384
2-385
2-385
2-388
2-389
2-392
2-393
2-395
2-396
2-396
2-398
2-399
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
6.11.1
6.11.2
6.11.3
6.11.4
6.11.5
2-400
2-400
2-401
2-402
2-403
Bead Optimization
2-405
2-407
2-408
2-408
2-413
2-429
www.3ds.com/tosca
2-433
2-434
2-434
2-435
2-437
2-438
2-439
0 - xix
SIMULIA
Tosca Structure
7.9
7.10
7.11
7.12
Sizing Optimization
2-451
2-455
2-456
2-458
2-459
2-461
2-463
2-465
2-466
2-467
2-469
2-471
2-473
2-476
2-477
2-477
2-479
2-483
2-487
2-491
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Mode tracking
Update strategy of the method of moving asymptotes
Settings of the mesh filter
FILTER_TYPE
2-495
2-497
2-498
2-499
2-499
2-500
2-500
2-501
2-501
2-505
www.3ds.com/tosca
2-506
2-507
2-510
2-516
2-519
2-520
2-525
2-529
2-533
2-536
2-538
2-540
2-542
2-545
2-549
2-549
2-552
2-562
2-562
0 - xxi
SIMULIA
Tosca Structure
2-565
2-580
2-582
2-588
2-591
2-592
2-594
2-595
2-596
2-596
2-596
2-597
2-599
2-600
2-600
2-602
2-603
2-604
2-606
2-607
2-608
2-609
2-610
2-611
2-612
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
2-613
2-615
2-616
2-616
2-617
2-618
2-619
2-622
2-624
2-630
2-632
2-632
2-635
2-637
2-638
2-639
2-640
2-642
2-644
2-645
2-645
2-647
2-649
2-649
www.3ds.com/tosca
2-652
2-653
2-657
2-657
2-657
2-658
2-658
2-659
2-659
2-660
2-662
0 - xxiii
SIMULIA
Tosca Structure
11.4.4
11.4.5
11.4.6
11.4.7
11.4.8
2-663
2-663
2-666
2-667
2-668
2-669
2-670
2-673
2-674
2-674
2-674
2-675
2-676
2-676
2-676
2-677
2-677
2-678
2-678
2-679
2-679
2-680
2-682
2-682
2-682
2-685
2-687
2-687
2-689
0 - xxiv
2-691
2-694
2-695
2-695
2-696
2-697
2-698
2-699
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
2-712
2-714
2-719
www.3ds.com/tosca
12.5.1 TOSCA_PREP
12.5.2 Files after preprocessing (TOSCA_PREP)
2-719
2-720
2-721
2-721
2-721
13 Troubleshooting
2-721
2-723
0 - xxv
SIMULIA
Tosca Structure
2-728
2-730
2-733
2-735
2-735
2-735
2-737
14 Appendix
2-741
2-741
2-741
2-742
Volume III
CONFIG
CONSTRAINT
CONTOURPLOT
CS_DEF
DRESP
DVCON_AUTO_SHAPE
DVCON_BEAD
DVCON_SHAPE
DVCON_SIZING
DVCON_TOPO
DV_BEAD
DV_SHAPE
DV_SIZING
0 - xxvi
3-3
3-24
3-26
3-29
3-31
3-52
3-53
3-55
3-58
3-61
3-67
3-68
3-69
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Commands Manual
DV_TOPO
FEM_INPUT
GROUP_AUTO_DEF
GROUP_DEF
GROUP_IMPORT
INCLUDE
LINK_BEAD
LINK_SHAPE
LINK_SIZING
LINK_TOPO
LIST
LIST, info
LOGICAL
MESH_SMOOTH
MORPH
MORPH_AREA
OBJ_FUNC
OPTIMIZE
OPTIONS
OPT_PARAM
REPORT
SELECT
SF_IDENT
SMOOTH
SOLID
STOP
TEST_BEAD
TEST_SHAPE
USER_FILE
VARIABLE
3-70
3-72
3-75
3-78
3-81
3-82
3-83
3-84
3-95
3-97
3-100
3-106
3-107
3-109
3-115
3-117
3-118
3-120
3-123
3-129
3-143
3-146
3-153
3-154
3-162
3-163
3-166
3-168
3-170
3-178
www.3ds.com/tosca
SIMULIA
Tosca Structure
0 - xxvii
SIMULIA
Tosca Structure
Volume IV
Examples Manual
Preface
4-3
Topology Optimization
4-5
Model
Optimization Task
Procedure: Summary
Procedure in Detail: Tosca ANSA environment
Procedure in Detail: Tosca Structure.gui
Results
4-6
4-6
4-7
4-7
4-7
4-10
Model
Optimization Task
Procedure: Summary
Procedure in Detail: Tosca ANSA environment
Procedure in Detail: Tosca Structure.gui
Optimization results
4-11
4-11
4-11
4-12
4-13
4-15
4-18
4-18
4-19
4-22
4-22
4-23
4-26
4-27
4-28
4-31
0 - xxviii
4-34
4-35
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
4-37
4-40
Procedure: Summary
Procedure in detail: Tosca ANSA environment
Procedure in detail: Tosca Structure.gui
Optimization results
4-45
4-45
4-46
4-49
Procedure: Summary
Procedure in detail: Tosca ANSA environment
Procedure in detail: Tosca Structure.gui
Optimization results
4-50
4-51
4-51
4-53
The model
Optimization task
Optimization task definition in Tosca ANSA environment
Optimization task definition in Tosca Structure.gui
Result discussion and validation run
4-56
4-57
4-57
4-59
4-62
4-66
4-66
4-67
Procedure: Summary
Procedure in detail: Tosca ANSA environment
Procedure in detail: Tosca Structure.gui
Optimization results when considering force constraints
4-70
4-71
4-72
4-77
www.3ds.com/tosca
Procedure: Summary
Procedure in detail: Tosca ANSA environment
Procedure in detail: Tosca Structure.gui
Optimization results
4-79
4-79
4-80
4-83
Procedure: Summary
Procedure in detail: Tosca ANSA environment
Procedure in detail: Tosca Structure.gui
Optimization results
4-84
4-85
4-86
4-88
0 - xxix
SIMULIA
Tosca Structure
Shape Optimization
4-89
Procedure: Summary
Procedure in detail: Tosca ANSA environment
Procedure in detail: Tosca Structure.gui
Optimization results
4-92
4-92
4-93
4-94
Procedure: Summary
Procedure in detail: Tosca ANSA environment
Procedure in detail: Tosca Structure.gui
Optimization results
4-95
4-96
4-96
4-97
Procedure: Summary
Procedure in detail: Tosca ANSA environment
Procedure in detail: Tosca Structure.gui
Optimization results
4-98
4-99
4-99
4-103
Procedure: Summary
Procedure in detail: Tosca ANSA environment
Procedure in detail: Tosca Structure.gui
Optimization results
4-104
4-104
4-105
4-108
4-110
4-111
4-111
4-112
4-114
4-115
4-116
4-118
4-119
4-120
Procedure: Summary
Procedure in detail: Tosca ANSA environment
Procedure in detail: Tosca Structure.gui
Optimization results
4-123
4-124
4-124
4-127
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
3.6.1
3.6.2
3.6.3
3.6.4
SIMULIA
Tosca Structure
The model
Optimization task
Procedure in Detail: Tosca ANSA environment
Procedure in Detail: Tosca Structure.gui
Result discussion
4-128
4-128
4-128
4-132
4-134
Procedure: Summary
Procedure in detail: Tosca ANSA environment
Procedure in detail: Tosca Structure.gui
Optimization results
4-136
4-136
4-136
4-137
The model
Procedure: Summary
Procedure in detail: Tosca ANSA environment
Procedure in detail: Tosca Structure.gui
Optimization results
Bead Optimization
4-139
4-140
4-140
4-141
4-143
4-147
4-149
4-149
4-150
www.3ds.com/tosca
4.3.1
4.3.2
4.3.3
4.3.4
Procedure: Summary
Procedure in Detail: Tosca ANSA environment
Procedure in Detail: Tosca Structure.gui
Optimization results
4-153
4-153
4-154
4-157
4.5
4-157
4-158
4-160
4-162
Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-164
Sizing
4-169
0 - xxxi
SIMULIA
Tosca Structure
5.2.1
5.2.2
5.2.3
5.2.4
5.2.5
5.2.6
Model
Optimization Task
Procedure: Summary
Procedure in Detail: Tosca ANSA environment
Procedure in Detail: Tosca Structure.gui
Results
4-170
4-171
4-171
4-171
4-173
4-176
Procedure: Summary
Procedure in Detail: Tosca ANSA environment
Procedure in Detail: Tosca Structure.gui
Optimization results
Shape Optimization in
Combination with Durability Analysis
4-178
4-178
4-179
4-181
4-183
Morphing
4-189
4-191
4-191
4-198
4-200
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
7.1.1
7.1.2
7.1.3
7.1.4
0 - xxxii
SIMULIA
Tosca Structure
General Remarks
General Remarks
Documentation Manuals
Tosca Structure documentation is contained in the following manuals:
Getting Started with Tosca Structure (volume 1)
User Manual (volume 2)
Commands Manual (volume 3)
Examples Manual (volume 4)
Installation Manual
Description of Manuals
A short description and comment of the content of each manual is given
below:
Getting Started Manual (volume 1)
This manual gives a compact introduction to Tosca Structure and the work
with the frontends Tosca ANSA environment, Tosca Structure.gui and Tosca
Extension for ANSYS/Workbench. The set-up, running and evalution of typical optimization tasks for each type of optimization are explained in detail.
Thus in particular new users are able to find an access to Tosca Structure
quickly and efficiently whereas experienced users can look up detailed
descriptions of specific work steps.
www.3ds.com/tosca
0-i
SIMULIA
Tosca Structure
Names which are addressed in detail in the text or which have a special
meaning in context are written in bold letters.
Chosen values are marked in square brackets.
Tosca ANSA environment buttons and functions are denoted in Courier
New.
Tosca Structure commands and parameters are either linked to the corresponding commands manual entry or denoted in Courier New.
If an action (normally right mouse click) or choice is required, brackets []
are used.
0 - ii
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
General Remarks
END_
DV_TOPO
ID_NAME
EL_GROUP
END_
STOP
ID_NAME
ITER_MAX
END_
The online documentation supports hypertext functions, therefore the navigation through the various manuals is easy and fast.
Acrobat Reader from Adobe or another pdf reader is needed to visualize the
pdf document. The reader is available at the internet address http://
www.adobe.com.
www.3ds.com/tosca
0 - iii
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
0 - iv
Volume I
Start Manual
www.3ds.com/tosca
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
SIMULIA
Tosca Structure
Preface
Preface
www.3ds.com/tosca
This manual demonstrates how to work with the structural optimization package Tosca Structure. In the chapters chapter 1 Getting Started with Tosca
ANSA environment, chapter 2 Getting Started with Tosca Structure.gui and
chapter 3 Getting Started with Tosca Extension for ANSYS/WB, it is explained
how these three different front ends can be used in order to define, start and
process the optimization task. The following tutorials demonstrate for all front
ends how to set up, run and evaluate typical topology, shape, bead and sizing optimization tasks. The step by step explanation contained in the tutorials
enables a user inexperienced with Tosca Structure to set up a simple optimization task. No emphasis has been placed on details about the single optimization settings. These details are covered in vol.2 User Manual and vol.3
Commands Manual.
Start Manual 1 - 3
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
1 - 4 Start Manual
SIMULIA
Tosca Structure
Getting Started with Tosca ANSA
www.3ds.com/tosca
Please note:
The current version of Tosca ANSA environment does not yet support sizing
optimization.
Start Manual 1 - 5
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
User Interface
1.1
User Interface
1 - 6 Start Manual
SIMULIA
Tosca Structure
Getting Started with Tosca ANSA
www.3ds.com/tosca
Start Manual 1 - 7
SIMULIA
Tosca Structure
User Interface
Certain windows and toolbars can also be shown or hidden using Windows
toolbar:
Task manager
Includes
Properties
Materials
Sets
Database
Mesh Parameters
1.1.1
1 - 8 Start Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Measure
SIMULIA
Tosca Structure
Getting Started with Tosca ANSA
LOCK: saves the current view so that ALL command returns to this view.
www.3ds.com/tosca
Start Manual 1 - 9
SIMULIA
Tosca Structure
User Interface
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
1 - 10 Start Manual
SIMULIA
Tosca Structure
Getting Started with Tosca ANSA
Draw Mode: defines how the model is to be colored: according to the type of geometric object
(ENT), property ID of elements (PID), material ID
of elements (MID) or another element-related
value.
www.3ds.com/tosca
1.1.2
Start Manual 1 - 11
SIMULIA
Tosca Structure
User Interface
1 - 12 Start Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Getting Started with Tosca ANSA
1.1.3
The marked button expands the tree making all items show. A new Tosca
Structure task is created by a command in Tasks | Tosca Structure task
| ... group that corresponds to the desired optimization type; this command produces a new top level item as well as the uninitialized children items
for each part of the process.
calls Update command for the current item (see
below);
www.3ds.com/tosca
Start Manual 1 - 13
SIMULIA
Tosca Structure
User Interface
Update: for the items associated with some action (as in the example, with
the start of the optimization), this action is performed and the item is marked
as checked in case of success. Calling Update for an item automatically
invokes this command for all unchecked items that the current item depends
upon.
View: for the items associated with groups, the group is shown (View |
Show), hidden (View | Hide) or shown alone (View | Show Only).
Edit Comments: opens the window for editing the comments for the item.
Disable: marks the item as disabled, so that its name is shown struckthrough and all actions proceed as if the item were not present. A disabled
item is returned to normal state by Enable command in context menu.
Set Break: sets the breakpoint to the item, so that, once this item is
reached while calling Update for another item (or with "update all" button),
the user is given the choice to either stop the actions or continue.
For some items, the subitems can be created using New | ... command of
the context menu. All items can be renamed: to do this, click an already
selected item once and wait until its text becomes editable. Note that, in some
cases, the name of the item is important because it defines some file name
(or a part of it).
1.1.4
All standard parameters are added to the task manager, advanced parameters will only appear in the database list.
Remarks
1. When importing an existing Tosca Structure parameter file, the output item
for the name of the parameter file and the job directory is named Output
by default and not automatically after the name of the imported parameter
file.
1 - 14 Start Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Getting Started with Tosca ANSA
1.1.5
www.3ds.com/tosca
1.1.6
Highlighting
There are two possibilities of highlighting:
You can use the highlighting button or you can put a checkmark at several
groups in database window.
highlighting button: switch the highlighting on and
off
With the highlight button in the Task Manager you can, for example, check the
demolding direction or other task definitions: Mark the corresponding defini-
Start Manual 1 - 15
SIMULIA
Tosca Structure
User Interface
tion and switch the highlight on. Direction definitions are shown as arrows in
the graphic window and the design group is marked in color.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Another important feature of highlighting is to visualize properties, grids, elements and so on, listed in the database. Doubleclick at the corresponding
topic, property in this case, and a new window opens. Now you can highlight
one or more definitions of the topic by using the corrsponding button.
1 - 16 Start Manual
SIMULIA
Tosca Structure
Getting Started with Tosca ANSA
The same highlight button can also be found in selection windows like SET,
for example. So it is possible to check definitions of sets like frozen or design
areas.
www.3ds.com/tosca
By using checkmarks in the database, you are able to switch on or off the visibility of database parameters like forces or boundary conditions, for example:
Start Manual 1 - 17
SIMULIA
Tosca Structure
User Interface
1.1.7
Both the model file name and the directory can be changed; however, keep in
mind that the file name and the directory should lead to the model not only
during the loading of the model but also after that. The directory where the
model is located is recognized as the working directory for Tosca ANSA environment, and the job directory of Tosca Structure will be created in it. Therefore, in order for Tosca Structure to access the model, it should be located in
the working directory. Note that Tosca Structure always starts with the initial
finite element model as supplied by the user, and all modifications done in
Tosca ANSA environment (e.g., deleting elements) will not influence the optimization but might affect the processing of optimization results. Therefore, it
is recommended not to modify the input model prior to the optimization.
As the working directory stored in PRE-PROCESSING item, a relative path can
be used; it can even be set to "./" indicating that the working directory is the
current directory. However, this path is relative to the directory Tosca ANSA
environment is started from, and not the path of the workspace. In order to
avoid confusion, it is recommended to define the workspace by an absolute
path. A reason to use a relative path might be that the workspace and the
model are expected to be moved from one location to another; in this case,
1 - 18 Start Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Getting Started with Tosca ANSA
use the relative path but take care concerning the directory where Tosca
ANSA environment is started from.
There is no quick way to unload an already loaded model; the only solution is
to delete all relevant entries in Database manually. However, this is rarely
needed since the model is unloaded at the moment when another model is
selected using Edit command of FILE item.
The job directory for Tosca Structure where all intermediate files as
well as optimization results are
stored is named after Tosca Structure parameter file that contains
the optimization task. The name
of this file equals Output.par by
default; it can be modified by
renaming the item Output that
represents the Tosca Structure
parameter file.
The parameter file as well as the job directory for Tosca Structure are created
in the working directory that is specified in PRE-PROCESSING item. The
actions after the optimization require the files stored in Tosca Structure job
directory, mostly from the subdirectories SAVE.onf and TOSCA_POST. See
for the details on log files created by Tosca Structure.
www.3ds.com/tosca
1.1.8
Start Manual 1 - 19
SIMULIA
Tosca Structure
User Interface
1.1.9
1 - 20 Start Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Getting Started with Tosca ANSA
To select, click the left mouse button on an object or close to it. Selected
objects become highlighted. Repeat for multiple selections. In order to deselect an object, click it with the right mouse button. Double clicking an object
selects its neighbors.
The selection is confirmed with the middle mouse button. In case that the
selection window is active (see the previous section), the properties window
will open for the first selected object.
www.3ds.com/tosca
Multiple geometric objects are selected by drawing a frame with the mouse
while holding the left mouse button. A frame with the right mouse button
pressed deselects the objects that lie inside it. Note that it is possible to select
nodes while they are hidden, but not hidden elements.
Start Manual 1 - 21
SIMULIA
Tosca Structure
User Interface
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Set the first node of polygon by clicking a point with the left mouse button (or,
for deselection, with the right mouse button) while holding Shift key. Then set
the consequent nodes by clicking the points with the mouse (holding Shift key
is not necessary), and finally click the middle mouse button to end the selection. Then, the polygon will close and the objects located inside it will be
selected (or deselected).
1 - 22 Start Manual
SIMULIA
Tosca Structure
Getting Started with Tosca ANSA
www.3ds.com/tosca
Start Manual 1 - 23
SIMULIA
Tosca Structure
User Interface
1.1.11.2 Translating
Moving the mouse while holding
Ctrl key and the right mouse button translates the view.
1.1.11.3 Zooming
By moving the mouse while holding Ctrl key and left and middle
mouse buttons simultaneously,
the view is zoomed in or out
according to the direction the
mouse is moved (see the figure).
A simpler alternative is to use the
mouse wheel; the zooming center is always the center of the visible area. Yet another possibility is
to use the keys F7 (zoom in) and
F8 (zoom out): then, the zooming
center is the current mouse position.
1 - 24 Start Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Getting Started with Tosca ANSA
www.3ds.com/tosca
The list of all keys supported by an input text field in some dialog and the
description of the field are shown in its tool tip:
Start Manual 1 - 25
SIMULIA
Tosca Structure
User Interface
Double clicking an item in this window inserts the group name in the text
field and closes SET HELP window. See the next section for more information about this window as well as about the definition of new groups.
If a field requires a node or element ID, then pressing F1 key closes the window temporarily and waits until the user selects a node or element from the
current view. Then, the window reappears and the ID of the selected object is
inserted in the text field. Pressing F2 key opens the options dialog for the
node or element with the ID from the text field. With F7 key, the current view
is zoomed in at the node or element with the selected ID.
When F3 key is pressed in any
text input field, the window
A_PARAMETERs is opened in
which the user defined parameters can be defined and then
selected.
Later, changing the value of a parameter is reflected in all text fields where
this parameter is used. The parameters can be assigned to numerical or literal values.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Getting Started with Tosca ANSA
double clicking the item SET in Database window opens the selection window for groups that is basically equivalent to SET HELP window
In this window, the groups loaded from the input model as well as the new
groups defined in Tosca ANSA environment are represented. Although only
the new groups are written to Tosca Structure parameter file, the optimization
task may contain references to already defined groups as well,
When SET HELP window is active, clicking an element or a node of the
model highlights all groups that this element or node belongs to.
The button Highlight turns on or off the highlighting of the selected group.
www.3ds.com/tosca
The command NEW creates a new group and starts the group selection mode
described in the next section. When the group selection ends, the group
properties window titled S E T [SET] is shown.
Start Manual 1 - 27
SIMULIA
Tosca Structure
User Interface
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
The selection or deselection of objects with desired IDs can be done in the
selection window. See for details on the selection window.
1 - 28 Start Manual
SIMULIA
Tosca Structure
Getting Started with Tosca ANSA
www.3ds.com/tosca
Note that, in this example, Database item GRID is highlighted, therefore the
nodes will be selected. The selection window is also titled GRID. To change
the type of objects being selected, click the corresponding Database item.
Start Manual 1 - 29
SIMULIA
Tosca Structure
User Interface
1 - 30 Start Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Getting Started with Tosca ANSA
The settings edited in this dialog are divided into two types: general settings
(TOSCA.defaults file) and GUI settings (TOSCA.xml file). On start of
Tosca ANSA environment, both files are first read from the directory config
located in the installation directory; then, the same files are searched for in
.BETA directory located in your home directory; if found, these files are
loaded and the settings defined in them override the ones read previously.
Please refer to for the details about Tosca Structure configuration.
www.3ds.com/tosca
Fig. 1
Start Manual 1 - 31
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
User Interface
1 - 32 Start Manual
SIMULIA
Tosca Structure
1.2
www.3ds.com/tosca
1.2.1
Start Manual 1 - 33
SIMULIA
Tosca Structure
Topology Optimization with Tosca ANSA environment
The Model
The component to be used within the tutorial represents a control arm for a
car and is found in the Tosca Structure installation directory (<tosca>) according to your FE-solver (<solver>) :
<tosca>/<solver>/examples/topo/control_arm
The model is loaded with one loadcase consisting of two fixtures in the upper
left and right areas and is loaded with one load in the lower bearing area. The
1 - 34 Start Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
1.2.2
SIMULIA
Tosca Structure
Design Area
Fig. 2
www.3ds.com/tosca
The model for the topology optimization was modified in such a way that the
inner areas of the component are filled with elements to create a design area
where the optimization system can remove or rearrange elements for getting
a better mechanical behavior of a component with a lower weight with the
same mechanical behavior .
The start model for the optimization represents a design of a control arm for a
car. The component has to be manufactured by forging and consists of aluminum. The red areas of the component are not free for the optimization
Start Manual 1 - 35
SIMULIA
Tosca Structure
Topology Optimization with Tosca ANSA environment
Fig. 3
The fixture is realized with spring elements on the right upper side. The
springs represent a rubber bearing. The left bearing is fixed in all three translation degrees of freedom, but is able to rotate about the x-axis. As loading a
force is applied in the center of the lower bearing.
Due to symmetry reasons only one half of the model is meshed so the symmetry plane is fixed in z-direction for ensuring the symmetry condition.
1 - 36 Start Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
because they are used for the fixtures and for the load application. One red
area is used for the mounting of a sensor for the headlight range adjustment.
SIMULIA
Tosca Structure
1.2.3
Optimization Task
The optimization task is to find a structure with the maximum stiffness for the
component with a volume or weight restriction. This represents the most common standard optimization task for the topology optimization.
The value to be optimized is the compliance which is the reciprocal value of
the stiffness. The compliance is represented as the sum of the strain energy
of the complete model. This value has to be minimized.
The constraint is the weight or volume constraint which is defined to be 70%
of the initial volume/weight of the structure.
As manufacturing constraint a casting/forging constraint has to be defined.
The idea of the constraint is to ensure that the created structure of the topology optimization has no undercuts and can be demolded (or removed from
the forging die).
1.2.4
www.3ds.com/tosca
Start Manual 1 - 37
SIMULIA
Tosca Structure
Topology Optimization with Tosca ANSA environment
1.2.5
Preprocessing
1 - 38 Start Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
www.3ds.com/tosca
Start Manual 1 - 39
SIMULIA
Tosca Structure
Topology Optimization with Tosca ANSA environment
1 - 40 Start Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
www.3ds.com/tosca
Start Manual 1 - 41
SIMULIA
Tosca Structure
Topology Optimization with Tosca ANSA environment
1 - 42 Start Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
www.3ds.com/tosca
2. In DEMOLD_CONTROL window,
choose GROUP_DEF from the
dropdown list below EL_GROUP
Start Manual 1 - 43
SIMULIA
Tosca Structure
Topology Optimization with Tosca ANSA environment
6. In DEMOLD_CONTROL window,
enter the values 0, 0, 1 in the
fields PULL_DIR_1,
PULL_DIR_2 and
PULL_DIR_3. These values
are the components of the pull
direction needed for the definition of the demolding
constraint.
Click OK.
1 - 44 Start Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
www.3ds.com/tosca
Start Manual 1 - 45
SIMULIA
Tosca Structure
Topology Optimization with Tosca ANSA environment
1 - 46 Start Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
www.3ds.com/tosca
Start Manual 1 - 47
SIMULIA
Tosca Structure
Topology Optimization with Tosca ANSA environment
1.2.6
Start Optimization
Postprocessing
Using Tosca Structure.report, the intermediate results of topology optimization, namely the densities of individual elements, can be visualized. This
subsection is optional.
1. Right click TOPO_MAT item
under
GENERATE_REPORT_FILE.
Select Update.
The generated VTFX file
containing the original (nonsmoothed) optimization result
will open in Tosca Structure.view.
1 - 48 Start Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
1.2.7
SIMULIA
Tosca Structure
www.3ds.com/tosca
Start Manual 1 - 49
SIMULIA
Tosca Structure
Topology Optimization with Tosca ANSA environment
1.2.8
Report Generation
1. Open your VTFX file again by
clicking
GENERATE_POST_FILE |
VTF_VISUALIZATION and
select View.
1 - 50 Start Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
5. Click at the left model: Now, this model is activated and its frame
becomes green. Choose the last iteration step by using the Step Backward button and move both views synchronously in an appropriate position (hold Ctrl and the appropriate mouse button while moving the
mouse).
www.3ds.com/tosca
Start Manual 1 - 51
SIMULIA
Tosca Structure
Topology Optimization with Tosca ANSA environment
10. In the Tosca Structure Report Builder window both siutations are listed.
By rightclicking at the situation you can delete it or change the order.
12. The last setting is used for capturing, thus the smoothed optimization
result is loaded as 3D model into the Tosca Structure Report Builder.
13. Load the smoothed optimization result (right window in Tosca Structure.view) as image into the Tosca Structure Report Builder. (Look at step
6 and 7, if necessary, and do not forget to activate the window).
1 - 52 Start Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
www.3ds.com/tosca
Start Manual 1 - 53
SIMULIA
Tosca Structure
Topology Optimization with Tosca ANSA environment
1 - 54 Start Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
20. A PowerPoint file is created. The order of figures and tables is determined by the template.
21. For tranferring into a word file use Create WordReport and the
template TOSCA_Structure_Word_Template_GenericTags.docx,
for a HTML file Create HTMLReport and the template
TOSCA_Structure_HTML_Template_GenericTags.html.
As the vtfx plug-in only works in combination with the internet explorer,
you can choose Video and image as Media type for other browsers.
1.2.9
www.3ds.com/tosca
Start Manual 1 - 55
SIMULIA
Tosca Structure
Topology Optimization with Tosca ANSA environment
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
1 - 56 Start Manual
SIMULIA
Tosca Structure
www.3ds.com/tosca
1. Right click
BATCH_RECONSTRUCT item
under VALIDATE and select
Edit or double click
BATCH_RECONSTRUCT.
Start Manual 1 - 57
SIMULIA
Tosca Structure
Topology Optimization with Tosca ANSA environment
3. Right click
BATCH_RECONSTRUCT item
and select Update.
BATCH_RECONSTRUCT generates a new, more regular triangular surface that can be used
for the remeshing of the volume
with tetrahedra.
1 - 58 Start Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
3. Choose the file name for the output model to be saved in the format of
the solver you use and click Save. In the Output Parameters window
click Ok.
4. Right click the item with the
chosen file name under VALIDATE and select Update.
www.3ds.com/tosca
Start Manual 1 - 59
SIMULIA
Tosca Structure
Topology Optimization with Tosca ANSA environment
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
1 - 60 Start Manual
SIMULIA
Tosca Structure
3. Choose the file name for the output model to be saved in .onf format and
click Save.
4. Right click the item with the
chosen file name under VALIDATE and select Update.
The topology optimization created a new design proposal for the control arm
component. The result of the topology optimization has to be discussed in
several ways.
First of all the optimization result has to be checked. This can be done with
viewing the convergence plot and with checking TOSCA.OUT file for warnings
and errors. If there is a critical error during the optimization the optimization
loop will be stopped. In other cases (if some results are missing) the optimization system will continue but the result may be not sufficient.
Second the resulting model and the finite element analysis of the model has
to be checked if the displacements, the stresses and all other finite element
related information are suitable.
www.3ds.com/tosca
Start Manual 1 - 61
SIMULIA
Tosca Structure
Topology Optimization with Tosca ANSA environment
Result
Strain Energy
Table 1
1645850
Final model
425093.5
Result comparison
Fig. 4
1 - 62 Start Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
For this optimization task the stresses are in the same range compared to the
initial model but the stiffness of the structure is higher and the material
amount necessary for the structure is lower. The values to be compared are
the volume or weight of the structure and the sum of the strain energy. The
strain energy is the measure for the compliance which is the reciprocal value
of the stiffness.
SIMULIA
Tosca Structure
Fig. 5
Optimization result represented after data reduction: IGES surfaces for CAD transfer
www.3ds.com/tosca
After checking the results the remaining structure can be passed to the
design department as a CAD model to be used as design proposal for the
fine tuning of the design. If the stresses within the component are not below
the allowed range the shape optimization of Tosca Structure (Tosca Structure.shape) will be able to remove the stress peaks so that the component will
be suitable from the mechanical point of view.
Start Manual 1 - 63
SIMULIA
Tosca Structure
Topology Optimization with Tosca ANSA environment
For sharing the result and the animation with colleagues or partners the VTFX
format is a comfortable way. This result format is able to contain a full 3D animated model with the optimization history. The model can be rotated and
zoomed during the animation. The viewer is available for free for different
1 - 64 Start Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Fig. 6
SIMULIA
Tosca Structure
platforms and there is also a possibilty to include the files into HTML-pages
and into Powerpoint presentations.
www.3ds.com/tosca
Fig. 7
Start Manual 1 - 65
SIMULIA
Tosca Structure
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
1 - 66 Start Manual
SIMULIA
Tosca Structure
1.3
www.3ds.com/tosca
1.3.1
Start Manual 1 - 67
SIMULIA
Tosca Structure
Shape Optimization with Tosca ANSA environment
1.3.2
The Model
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
1 - 68 Start Manual
SIMULIA
Tosca Structure
De
sig
n
are
a
Fig. 8
www.3ds.com/tosca
Loaded nodes are connected with MPCs to the inner side of the conrod
mounts. Nodes in the big eye nodes on the inner radius (crankshaft bearing)
are fixed in all three coordinate directions.
There are five loadcases realized in the model (see Fig. 9):
Loadcase 1:
Centrifugal force (a in Fig. 9), 15000 N applied in z-direction
Screw fixation
Loadcase 2:
Gas pressure (b in Fig. 9), 25000 N applied in negative z-direction
Fixation in nodes of big eye
Loadcase 3:
Bending about the x-axis
Fixation in nodes of big eye
Start Manual 1 - 69
SIMULIA
Tosca Structure
Shape Optimization with Tosca ANSA environment
Loadcase 4:
Bending moment about the y-axis
Fixation in nodes of big eye
Loadcase 5:
Torsion about the z-axis.
Fixation in nodes of big eye
Fig. 9
1.3.3
Loads and boundary conditions of the model conrod: (a) centrifugal force,
right: force caused by gas pressure (b), bending and torsion
about x-, y- and z-axis.
Optimization Task
The goal is to reduce stress peaks on the surface of the component with
small changes at the surface of the component. Thus the optimization task is
to minimize the maximum stresses of the loadcases on the connecting rod,
1 - 70 Start Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
see Fig. 9. The design area is shown in Fig. 8 and consists of the surface
nodes of the area in the inner rectangle.
1.3.4
www.3ds.com/tosca
Start Manual 1 - 71
SIMULIA
Tosca Structure
Shape Optimization with Tosca ANSA environment
1.3.5
Preprocessing
1 - 72 Start Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
www.3ds.com/tosca
Start Manual 1 - 73
SIMULIA
Tosca Structure
Shape Optimization with Tosca ANSA environment
1 - 74 Start Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
www.3ds.com/tosca
2. If needed, bring the model to the view shown in the figure by pressing F2
key and select the faces of the part shown in the left figure by enclosing
them in a frame drawn with the mouse while holding the left mouse
button. The enframed part disappears. Then select the faces of the part
shown in the right figure.
Start Manual 1 - 75
SIMULIA
Tosca Structure
Shape Optimization with Tosca ANSA environment
1 - 76 Start Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
www.3ds.com/tosca
Start Manual 1 - 77
SIMULIA
Tosca Structure
Shape Optimization with Tosca ANSA environment
1 - 78 Start Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
www.3ds.com/tosca
Start Manual 1 - 79
SIMULIA
Tosca Structure
Shape Optimization with Tosca ANSA environment
7. Select the surface outside of geometry and neglect the intersection plane
and the bushing.
1 - 80 Start Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
bushing
SIMULIA
Tosca Structure
www.3ds.com/tosca
10. Confirm your selection (click middle mouse button) and proceed to SET
window. Note that although the resulting group consists of faces, it is
later transformed into a node group that is then written to the Tosca
Structure parameter file.
Start Manual 1 - 81
SIMULIA
Tosca Structure
Shape Optimization with Tosca ANSA environment
1 - 82 Start Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
14. You can check your group selection by clicking Windows | Sets in
main menu. In SET window switch on the highlight button. Selected
groups will be marked in different colors.
SIMULIA
Tosca Structure
www.3ds.com/tosca
Start Manual 1 - 83
SIMULIA
Tosca Structure
Shape Optimization with Tosca ANSA environment
Remark:
1. As an alternative it is possible to define a second DOF control at the hidden
outer surface. Then the reduction of the upper half of the conrod eye is not
necessary and the whole small eye can be added to the mesh smooth
area. The second DOF control is necessary as the outer surface of the
upper half of the eye should also remain unchanged.
1 - 84 Start Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
www.3ds.com/tosca
Start Manual 1 - 85
SIMULIA
Tosca Structure
Shape Optimization with Tosca ANSA environment
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
1 - 86 Start Manual
SIMULIA
Tosca Structure
www.3ds.com/tosca
1.3.6
Start Manual 1 - 87
SIMULIA
Tosca Structure
Shape Optimization with Tosca ANSA environment
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
1 - 88 Start Manual
SIMULIA
Tosca Structure
8. Right click
VTF_VISUALIZATION item
and select View.
Tosca Structure.view window
opens.
www.3ds.com/tosca
7. Right click
TEST_SHAPE_CHECK item and
select New |
VTF_VISUALIZATION.
Start Manual 1 - 89
SIMULIA
Tosca Structure
Shape Optimization with Tosca ANSA environment
1 - 90 Start Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
1.3.7
Start Optimization
www.3ds.com/tosca
1.3.8
Postprocessing
Using Tosca Structure.report, the geometry after the shape optimization as
well as the values of controller input (von Mises stress in the example) can
be visualized. This subsection is optional.
Start Manual 1 - 91
SIMULIA
Tosca Structure
Shape Optimization with Tosca ANSA environment
1 - 92 Start Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
www.3ds.com/tosca
5. In Case Panel choose your result case, either a 3D animation of an optimization plot or a result plot. The animation starts and stops by clicking
on the start forward/backward, pause and stop symbol in the task menu.
Close the Tosca Structure.view, the TOSCA_POST and the TOSCA Job
window in order to proceed.
Start Manual 1 - 93
SIMULIA
Tosca Structure
Shape Optimization with Tosca ANSA environment
1.3.9
Report Generation
1. Open your VTFX file again by
clicking
GENERATE_POST_FILE |
VTF_VISUALIZATION and
select View.
1 - 94 Start Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
www.3ds.com/tosca
5. Click at the left model: Now, this model is activated and its frame
becomes green. Choose the last iteration step by using the Step Backward button and move both views synchronously in an appropriate position (hold Ctrl and the appropriate mouse button while moving the
mouse).
Start Manual 1 - 95
SIMULIA
Tosca Structure
Shape Optimization with Tosca ANSA environment
1 - 96 Start Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
www.3ds.com/tosca
Start Manual 1 - 97
SIMULIA
Tosca Structure
Shape Optimization with Tosca ANSA environment
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
1 - 98 Start Manual
SIMULIA
Tosca Structure
www.3ds.com/tosca
20. A PowerPoint file is created. The order of figures and tables is determined by the template.
Start Manual 1 - 99
SIMULIA
Tosca Structure
Shape Optimization with Tosca ANSA environment
21. For tranferring into a word file use Create WordReport and the
template TOSCA_Structure_Word_Template_GenericTags.docx,
for a HTML file Create HTMLReport and the template
TOSCA_Structure_HTML_Template_GenericTags.html.
As the vtfx plug-in only works in combination with the internet explorer,
you can choose Video and image as Media type for other browsers.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
2. Make sure that TASK is set to SURFACE and choose the output formats
you need for CAD transfer (STL and IGES1 in this example); refer to
vol.2 chapter 9.1.9, Output parameters for the differences between
different IGES formats and the description of other formats.
If the output of slices is desired, check slices checkbox and then fill in
the fields SLICE_NUMBER (number of section planes), SLICE_NORMAL
(normal direction of section planes) and SLICE_FORMAT (choice
between polygon or spline slices). Refer to vol.2 chapter 9.1.10, Slices
through 3D models and border of 2D models for more information.
Click OK.
www.3ds.com/tosca
SIMULIA
Tosca Structure
Shape Optimization with Tosca ANSA environment
Besides the new geometry loaded into Tosca ANSA environment, the results
of Tosca Structure.smooth (by default saved in TOSCA_POST subdirectory of
your working directory (named Output by default)) might include:
VTFX file for visualization (SMOOTH_INSTANCE.vtfx);
STL file with the optimized geometry (SMOOTH_INSTANCE.stl);
IGES file with the optimized geometry (SMOOTH_INSTANCE.igs);
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
www.3ds.com/tosca
SIMULIA
Tosca Structure
Shape Optimization with Tosca ANSA environment
Stress reduction in the design area from 197 MPa to 134 MPa in
5 iterations (see chapter 1.3.12.3 Redefine the global stop condition)
In Fig. 10 the stress reduction is clearly seen. The maximal stress has been
decreased about 32%. The remaining stress concentration in Fig. 10 can not
be removed because further nodal optimization displacement would lead to
inacceptable element quality. A solution would be to remesh the two areas or
the whole part and to restart the optimization.
1.3.12 Extensions
1.3.12.1 Design variable constraints
There may be different manufacturing constraints for the conrod. Assume that
it is produced by casting and therefore must comply to the following requirements:
1. be demoldable;
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Fig. 10
SIMULIA
Tosca Structure
2. be symmetric to x-z-plane.
These requirements can be realized in different ways in Tosca Structure.shape. In the following only one of these ways is described in detail,
some alternatives will be discussed at the end of the chapter.
Casting Constraint
www.3ds.com/tosca
SIMULIA
Tosca Structure
Shape Optimization with Tosca ANSA environment
2. Define settings for the casting constraint. Set your demolding direction
(DEMOLD_DIR_1 to DEMOLD_DIR_3 fields) to (1, 0, 0). Define a new
group of solidfacets consisting the exterior of the positive half in x-axisdirection. Its important to avoid intersection! Set ND_GROUP and
CHECK_GROUP fields to your new node group (e.g. SURF_DEMOLD_POS).
Repeat this step with the negative part and the demolding direction
(-1,0,0).
Symmetry to x-z-plane
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
www.3ds.com/tosca
1. In PRE-PROCESSING |
SHAPE_OPTIMIZATION_CONT
ROLLER |CONSTRAINTS item,
select New |
VOLUME_CONSTRAINT.
SIMULIA
Tosca Structure
Shape Optimization with Tosca ANSA environment
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
www.3ds.com/tosca
SIMULIA
Tosca Structure
Shape Optimization with Tosca ANSA environment
1.3.13 Troubleshooting
Fig. 11
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
In most cases, the problems during shape optimization are related to the
mesh problems, causing the optimization to stop.
SIMULIA
Tosca Structure
www.3ds.com/tosca
A good mesh for shape optimization does not always mean a high quality calculation mesh. Avoid using mesh refinement on the surface and instead
mesh a little coarser than usual and uniformly.
SIMULIA
Tosca Structure
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
1.4
1.4.1
www.3ds.com/tosca
a)
Fig. 12
b)
Simple plate in bending with loading and supports (a) and an optimal bead (b). The maximal displacement of (a) is 6.6 mm and (b)
is 0.25 mm
SIMULIA
Tosca Structure
Bead Optimization with Tosca ANSA environment
In Fig. 12, a simple flat plate in bending is shown. It is evident that the solution in Fig. 12 (b) has a much greater stiffness than the original flat plate in
Fig. 12 (a).
Regarding the simple example in Fig. 12 a couple of comments must be
made:
bead height
bead width
Fig. 13
The bead height (see Fig. 13) has the most significant effect on the stiffness of the plate structure. Usually, the greater the bead height the greater
the stiffness. But, the bead height is usually controlled by manufacturing
capabilities, i.e. how deep one can draw a bead with your available tools.
Increasing stiffness
Fig. 14
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
The bead width (see Fig. 13) has an effect on the possible designs. As
seen in Fig. 14 a small or a large bead width is not necessarily related to
the stiffness of the sheet structure. Tosca Structure.bead default values
usually suffice, but if an optimal solution is sought you must try more bead
widths.
SIMULIA
Tosca Structure
Thus, an easy way to find a good bead pattern is to use Tosca Structure.bead.
The Model
Model information:
A model of an oilpan is found in the Tosca Structure installation directory
(<tosca>) according to your FE-solver (<solver>) :
www.3ds.com/tosca
1.4.2
SIMULIA
Tosca Structure
Bead Optimization with Tosca ANSA environment
<tosca>/<solver>/examples/bead/oil_pan
x
Fig. 15
Dimensions:
Length (z-direction): ~ 500 mm
width (x-direction): ~ 305 mm,
depth (y-direction): ~42 mm,
thickness: 1.3 mm
Mesh: Average element edge length: ~ 7 mm, mostly linear quads and a
few trias.
Initial 1st eigenvalue: 179 Hz
Boundary conditions are for simplicity crude full supports on the edges of
the oilpan. Real life boundary condition could be obtained by using the full
body-in-white model of a car which would also run with Tosca Structure - of
course with unreasonable runtimes for this simple introduction.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
The element normals of the shell elements are in the negative y-direction.
y
x
Fig. 16
1.4.3
Design area
Optimization Task
Maximize the natural (1st) eigenfrequency of the oil pan using controller
based algorithm. The maximal bead height is 5 mm and the bead direction
must be in the positive y-direction, see Fig. 15.
Note that, with some minor modifications, the same task can be solved using
the sensitivity-based bead optimization. However, for this example, the controller-based algorithm is chosen because it leads to shorter optimization
time.
1.4.4
www.3ds.com/tosca
SIMULIA
Tosca Structure
Bead Optimization with Tosca ANSA environment
Please note that Tosca Structure 7.0 or higher is required in order to complete the optimization task. With previous versions of Tosca Structure
some changes may be necessary to achieve the same results.
1.4.5
Preprocessing
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
www.3ds.com/tosca
SIMULIA
Tosca Structure
Bead Optimization with Tosca ANSA environment
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
www.3ds.com/tosca
SIMULIA
Tosca Structure
Bead Optimization with Tosca ANSA environment
6. If needed, bring the model to the view shown in the figure by pressing F1
key. Then, enclose all nodes but those that belong to the outer rim in a
frame drawn with the mouse while holding the left mouse button. Make
sure that the nodes on the upper flat surface are not selected. Click with
the middle mouse button to confirm the selection and to proceed to SET
window.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
www.3ds.com/tosca
SIMULIA
Tosca Structure
Bead Optimization with Tosca ANSA environment
2. In CONSTRAINT_ITEM window,
select ABS in the dropdown list
MAGNITUDE and set the value
of VALUE field to 5.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
6. Click OK.
www.3ds.com/tosca
SIMULIA
Tosca Structure
Bead Optimization with Tosca ANSA environment
The Tosca Structure parameter file contains commands which define all
settings for the optimization task.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
www.3ds.com/tosca
1.4.6
SIMULIA
Tosca Structure
Bead Optimization with Tosca ANSA environment
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
www.3ds.com/tosca
8. Right click
VTF_VISUALIZATION item
and select View.
Tosca Structure.view window
opens.
SIMULIA
Tosca Structure
Bead Optimization with Tosca ANSA environment
1.4.7
Start Optimization
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
1.4.8
Postprocessing
Using Tosca Structure.report, the geometry after the bead optimization as
well as the values of controller input can be visualized. This subsection is
optional.
www.3ds.com/tosca
SIMULIA
Tosca Structure
Bead Optimization with Tosca ANSA environment
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
www.3ds.com/tosca
6. Click POST-PROCESSING |
Update.
SIMULIA
Tosca Structure
Bead Optimization with Tosca ANSA environment
1.4.9
Report Generation
1. Open your VTFX file:
GENERATE_POST_FILE |
VTF_VISUALIZATION >
View.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
www.3ds.com/tosca
5. Click at the left model: Now, this model is activated and its frame
becomes green. Choose the last iteration step by using the Step Backward button and move both views synchronously in an appropriate position (hold Ctrl and the appropriate mouse button while moving the
mouse).
SIMULIA
Tosca Structure
Bead Optimization with Tosca ANSA environment
10. In the Tosca Structure Report Builder window now both siutations are
listed. By rightclicking at the situation you can delete it.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
www.3ds.com/tosca
SIMULIA
Tosca Structure
Bead Optimization with Tosca ANSA environment
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
www.3ds.com/tosca
20. A PowerPoint file is created. The order of figures and tables is determined by the template.
SIMULIA
Tosca Structure
Bead Optimization with Tosca ANSA environment
21. For tranferring into a word file use Create WordReport and the
template TOSCA_Structure_Word_Template_GenericTags.docx,
for a HTML file Create HTMLReport and the template
TOSCA_Structure_HTML_Template_GenericTags.html.
As the vtfx plug-in only works in combination with the internet explorer,
you can choose Video and image as Media type for other browsers.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
3. Choose the output formats you need for CAD transfer (STL and IGES in
this example); refer for the differences between different IGES formats
and the description of other formats and click OK.
www.3ds.com/tosca
SIMULIA
Tosca Structure
Bead Optimization with Tosca ANSA environment
Besides the new geometry loaded into Tosca ANSA environment, the results
of Tosca Structure.smooth (by default saved in TOSCA_POST subdirectory of
your working directory (named Output by default)) might include:
VTFX file for visualization (SMOOTH_INSTANCE.vtfx);
STL file with the optimized geometry (SMOOTH_INSTANCE.stl);
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
a)
www.3ds.com/tosca
Fig. 17
b)
SIMULIA
Tosca Structure
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
1.5
Fig. 18
www.3ds.com/tosca
1.5.1
SIMULIA
Tosca Structure
Sizing with Tosca ANSA environment
1.5.2
Model
The component to be used within the tutorial represents a holder for a gear
shift control and is found in the Tosca Structure installation directory (<tosca>)
according to your FE-solver (<solver>) (available for Abaqus and ANSYS):
<tosca>/<solver>/examples/sizing/holder
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
The model is meshed with linear homogenous shell elements with an initial
thickness of 3.5.
There are two loadcases defined. The first one is a bending loadcase with a
load Fx =-2500N at node 5 and the second one is a torsional moment Mx =
SIMULIA
Tosca Structure
80000 Nmm at node 5. Further, all drill holes are fixed in all directions (cf. Fig.
19).
Fig. 19
www.3ds.com/tosca
The design area consists of the elements in the interior of the structure, colored yellow in Fig. 19 . The elements of the design area are combined to a
group design_all which can later be used for the optimization. For further
SIMULIA
Tosca Structure
Sizing with Tosca ANSA environment
Fig. 20
1.5.3
Optimization Task
The optimization task is to find a structure with maximum stiffness for the
component for both static load cases. Additionally, a volume constraint of
maximum 100 % of the initial volume should be considered.
The value to be optimized is the compliance which is the reciprocal value of
the stiffness. The compliance is represented as the sum of the strain energy
of the complete model. This value has to be minimized.
The value for the first constraint is calculated from the sum of the volumes of
all elements.The first eigenmode is derived from a modal analysis.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
tasks using clustering this design domain is split into several subgroups as
described below:
SIMULIA
Tosca Structure
The shell thicknesses should vary between an absolute value of 0.1 and 3.0.
Four variants of the optimization can be performed:
Free sizing (i.e. the shell thicknesses of all design elements can be modified independently)
Clustering with horizontal areas (the design area is split horizontally into
several areas in which the shell size will vary simultaneously)
Clustering with vertical areas (the design area is split vertically)
Clustering with "circular" areas (the design area is split into several "round"
areas) - this cluster variant is motivated by the result of the free sizing.
1.5.4
www.3ds.com/tosca
SIMULIA
Tosca Structure
Sizing with Tosca ANSA environment
Start optimization
11.Running Tosca Structure: START_OPTIMIZATION | RUN
Postprocessing
12.Viewing the intermediate results:POST-PROCESSING |
GENERATE_REPORT_FILE
Please note that Tosca Structure 8.0 or higher is required in order to complete the optimization task.
1.5.5
Preprocessing
In the following detailed description the setup of a typical sizing optimization
task with Tosca ANSA environment is shown.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
www.3ds.com/tosca
SIMULIA
Tosca Structure
Sizing with Tosca ANSA environment
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
www.3ds.com/tosca
SIMULIA
Tosca Structure
Sizing with Tosca ANSA environment
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
2. In THICKNESS_BOUNDS
window, choose GROUP_DEF
from the dropdown list below
EL_GROUP
www.3ds.com/tosca
SIMULIA
Tosca Structure
Sizing with Tosca ANSA environment
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
www.3ds.com/tosca
2. In CLUSTER_GROUPS window,
choose GROUP_DEF from the
dropdown list below
EL_GROUP. Type "?" to
access the list of predefined
groups.
SIMULIA
Tosca Structure
Sizing with Tosca ANSA environment
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
www.3ds.com/tosca
SIMULIA
Tosca Structure
Sizing with Tosca ANSA environment
1.5.6
Start Optimization
The following chapters describe how to start the optimization with an illustrated step-by-step instruction.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
1.5.7
Postprocessing
Using Tosca Structure.report, the intermediate results of sizing optimization, namely the thicknesses of element shells, can be visualized. This subsection is optional.
1. Right click
SIZING_THICKNESS item
under
GENERATE_REPORT_FILE.
Select Update.
A VTFX file containing the optimization results will be generated.
www.3ds.com/tosca
SIMULIA
Tosca Structure
Sizing with Tosca ANSA environment
1.5.8
Report Generation
1. Open your VTFX file:
GENERATE_POST_FILE |
VTF_VISUALIZATION >
View.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
5. Click at the left model: Now, this model is activated and its frame
becomes green. Choose the last iteration step by using the Step Backward button and move both views synchronously in an appropriate position (hold Ctrl and the appropriate mouse button while moving the
mouse).
www.3ds.com/tosca
SIMULIA
Tosca Structure
Sizing with Tosca ANSA environment
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
10. In Tosca Structure Report Builder window both model situations are
now listed. By rightclicking at the situation you can delete it or change the
order.
SIMULIA
Tosca Structure
www.3ds.com/tosca
SIMULIA
Tosca Structure
Sizing with Tosca ANSA environment
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
20. A PowerPoint file is created. The order of figures and tables is determined by the template.
21. For transferring into a word file use Create WordReport and the
template TOSCA_Structure_Word_Template_GenericTags.docx,
for a HTML file Create HTMLReport and the template
TOSCA_Structure_HTML_Template_GenericTags.html.
As the vtfx plug-in only works in combination with Internet Eplorer, you
can choose Video and image as Media type for other browsers.
1.5.9
Result Discussion
www.3ds.com/tosca
SIMULIA
Tosca Structure
Sizing with Tosca ANSA environment
Fig. 22 and Fig. 23 show the shell thickness in the design area for different
cases: The differences in the results of the optimization without clustering and
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Fig. 21
SIMULIA
Tosca Structure
www.3ds.com/tosca
with the several kinds of clustering are obvious. Furthermore, the result of
optimization with vertical clustering indicates the unsymmetric load.
Fig. 22
Optimization results: Final shell thickness in the design area without clustering (left) and with horizontal clustering (right)
Fig. 23
SIMULIA
Tosca Structure
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Getting Started with Tosca Structure.gui
Fig. 24
2.1
User interface
2.1.1
www.3ds.com/tosca
Tosca Structure.gui is the classical user interface for the definition, start and
postprocessing of Tosca Structure optimization tasks.
SIMULIA
Tosca Structure
User interface
Tosca Structure.gui is started by calling the jar files tosca_gui.jar. When using
Unix, type tosca_gui in a command line. For Windows, Tosca Structure.gui
can be found in the Start Menu.
In order to gain the most from all program functionalities a few default settings
may need to be made. The window Edit Configuration shows the paths of
the external programs used by Tosca Structure.gui, the Tosca Structure
installation directory (Tosca StructureHome) and extensions of the solver
files. The paths are set to standard paths during installation. Using the button
"Reset to Defaults" the paths are read from the Tosca Structure configuration
and entered on the screen.
The settings are saved (button Save) in a file toscagui##.ini (## = current
Tosca Structure version) in the user directory (and in the user profile). This file
also serves as a configuration file for Tosca Structure.pre. Should there be
deviations in the paths from standard during installation of the modules, some
paths may need to be set individually.
2.1.2
Tosca Structure.pre
The optimization task is defined using Tosca Structure.pre and the settings
are stored in a parameter file. A predefined parameter file can be loaded into
Tosca Structure.pre (File -> open) and is then available for any desired modifications or the optimization task can be defined from scratch. The optimiza-
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Fig. 25
SIMULIA
Tosca Structure
Getting Started with Tosca Structure.gui
Fig. 26
www.3ds.com/tosca
2.1.2.1 Overview
The graphical user interface of Tosca Structure.pre consists of a menu, a toolbar, a status line and a split inner frame.
The left frame shows the entire parameter file in text format, compact format
or tree format. The compact format only shows command types and the ID
name of each command. By "Opening" the command the complete definition
is shown. Using the text view (text format in left frame) of the parameter file, a
double click on a command opens the corresponding command template in
the right frame. In the tree format, commands can be edited by simply clicking
on an entry in the tree. Commands of the same type are grouped in the tree
view. The order of the commands corresponds to the best sequence for creating a new parameter file.
In the right frame, a selected command can be created or modified in a command template.
SIMULIA
Tosca Structure
User interface
The toolbar provides buttons to move commands, save and open parameter
files, undo and redo buttons and a help button that opens the Tosca Structure
help file.
Fig. 27
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
The menu item File/New File creates a new (empty) parameter file.
There is no difference between the creation of a parameter file for a bead,
topo or shape optimization task.
SIMULIA
Tosca Structure
Getting Started with Tosca Structure.gui
The new parameter file contains only a standard header and the final EXIT
command.
Fig. 28
The menu item File/Open can open an existing parameter file. The parameter file can be selected in a file dialog. If the parameter file contains
FEM_INPUT or GROUP_IMPORT definitions, the corresponding files will
automatically be scanned for group definitions. These groups are available
whenever a group can be selected by a command. The content of these
groups can not be modified. Nastran bdf files do not contain any group definitions, therefore this feature is not available for Nastran files.
Saving a parameter file
The parameter file can be saved by pressing the save button in the toolbar or
in the file menu.
www.3ds.com/tosca
SIMULIA
Tosca Structure
User interface
Fig. 29
Fig. 30
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Getting Started with Tosca Structure.gui
A template will open in the right frame where parameters for the commands
can be set. A basic syntax check is performed when creating a new command. By pressing the button "Create" the command is inserted into the
parameter file. The position of the command in the parameter file is deter-
www.3ds.com/tosca
Fig. 31
SIMULIA
Tosca Structure
User interface
Objects defined by previous commands can be referenced in other commands by choosing them in the selection boxes (see Fig. 32). The solver
input files that are specified in the READ or GROUP_IMPORT commands will
be scanned for definitions of element and node groups. These groups can be
referenced by various commands too (see vol.1 chapter 2.1.2.4).
Modifying commands
If an existing command should be changed, it has to be selected in the
parameter file. The command is opened with an appropriate template in the
right frame where the parameters can be changed. The changes are
accepted by pressing the button "Modify".
To copy a command it first has to be selected in the parameter file view (left
frame). The id name of the command must now be changed in the command
editor. By pressing "Create" the command is inserted as a copy of the original
command. It is essential to change the id name of the command, because
two commands of the same type must not have identical id names.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Fig. 32
SIMULIA
Tosca Structure
Getting Started with Tosca Structure.gui
When using the text view for editing the parameter file, commands can be
copied with copy & paste, but the id name has to be modified manually afterwards!
Fig. 33
Some commands are only allowed once in the parameter file (e.g.
FEM_INPUT) and can not be copied.
www.3ds.com/tosca
Deleting commands
The button "Delete" removes the selected command from the parameter file.
Arrangement of the commands
The arrangement of the individual commands in the parameter file is arbitrary.
Only if a command references another command, the referenced command
has to be defined before.
New commands will be added automatically to the parameter file in a suitable
position.
Comments
Comments can be added anywhere in the parameter file (even inside of commands). Commands are not available as a command, but have to be inserted
SIMULIA
Tosca Structure
User interface
manually in the text view of the parameter file. Comment lines always start
with an !.
Existing comments can be loaded and edited in a command template.
INCLUDE commands
An INCLUDE statement inserts Tosca Structure commands from another file
into the current parameter file. A file can be selected in a file selection box by
Add Include from the menu "Edit" and from the context menu, respectfully. INCLUDE-commands are always by default inserted at the end of the
parameter file. Therefore, it has to be moved manually to the desired position.
Adding free text
Tosca Structure.pre does not support all available commands (e.g. SELECT).
These commands can be added as free text. There is no command item for
free text. However, free text can just be added into the text view of the parameter file.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Getting Started with Tosca Structure.gui
First natural frequency: used for defining the objective function in shape
and topology optimization
Maximum absolute displacement: can be used as a constraint in topology
optimization
Maximum von Mises stress: used to define the objective function in shape
optimization
Sum of Strain Energy: can be used to define the objective function in topology optimization
Volume (Shape): total volume of the model; which can be used to define
constraints in shape optimization
Volume (Topology): relative volume of the model; which defines volume
constraints in topology optimization
Bead height: used for defining the constraint in bead optimization.
www.3ds.com/tosca
Fig. 34
SIMULIA
Tosca Structure
User interface
Wizard
New parameter files can be generated using a wizard. The wizard is available
in the menu File/TOSCA.wizard or by pressing the "New" button in the
toolbar.
Fig. 35
Tosca Structure.wizard
When finishing the wizard, a parameter file with all absolutely required definitions is created. Afterwards, the parameter file can be modified as usual.
The wizard is limited to the following topics:
selection of optimization type (Topo, Shape, Bead)
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Getting Started with Tosca Structure.gui
output requests
www.3ds.com/tosca
Fig. 36
Design nodes and elements are defined by an element or a node group. If the
groups are available in the solver input file, they can be selected in the wizard. Alternatively, a new group can be defined as an element or node list.
After completing the wizard, the commands can be modified or new commands can be added as usual.
2.1.3
SIMULIA
Tosca Structure
User interface
Fig. 37
When pressing the button "Abort", the current optimization aborts. To resume
the optimization has to be started again with the option "-restart".
A small queueing system is available in the template "Start Tosca Structure".
It can be used to start multiple Tosca Structure jobs successively on your
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Getting Started with Tosca Structure.gui
local computer. If a Tosca Structure job is already running and a new job is
started, the new job will automatically be added to the queue.
Fig. 38
www.3ds.com/tosca
By the button "Edit queue" it is possible to display the status of the queue. All
optimization jobs that will be started after the current job are listed here. Each
individual job can be moved or deleted.
If the current optimization is aborted, the optimization stops and the queue is
paused. Meaning that no new optimization is started until the pause mode is
ended.
Fig. 39
2.1.4
Tosca Structure.smooth
Tosca Structure.smooth prepares the optimization result for transfer into a
CAD-system or FE-preprocessor. The Tosca Structure.gui window Tosca
Structure.smooth enables you to enter parameters to perform and control sur-
SIMULIA
Tosca Structure
User interface
Fig. 40
2.1.5
2.1.6
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Getting Started with Tosca Structure.gui
www.3ds.com/tosca
Fig. 41
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
User interface
SIMULIA
Tosca Structure
2.2
www.3ds.com/tosca
2.2.1
SIMULIA
Tosca Structure
Topology Optimization with Tosca Structure.gui
The Model
The component to be used within the tutorial represents a control arm for a
car and is found in the Tosca Structure installation directory (<tosca>) according to your FE-solver (<solver>) :
<tosca>/<solver>/examples/topo/control_arm
The model is loaded with one loadcase consisting of two fixtures in the upper
left and right areas and is loaded with one load in the lower bearing area. The
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
2.2.2
SIMULIA
Tosca Structure
Design Area
The model for the topology optimization was modified in such a way that the
inner areas of the component are filled with elements to create a design area
where the optimization system can remove or rearrange elements for getting
a better mechanical behavior of a component with a lower weight.
The start model for the optimization represents a design of a control arm for a
car. The component has to be manufactured by forging and consists of aluminum. The red areas of the component are not free for the optimization
because they are used for the fixtures and for the load application. One red
area is used for the mounting of a sensor for the headlight range adjustment.
www.3ds.com/tosca
Fig. 42
SIMULIA
Tosca Structure
Fig. 43
The fixture is realized with spring elements on the right upper red area. The
springs represent a rubber bearing. The left bearing is fixed in all three translation degrees of freedom, but is able to rotate about the x-axis. As loading a
force is applied in the center of the lower bearing.
Due to symmetry reasons only one half of the model is meshed so the symmetry plane is fixed in z-direction for ensuring the symmetry condition.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
2.2.3
Optimization Task
The optimization task is to find a structure with the maximum stiffness for the
component with a volume or weight restriction. This represents the most common standard optimization task for the topology optimization.
The value to be optimized is the compliance which is the reciprocal value of
the stiffness. The compliance is represented as the sum of the strain energy
of the complete model. This value has to be minimized.
The constraint is the weight or volume constraint which is defined to be 70%
of the initial volume/weight of the structure.
As manufacturing constraint a casting/forging constraint has to be defined.
The idea of the constraint is to ensure that the created structure of the topology optimization has no undercuts and can be demolded (or removed from
the forging die).
2.2.4
www.3ds.com/tosca
TOSCA
SIMULIA
Tosca Structure
Topology Optimization with Tosca Structure.gui
Postprocessing
12.Generating material distibution file: Tosca Structure.report | Generate
Report
Result Transfer and Validation Run
13.Generating smooth surfaces: Tosca Structure.smooth |
Start Smoothing
Performing a complete validation run as well as generating the whole setup
for a validation run is not possible automatically using Tosca Structure.gui.
Nevertheless, different output formats for the optimized structure are supported as basis for validation models. However, further preprocessing (manual addition of loads and boundary conditions) is required by the user in order
to generate a FE model using the optimized structure.
Please note that Tosca Structure 7.0 or higher is required in order to complete the optimization task. With previous versions of Tosca Structure
some changes may be necessary to achieve the same results.
2.2.5
Preprocessing
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
www.3ds.com/tosca
SIMULIA
Tosca Structure
Topology Optimization with Tosca Structure.gui
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
www.3ds.com/tosca
SIMULIA
Tosca Structure
Topology Optimization with Tosca Structure.gui
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Design variable constraints introduce restrictions on the shape of the optimized model. Besides the demolding constraint discussed below, other
types of design constraints such as symmetry and member size restrictions
are supported by Tosca Structure.
SIMULIA
Tosca Structure
4. Choose DESIGN_ELEMENTS
from the Check Group dropdown list to define the check
group for the cast restriction
and click Create to add the
item DVCON_CAST to the optimization task tree.
www.3ds.com/tosca
SIMULIA
Tosca Structure
Topology Optimization with Tosca Structure.gui
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
www.3ds.com/tosca
SIMULIA
Tosca Structure
Topology Optimization with Tosca Structure.gui
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
www.3ds.com/tosca
SIMULIA
Tosca Structure
Topology Optimization with Tosca Structure.gui
2. Select TOPO_CONTROLLER
from the Strategy dropdown
list to choose the optimization
strategy. Design area and
objective function are selected
automatically.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
www.3ds.com/tosca
SIMULIA
Tosca Structure
Topology Optimization with Tosca Structure.gui
Start Optimization
1. Switch to the Start TOSCA
Structure module from the
Module dropdown list in the
upper right corner.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
2.2.6
SIMULIA
Tosca Structure
www.3ds.com/tosca
SIMULIA
Tosca Structure
Topology Optimization with Tosca Structure.gui
2.2.7
Postprocessing
Viewing the intermediate results using Tosca Structure.report.
Using Tosca Structure.report, the intermediate results of topology optimization, namely the densities of individual elements, can be visualized.
1. Switch to the Tosca Structure.report module from the
Module dropdown list in the
upper right corner.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
www.3ds.com/tosca
SIMULIA
Tosca Structure
Topology Optimization with Tosca Structure.gui
8. The Animation starts and stops by clicking on the start forward/backward, pause and stop symbol in the task menu.
The described example is generated using the FE solver MSC Nastran.
Please note that slight differencies in the optimized design are possible
for the different solvers. However the design conception remains the
same.
2.2.8
Report Generation
1. Click View Report to view the
material distribution in the optimized structure. The Open
dialog appears. Open your vtfx
file.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
5. Click at the left model: Now, this model is activated and its frame
becomes green. Choose the last iteration step by using the Step Backward button and move both views synchronously in an appropriate position (hold Ctrl and the appropriate mouse button while moving the
mouse).
www.3ds.com/tosca
SIMULIA
Tosca Structure
Topology Optimization with Tosca Structure.gui
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
10. In Tosca Structure Report Builder window both model siutations are
now listed. By rightclicking at the situation you can delete it or change the
order.
SIMULIA
Tosca Structure
www.3ds.com/tosca
SIMULIA
Tosca Structure
Topology Optimization with Tosca Structure.gui
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
20. A PowerPoint file is created. The order of figures and tables is determined by the template.
21. For tranferring into a word file use Create WordReport and the
template TOSCA_Structure_Word_Template_GenericTags.docx,
for a HTML file Create HTMLReport and the template
TOSCA_Structure_HTML_Template_GenericTags.html.
As the vtfx plug-in only works in combination with the internet explorer,
you can choose Video and image as Media type for other browsers.
2.2.9
www.3ds.com/tosca
SIMULIA
Tosca Structure
Topology Optimization with Tosca Structure.gui
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
www.3ds.com/tosca
SIMULIA
Tosca Structure
Topology Optimization with Tosca Structure.gui
The topology optimization created a new design proposal for the control arm
component. The result of the topology optimization has to be discussed in
several ways.
First of all the optimization result has to be checked. This can be done with
viewing the convergence plot and with checking the TOSCA.OUT file for
warnings and errors. If there is a critical error during the optimization the optimization loop will be stopped. In other cases (if some results are missing) the
optimization system will continue but the result may be not sufficient.
Second the resulting model and the finite element analysis of the model has
to be checked if the displacements, the stresses and all other finite element
related information are suitable.
Initial model (complete
model with 70% of
material homogeneously
distributed)
Result
Strain Energy
Table 2
1 - 218 Start Manual
1645850
Result comparison
Final model
425093.5
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Fig. 44
After checking the results the remaining structure can be passed to the
design department as a CAD model to be used as design proposal for the
fine tuning of the design. If the stresses within the component are not below
the allowed range the shape optimization of Tosca Structure (Tosca Struc-
www.3ds.com/tosca
For this optimization task the stresses are in the same range compared to the
initial model but the stiffness of the structure is higher and the material
amount necessary for the structure is lower. The values to be compared are
the volume or weight of the structure and the sum of the strain energy. The
strain energy is the measure for the compliance which is the reciprocal value
of the stiffness
SIMULIA
Tosca Structure
Topology Optimization with Tosca Structure.gui
Fig. 45
Optimization result represented after data reduction: IGES surfaces for CAD transfer
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
ture.shape) will be able to remove the stress peaks so that the component will
be suitable from the mechanical point of view.
SIMULIA
Tosca Structure
For sharing the result and the animation with colleagues or partners the VTFX
format is comfatable way. This result format is able to contain a full 3D animated model with the optimization history. The model can be rotated and
zoomed during the animation. The viewer is available for free for different
www.3ds.com/tosca
Fig. 46
SIMULIA
Tosca Structure
Topology Optimization with Tosca Structure.gui
platforms and there is also a possibility to include the files into HTML-pages
and into Powerpoint presentations.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Fig. 47
SIMULIA
Tosca Structure
2.3
www.3ds.com/tosca
2.3.1
SIMULIA
Tosca Structure
Shape Optimization with Tosca Structure.gui
2.3.2
The Model
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
De
sig
n
are
a
Fig. 48
www.3ds.com/tosca
Loaded nodes are connected with MPCs to the inner side of the conrod
mounts. Nodes in the big eye nodes on the inner radius (crankshaft bearing)
are fixed in all three coordinate directions.
There are five loadcases realized in the model (see Fig. 49):
Loadcase 1:
Centrifugal force (a in Fig. 49), 15000 N applied in z-direction
Screw fixation
Loadcase 2:
Gas pressure (b in Fig. 49), 25000 N applied in negative z-direction
Fixation in nodes of big eye
Loadcase 3:
Bending about the x-axis
Fixation in nodes of big eye
SIMULIA
Tosca Structure
Shape Optimization with Tosca Structure.gui
Loadcase 4:
Bending moment about the y-axis
Fixation in nodes of big eye
Loadcase 5:
Torsion about the z-axis.
Fixation in nodes of big eye
Fig. 49
2.3.3
Loads and boundary conditions of the model conrod: (a) centrifugal force,
right: force caused by gas pressure (b), bending and torsion
about x-, y- and z-axis.
Optimization Task
The goal is to reduce stress peaks on the surface of the component with
small changes at the surface of the component. Thus the optimization task is
to minimize the maximum stresses of the loadcases on the connecting rod,
see Fig. 49. The design area is shown in Fig. 48 and consists of the surface
nodes of the area in the inner rectangle.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
2.3.4
www.3ds.com/tosca
SIMULIA
Tosca Structure
Shape Optimization with Tosca Structure.gui
Result Transfer
17.Generating CAD output: Tosca Structure.smooth | igs |
Start Smoothing
Extensions
18.Link Conditions: Tosca Structure.pre | LINK_SHAPE |
SURFACE_DEMOLD
19.Design Variable Constraints: Tosca Structure.pre | DVCON_SHAPE |
Link Condition
20.Design Responses: Tosca Structure.pre | DRESP
21.Constraints: Tosca Structure.pre | CONSTRAINT
22.Mesh Smooth: Tosca Structure.pre | MESH_SMOOTH
23.Global Stop Condition: Tosca Structure.pre | STOP
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Please note that Tosca Structure 7.0 or higher is required in order to complete the optimization task. With previous versions of Tosca Structure
SIMULIA
Tosca Structure
2.3.5
Preprocessing
www.3ds.com/tosca
SIMULIA
Tosca Structure
Shape Optimization with Tosca Structure.gui
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
www.3ds.com/tosca
SIMULIA
Tosca Structure
Shape Optimization with Tosca Structure.gui
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
12. Repeat these steps from 1 to 6 with set number 3 to create a group
FIXED_NODES.
www.3ds.com/tosca
13. Still two groups are necessary for a further step in this example (see
chapter 2.3.12 Extensions). So repeat all steps from 1 to 6 twice again to
create two more node groups. Name the first group SURF_DEMOLD_POS
and select the NASTRAN set number 4 in the Select Nastran Set
dialog. Choose the name SURF_DEMOLD_NEG for the second node group
and select the Nastran set number 5 in the Select Nastran Set
dialog.
SIMULIA
Tosca Structure
Shape Optimization with Tosca Structure.gui
In order to specify optimization target and constraints you must first define
design responses. The design responses are assigned to output parameters from the FE analysis. In this example design responses for the von
Mises stress for both loadcases will be needed.
1. Select the item DRESP from the
optimization task tree. The
DRESP menu appears on the
right.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
www.3ds.com/tosca
SIMULIA
Tosca Structure
Shape Optimization with Tosca Structure.gui
8. Repeat all steps from 1 to 7 four times again to create four other design
responses for von Mises stress. Name the design response
DRESP_MISES_LC2, DRESP_MISES_LC3 and so on and select the
loadcase number 2, 3, 4 and 5 in the Select Loadcase dialog.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
www.3ds.com/tosca
SIMULIA
Tosca Structure
Shape Optimization with Tosca Structure.gui
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
2. Select SHAPE_CONTROLLER
from the Strategy dropdown
list to choose the optimization
strategy. Design area and
objective function are selected
automatically.
4. Activate the
DVCON_DOF_CONTROL button
and press Ok.
www.3ds.com/tosca
SIMULIA
Tosca Structure
Shape Optimization with Tosca Structure.gui
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
2.3.6
Check Inputs
Before starting an eventually long running optimization task you should
always check if your definitions make sense and are complete. Missing settings may require a complete rerun of your optimization.
2.3.6.1 TEST_SHAPE
The command TEST_SHAPE creates a simple optimization displacement
on all your design nodes. Then you can see if everything works as you
imagined it.
1. From the Command menu
select TEST_SHAPE. The
TEST_SHAPE menu appears on
the right.
www.3ds.com/tosca
SIMULIA
Tosca Structure
Shape Optimization with Tosca Structure.gui
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
www.3ds.com/tosca
SIMULIA
Tosca Structure
Shape Optimization with Tosca Structure.gui
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
9. In the animation appearing after the test run it should be quite easy to
check:
Are the design nodes (moving nodes) correctly defined?
www.3ds.com/tosca
SIMULIA
Tosca Structure
Shape Optimization with Tosca Structure.gui
2.3.7
Start Optimization
1. Switch back to the Start
TOSCA Structure module
from the Module dropdown list
in the upper right corner.
This will cause the sequential start of both the test run and the real optimization. In order to skip the test run you can go to the Tosca Structure.pre
module and delete the TEST_SHAPE item from the optimization task.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
2.3.8
Postprocessing
1. Switch again to the Tosca
Structure.report module from
the Module dropdown list in the
upper right corner.
To view also the changes in the shape of the structure with the amounts of
the nodal displacements of the design nodes, activate also the button next
to Optimization Displacements or next to Opt. Displacements
Value.
www.3ds.com/tosca
SIMULIA
Tosca Structure
Shape Optimization with Tosca Structure.gui
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
www.3ds.com/tosca
2.3.9
Report Generation
1. Click View Report to view the
material distribution in the optimized structure. The Open
dialog appears. Open your vtfx
file.
SIMULIA
Tosca Structure
Shape Optimization with Tosca Structure.gui
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
www.3ds.com/tosca
5. Click at the left model: Now, this model is activated and its frame
becomes green. Choose the last iteration step by using the Step Backward button and move both views synchronously in an appropriate position (hold Ctrl and the appropriate mouse button while moving the
mouse).
SIMULIA
Tosca Structure
Shape Optimization with Tosca Structure.gui
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
www.3ds.com/tosca
SIMULIA
Tosca Structure
Shape Optimization with Tosca Structure.gui
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
www.3ds.com/tosca
20. A PowerPoint file is created. The order of figures and tables is determined by the template.
SIMULIA
Tosca Structure
Shape Optimization with Tosca Structure.gui
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
21. For transfer into a word file use Create WordReport and the
template TOSCA_Structure_Word_Template_GenericTags.docx,
for a HTML file Create HTMLReport and the template
TOSCA_Structure_HTML_Template_GenericTags.html.
As the vtfx plug-in only works in combination with the internet explorer,
you can choose Video and image as Media type for other browsers.
SIMULIA
Tosca Structure
www.3ds.com/tosca
SIMULIA
Tosca Structure
Shape Optimization with Tosca Structure.gui
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
www.3ds.com/tosca
14. Click Start Tosca Structure.smooth. After Tosca Structure is finished click View
Result and navigate in the
Open window to your smooth
results in your job directory in
the subdirectory
TOSCA_POST.
SIMULIA
Tosca Structure
Shape Optimization with Tosca Structure.gui
Stress reduction in the design area from 197 MPa to 134 MPa in
5 iterations (see chapter 2.3.12.4 Redefine the global stop condition)
In Fig. 50 the stress reduction is clearly seen. The maximal stress is minimized with around 32%. The staying stress concentrations in Fig. 50 can not
be removed because of the element quality prohibits futher nodal optimization
displacement. A solution would be to remesh the two areas or the whole part
and restart the optimization.
2.3.12 Extensions
2.3.12.1 Design variable constraints
There may be different manufacturing constraints for the conrod. Lets
assume that in the production it is cast and must therefore:
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Fig. 50
SIMULIA
Tosca Structure
1. be demoldable;
2. be symmetric to x-z-plane.
These requirements can be realized in different ways in Tosca Structure.shape. In the following only one of these ways is described in detail,
some alternatives will be discussed at the end of the chapter.
Casting Constraint
1. Go back to the Tosca Structure.pre module. If neccessary
load again your parameter file.
From the Command menu select
LINK_SHAPE. The
LINK_SHAPE menu appears on
the right.
www.3ds.com/tosca
SIMULIA
Tosca Structure
Shape Optimization with Tosca Structure.gui
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
www.3ds.com/tosca
Symmetry to x-z-plane
SIMULIA
Tosca Structure
Shape Optimization with Tosca Structure.gui
8. Define symmetry for all design nodes with a symmetry plane normal to
the y-axis through the point (0,0,100). First define a Cartesian coordinate
system with origin in point (0,0,100). Then define plane symmetry using
LINK_SHAPE: The symmetry plane contains the origin of the referenced
coordinate system and the normal vector is defined by CLIENT_DIR.
Third, reference LINK_SHAPE in DVCON_SHAPE for all design nodes.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
www.3ds.com/tosca
SIMULIA
Tosca Structure
Shape Optimization with Tosca Structure.gui
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Although the very efficient shape optimization often does a really good job in
only 5 iterations a few percent more may be gained by letting the optimizer
run a little longer. The simplest way to do this is to change the maximum number of iterations. The change of the global stop condition is described in vol.2
chapter 6.11.1, Global Stop Condition. Modify the item MY_STOP and change
the iteration number to 10.
www.3ds.com/tosca
SIMULIA
Tosca Structure
Shape Optimization with Tosca Structure.gui
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Remark:
SIMULIA
Tosca Structure
2.3.13 Troubleshooting
Shape optimization is often seen as a difficult optimization type which is in
most cases related to the mesh problems that may arise during optimization.
This can cause the optimization to stop.
www.3ds.com/tosca
The best solution is of course to remesh, but this may be a time consuming
task.
The second best solution is to check the solver log file and find out which elements are causing the problems. Look these elements up in your preprocessor. If you only have a few problematic elements at the edge of the
MESH_SMOOTH area, try to remove these problematic elements from the
MESH_SMOOTH area.
A good mesh for shape optimization is not always equal to a high quality calculation mesh. Avoid using mesh refinement on the surface and rather mesh
a little coarser than usual and uniformly.
SIMULIA
Tosca Structure
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
2.4
2.4.1
www.3ds.com/tosca
a)
Fig. 51
b)
SIMULIA
Tosca Structure
Bead Optimization with Tosca Structure.gui
In Fig. 51 is a simple flat plate in bending shown. It is evident that the solution
in Fig. 51 (b) has a much greater stiffness than the original flat plate in Fig. 51
(a).
Regarding the simple example in Fig. 51 a couple of comments must be
made:
bead height
Fig. 52
bead width
Bead height and bead width
The bead height (see Fig. 52) has the most significant effect on the stiffness of the plate structure. Usually, the greater the bead height the greater
the stiffness. But, the bead height is usually controlled by manufactoring
capabilities i.e. how deep can you draw a bead with your available tools.
Increasing stiffness
Fig. 53
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
The bead width (see Fig. 52) has an effect on the possible designs. As
seen in Fig. 53 a small or a large bead width is not necessarily related to
the stiffness of the sheet structure. The Tosca Structure.bead default values usually suffice, but if an optimal solution is saught you must try more
bead widths.
SIMULIA
Tosca Structure
Thus, an easy way to find a good bead pattern is to use Tosca Structure.bead.
Model
Model information:
A model of an oilpan is found in the Tosca Structure installation directory
(<tosca>) according to your FE-solver (<solver>) :
www.3ds.com/tosca
2.4.2
SIMULIA
Tosca Structure
Bead Optimization with Tosca Structure.gui
<tosca>/<solver>/examples/bead/oil_pan
x
Fig. 54
Dimensions:
length (z-direction): ~ 500 mm
width (x-direction): ~ 305 mm,
depth (y-direction): ~42 mm,
thickness: 1.3 mm.
Mesh: Average element edge lenght: ~ 7 mm, mostly linear quads and a
few trias.
Initial 1st eigenvalue: 179 Hz
Boundary conditions are for simplicity crude full supports on the edges of
the oilpan. Real life boundary condition could be obtained by using the full
body-in-white model of a car which would also run with Tosca Structure - of
course with unreasonable runtimes for this simple introduction.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
The element normals of the shell elements are in the negative y-direction
y
x
Fig. 55
2.4.3
Design area
Optimization Task
Task 1:
Maximize the natural (1st) eigenfrequency of the oil pan using controller
based algorithm.
The maximum bead height is 5 mm and the bead direction must be in the
positive y-direction, see Fig. 54.
Prerequisites
Tosca ANSA environment Basics - read and understood
FE-model oil_pan_tosca_env.<ext> for your solver
www.3ds.com/tosca
2.4.4
SIMULIA
Tosca Structure
Bead Optimization with Tosca Structure.gui
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Please note that Tosca Structure 7.0or higher is required in order to complete the optimization task. With previous versions of Tosca Structure
some changes may be necessary to achieve the same results.
SIMULIA
Tosca Structure
2.4.5
Preprocessing
www.3ds.com/tosca
SIMULIA
Tosca Structure
Bead Optimization with Tosca Structure.gui
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
www.3ds.com/tosca
SIMULIA
Tosca Structure
Bead Optimization with Tosca Structure.gui
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
www.3ds.com/tosca
SIMULIA
Tosca Structure
Bead Optimization with Tosca Structure.gui
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
www.3ds.com/tosca
SIMULIA
Tosca Structure
Bead Optimization with Tosca Structure.gui
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
2. Select BEAD_CONTROLLER
from the Strategy dropdown
list to choose the optimization
strategy. Design area and
objective function are selected
automatically.
www.3ds.com/tosca
SIMULIA
Tosca Structure
Bead Optimization with Tosca Structure.gui
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
2.4.6
Check Inputs
www.3ds.com/tosca
SIMULIA
Tosca Structure
Bead Optimization with Tosca Structure.gui
2.4.6.1 TEST_BEAD
The command TEST_BEAD creates a simple optimization displacement on
all your design nodes. Then you can see if everything works as you imagined it.
1. From the Command menu
select TEST_BEAD. The
TEST_BEAD menu appears on
the right.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
www.3ds.com/tosca
SIMULIA
Tosca Structure
Bead Optimization with Tosca Structure.gui
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
www.3ds.com/tosca
8. Click to the start and stop button to animate the test result.
SIMULIA
Tosca Structure
Bead Optimization with Tosca Structure.gui
In the animation appearing after the test run it should be quite easy to
check:
Are the design nodes (moving nodes) correctly defined?
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
2.4.7
Start Optimization
1. Close Tosca Structure.view and
switch back to the Start
TOSCA Structure module
from the Module dropdown list
in the upper right corner.
2. Change the optimization type to
all from the dropdown list next
to Type. This will cause the
sequential start of both the test
run and the real optimization.
In order to skip the test run you can go to the Tosca Structure.pre module
and delete the TEST_BEAD item from the optimization task.
3. Click Start TOSCA to start the
optimization. Status information about the optimization run
is displayed in the field below.
www.3ds.com/tosca
2.4.8
Postprocessing
1. Switch again to the Tosca
Structure.report module from
the Module dropdown list in the
upper right corner.
SIMULIA
Tosca Structure
Bead Optimization with Tosca Structure.gui
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
www.3ds.com/tosca
SIMULIA
Tosca Structure
Bead Optimization with Tosca Structure.gui
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
www.3ds.com/tosca
2.4.9
Report Generation
1. Open your VTFX file by
clicking View Result.
SIMULIA
Tosca Structure
Bead Optimization with Tosca Structure.gui
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
www.3ds.com/tosca
5. Click at the left model: Now, this model is activated and its frame
becomes green. Choose the last iteration step by using the Step Backward button and move both views synchronously in an appropriate position (hold Ctrl and the appropriate mouse button while moving the
mouse).
SIMULIA
Tosca Structure
Bead Optimization with Tosca Structure.gui
10. In the Tosca Structure Report Builder window now both siutations are
listed. By rightclicking at the situation you can delete it.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
www.3ds.com/tosca
SIMULIA
Tosca Structure
Bead Optimization with Tosca Structure.gui
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
www.3ds.com/tosca
20. A PowerPoint file is created. The order of figures and tables is determined by the template.
SIMULIA
Tosca Structure
Bead Optimization with Tosca Structure.gui
21. For tranferring into a word file use Create WordReport and the
template TOSCA_Structure_Word_Template_GenericTags.docx,
for a HTML file Create HTMLReport and the template
TOSCA_Structure_HTML_Template_GenericTags.html.
As the vtfx plug-in only works in combination with the internet explorer,
you can choose Video and image as Media type for other browsers.
a)
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Fig. 56
b)
SIMULIA
Tosca Structure
2.5
Fig. 57
www.3ds.com/tosca
2.5.1
SIMULIA
Tosca Structure
Sizing Optimization with Tosca Structure.gui
2.5.2
Model
The component to be used within the tutorial represents a holder for a gear
shift control and is found in the Tosca Structure installation directory (<tosca>)
according to your FE-solver (<solver>) (available for Abaqus and ANSYS):
<tosca>/<solver>/examples/sizing/holder
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
The model is meshed with linear homogenous shell elements with an initial
thickness of 3.5.
There are two loadcases defined. The first one is a bending loadcase with a
load Fx =-2500N at node 5 and the second one is a torsional moment Mx =
80000Nmm at node 5. Further, all drill holes are fixed in all directions (cf. Fig.
58)
SIMULIA
Tosca Structure
Fig. 58
www.3ds.com/tosca
The design area consists of the elements in the interior of the structure, colored yellow in Fig. 58 . The elements of the design area are combined to a
group design_all which can later be used for the optimization. For further
SIMULIA
Tosca Structure
Sizing Optimization with Tosca Structure.gui
Fig. 59
2.5.3
Optimization Task
The optimization task is to find a structure with maximum stiffness for the
component for both static load cases. Additionally, a weight constraint of
maximum 100 % of the initial weight should be considered.
The value to be optimized is the compliance which is the reciprocal value of
the stiffness. The compliance is represented as the sum of the strain energy
of the complete model. This value has to be minimized.
The value for the first constraint is calculated from the sum of the volumes of
all elements.The first eigenmode is derived from a modal analysis.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
tasks using clustering this design domain is split into several subgroups as
described below:
SIMULIA
Tosca Structure
The shell thicknesses should vary between an absolute value of 0.1 and 3.0.
Four variants of the optimization can be performed:
Free sizing (i.e. the shell thicknesses of all design elements can be modified independently)
Clustering with horizontal areas (the design area is split horizontally into
several areas in which the shell size will vary simultaneously)
Clustering with vertical areas (the design area is split vertically)
Clustering with "circular" areas (the design area is split into several "round"
areas) - this cluster variant is motivated by the result of the free sizing.
2.5.4
www.3ds.com/tosca
SIMULIA
Tosca Structure
Sizing Optimization with Tosca Structure.gui
Postprocessing
11.Generating result displacement file: Tosca Structure.report | Generate
Report
Please note that Tosca Structure 8.0 or higher is required in order to complete the optimization task.
2.5.5
Preprocessing
In the following detailed description the setup of a typical sizing optimization
task with Tosca Structure.gui is shown.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
www.3ds.com/tosca
SIMULIA
Tosca Structure
Sizing Optimization with Tosca Structure.gui
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
www.3ds.com/tosca
Please note that the ID_NAME is a special mark of any component of the
optimization task. The ID_NAME must be unique for each component.
Using the ID_NAME you can select between different components of the
same type during the optimization setup. If no other component of the same
type appears in the optimization task, the change of the ID_NAME is
optional and the Tosca Structure default ID_NAME can be used.
SIMULIA
Tosca Structure
Sizing Optimization with Tosca Structure.gui
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
www.3ds.com/tosca
SIMULIA
Tosca Structure
Sizing Optimization with Tosca Structure.gui
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
www.3ds.com/tosca
11. Repeat steps 4-10 to define a second design response for the strain
energy of load case 2.
SIMULIA
Tosca Structure
Sizing Optimization with Tosca Structure.gui
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
www.3ds.com/tosca
SIMULIA
Tosca Structure
Sizing Optimization with Tosca Structure.gui
2. Select SIZING_SENSITIVITY
from the Strategy dropdown
list to choose the optimization
strategy. Design area and
objective function are selected
automatically.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
6. Activate
VOLUME_CONSTRAINT and
press Ok. The corresponding
items appear in the Constraints field.
www.3ds.com/tosca
SIMULIA
Tosca Structure
Sizing Optimization with Tosca Structure.gui
Start Optimization
1. Switch to the Start TOSCA
Structure module from the
Module dropdown list in the
upper right corner.
2. Choose all from the Type
dropdown list . This option
includes a preprocessing test
and the optimization run.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
2.5.6
SIMULIA
Tosca Structure
www.3ds.com/tosca
SIMULIA
Tosca Structure
Sizing Optimization with Tosca Structure.gui
2.5.7
Postprocessing
Viewing the intermediate results using Tosca Structure.report.
Using Tosca Structure.report, the intermediate results of sizing optimization, namely the thicknesses of element shells, can be visualized.
1. Switch to the Tosca Structure.report module from the
Module dropdown list in the
upper right corner.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
www.3ds.com/tosca
SIMULIA
Tosca Structure
Sizing Optimization with Tosca Structure.gui
8. The animation starts and stops by clicking on the start forward/backward, pause and stop symbol in the task menu.
The described example is generated using the FE solver Abaqus. Please
note that slight differencies in the optimized design are possible for the
different solvers. However the design conception remains the same.
2.5.8
Report Generation
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
5. Click at the left model: Now, this model is activated and its frame
becomes green. Choose the last iteration step by using the Step Backward button and move both views synchronously in an appropriate position (hold Ctrl and the appropriate mouse button while moving the
mouse).
www.3ds.com/tosca
SIMULIA
Tosca Structure
Sizing Optimization with Tosca Structure.gui
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
10. In Tosca Structure Report Builder window both model siutations are
now listed. By rightclicking at the situation you can delete it or change the
order.
11. Switch back to Tosca Structure.view window. Now, select
the right window and click
Quick Capture active
view in the quick access
toolbar or select File |
Quick Capture Situation.
12. The last setting is used for capturing, thus, the smoothed optimization
result is loaded as 3D model into the Tosca Structure Report Builder.
13. Load the optimization result ELEMENT_DELTA_THICKNESS (right
window in Tosca Structure.view) as image into the Tosca Structure
Report Builder. (Look at step 6 and 7, if necessary, and do not forget to
activate the window).
www.3ds.com/tosca
SIMULIA
Tosca Structure
Sizing Optimization with Tosca Structure.gui
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
www.3ds.com/tosca
20. A PowerPoint file is created. The order of figures and tables is determined by the template.
SIMULIA
Tosca Structure
Sizing Optimization with Tosca Structure.gui
21. For tranferring into a word file use Create WordReport and the
template TOSCA_Structure_Word_Template_GenericTags.docx,
for a HTML file Create HTMLReport and the template
TOSCA_Structure_HTML_Template_GenericTags.html.
As the vtfx plug-in only works in combination with the internet explorer,
you can choose Video and image as Media type for other browsers.
2.5.9
Result Discussion
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Fig. 61 and Fig. 62 show the shell thickness in the design area for different
cases: The differences in the results of the optimization without clustering and
www.3ds.com/tosca
Fig. 60
SIMULIA
Tosca Structure
Sizing Optimization with Tosca Structure.gui
Fig. 61
Optimization results: Final shell thickness in the design area without clustering (left) and with horizontal clustering (right)
Fig. 62
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
with the several kinds of clustering are obvious. Furthermore, the result of
optimization with vertical clustering indicates the unsymmetric load.
SIMULIA
Tosca Structure
Getting Started with Tosca Extension for
3.1
User Interface
www.3ds.com/tosca
The entire optimization from model creating to the last step of the optimization takes place in three main windows / applications.
The main window, the ANSYS Workbench with its Project Schematic
collects all parts of a project in a graphically clear manner. Every subsystem
or template is listed and connections between the single systems are visible.
SIMULIA
Tosca Structure
Fig. 63
ANSYS Workbench overview. The Project Schematic shows the used systems / templates
Fig. 64
Fig. 65
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
User Interface
SIMULIA
Tosca Structure
Getting Started with Tosca Extension for
Fig. 66
3.1.1
Buttons
www.3ds.com/tosca
The relevant buttons for the use of the Tosca Extension for ANSYS/Workbench can be found in the upper toolbar of the Mechanical application. All
optimization options, controls and conditions will be inserted with these buttons.
SIMULIA
Tosca Structure
User Interface
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Getting Started with Tosca Extension for
Adds a smoothed surface model of the optimization result. Smooth Result is needed
for the Valudation Run.
Imports external solved results.
3.1.2
Handling Tips
If there are for example optimization options inserted in the Tree Outline and you want them to be ignored during an optimization run, the
Suppress / Unsuppress buttons work with Tosca Extension for
ANSYS/Workbench as well as with any other system in ANSYS Workbench.
www.3ds.com/tosca
SIMULIA
Tosca Structure
User Interface
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Getting Started with Tosca Extension for
tial systems, they cant be shared anymore. You have to reassign faces for
the boundary conditions for each system again. Alternatively its possible to
use multiple steps in one analysis instead of multiple systems.
www.3ds.com/tosca
Tosca Extension for ANSYS/WB needs to know the path of the Tosca
Installation (Tosca Bin Dir). If you use the Extension for the first time, you
have to specify the path in Mechanical in Analysis Settings | Tosca
Bin folder (ends with "...\bin"). When clicking Solve to start the first
Optimization, the entered path will be saved and used again in your future
projects.
If you want to change the path again, declare a new one in the analysis settings. Clicking Solve will save it again as default path.
SIMULIA
Tosca Structure
User Interface
If you just want to set up the optimization and run it on another machine or
cluster, it is possible to generate the needed input files (parameter-file and
FE input deck) using Tosca Extension for ANSYS/WB. Set up the whole
optimization (FE-Mesh, Boundary Conditions, Design Area, Design
Responses, Objective Function, Constraint, etc.) within the extension,
select Tosca in the Tree Outline and then click on Optimization |
Write out PAR-File. Choose or create the desired export folder in the
pop up window and click OK.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Getting Started with Tosca Extension for
www.3ds.com/tosca
The captions of all Tosca "loads" (Design Area, Design Response etc.) in
the Tree Outline of Mechanical will be reused in the Tosca parameter-file.
Rename these objects (F2-button) to avoid missunderstandings in Workbench and to facilitate the readability of the parameter-file.
Attention:
Do not name your items manually with a blank followed by a number
SIMULIA
Tosca Structure
User Interface
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Getting Started with Tosca Extension for
www.3ds.com/tosca
SIMULIA
Tosca Structure
User Interface
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
If you run an optimization, change some settings and want to start a second optimization, there might occur an error. Before starting the new optimization, its recommended to delete the existing files (Tree Outline |
Solution | Clear Generated Data) and close and reopen the
Mechanical application.
SIMULIA
Tosca Structure
3.2
3.2.1
The model
www.3ds.com/tosca
Fig. 67
3.2.2
SIMULIA
Tosca Structure
Topology Optimization with Tosca Extension for ANSYS/WB
Check the box for the current Tosca Extension for ANSYS/Workbench (8.1.0).
The extension is loaded immediately; close the Extensions Manager and
wait for the Busy icon in the down left corner of the screen to disappear.
Fig. 68
3.2.3
Example files
Dependent on where you want to start the procedure, you can choose one of
the following files. You find all necessary files in the directory
<tosca_install_dir>\ansys\TS_Ext_for_WB\examples\topo\.
1. Start from scratch using the provided control_arm.stp geometry file. Continue at chapter 3.2.4 Preparing the model.
2. Start the project with an imported geometry file. Use the ANSYS Workbench project archive control_arm.wbpz. Continue at chapter 3.2.4 Preparing
the model, step 15.
3. Start the project with an imported geometry file and defined boundary conditions. Use the ANSYS Workbench project archive control_arm_bc.wbpz.
Continue at chapter 3.2.5 Optimization preprocessing.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
If you save a project and the extension is used, it is loaded automatically the
next time the project will be opened.
SIMULIA
Tosca Structure
3.2.4
www.3ds.com/tosca
3. Double-click Geometry in
order to open the application
Design Modeler.
Select mm as unit and confirm.
SIMULIA
Tosca Structure
Topology Optimization with Tosca Extension for ANSYS/WB
9. Click Extrude.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
www.3ds.com/tosca
SIMULIA
Tosca Structure
Topology Optimization with Tosca Extension for ANSYS/WB
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
www.3ds.com/tosca
SIMULIA
Tosca Structure
Topology Optimization with Tosca Extension for ANSYS/WB
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
www.3ds.com/tosca
SIMULIA
Tosca Structure
Topology Optimization with Tosca Extension for ANSYS/WB
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
www.3ds.com/tosca
3.2.5
Optimization preprocessing
Now that the calculation put out all the requested solutions, an optimization
task can be set up.
It is not mandatory to solve any stresses or strains before the optimization.
Loads and boundary conditions are enough. It is recommended though, since
it can be checked whether the analysis is correctly set up or not.
36. Close the Mechanical application and continue working in the
Project Schematic. Now
use a TOSCA Structure.topology system.
SIMULIA
Tosca Structure
Topology Optimization with Tosca Extension for ANSYS/WB
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
40. Add the options for the optimization run. The area to be optimized is defined with a
Topology | Design Area.
www.3ds.com/tosca
SIMULIA
Tosca Structure
Topology Optimization with Tosca Extension for ANSYS/WB
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
www.3ds.com/tosca
SIMULIA
Tosca Structure
Topology Optimization with Tosca Extension for ANSYS/WB
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
3.2.6
Postprocessing
The Tosca Extension for ANSYS/Workbench offers in the Mechanical application some visualization options. The optimization result can be displayed in
different ways, single iterations can be showed, too.
www.3ds.com/tosca
SIMULIA
Tosca Structure
Topology Optimization with Tosca Extension for ANSYS/WB
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
3.2.7
Validation Run
As continuation after an optimization and smoothing run, a validation run can
be performed.
The smoothed model describes the surface of the optimization result. Based
on this resulting model, a solid three dimensional model is reconstructed
which can be loaded with the original forces and supported with the original
boundary conditions.
The validation run can only be executed after a smoothing run.
www.3ds.com/tosca
SIMULIA
Tosca Structure
Topology Optimization with Tosca Extension for ANSYS/WB
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
www.3ds.com/tosca
SIMULIA
Tosca Structure
Topology Optimization with Tosca Extension for ANSYS/WB
3.2.8
Troubleshooting
Wrong connection in Project Schematic
Make sure the Tosca Optimizer has all the input it needs: Engineering
Data, Geometry, Model. Loads cannot be specified in a standalone
TOSCA Structure.topology system.
Optimization strategy
The controller based algorithm is developed to solve a volume contraint / stiffness maximization. For problems involving Displacement or Membersize Control for example, a sensivity based algorithm is needed.
At the same time, controller based algorithm solutions work with equality constraints while the sensivity based algorithm handles unequality constraints
like greater or less than a certain value.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
www.3ds.com/tosca
SIMULIA
Tosca Structure
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
3.3
3.3.1
The model
www.3ds.com/tosca
Fig. 69
SIMULIA
Tosca Structure
Shape Optimization with Tosca Extension for ANSYS/WB
In the FE-Model of the conrod loaded nodes are connected with MPCs to the
inner side of the conrod mounts. Nodes on the inner radius of the big eye
(crankshaft bearing) are fixed in all three coordinate directions.
There are five loadcases realized in the model (see Fig. 2):
Loadcase 1:
Centrifugal force (a in Fig. 2), 15000 N applied in z-direction
Screw fixation
Loadcase 2:
Gas pressure (b in Fig. 2), 25000 N applied in negative z-direction
Fixation in nodes of big eye
Loadcase 3:
Bending about the x-axis, 1000 N applied in negative x-direction
Fixation in nodes of big eye
Loadcase 4:
Bending moment about the y-axis (-10000Nmm)
Fixation in nodes of big eye
Loadcase 5:
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
For simplicity reasons only loadcase 2 will be described in depth in this manual as this is the most dominant loadcase causing the highest stresses. An
optional ANSYS Workbench project archive exists in which all five loadcases
are predefined.
www.3ds.com/tosca
Fig. 70
SIMULIA
Tosca Structure
Shape Optimization with Tosca Extension for ANSYS/WB
3.3.2
If you save a project and the extension is used, it is loaded automatically the
next time the project will be opened.
3.3.3
Example files
Dependent on where you want to start the procedure, you can choose one of
the following files. You find all necessary files in the directory
<tosca_install_dir>\ansys\TS_Ext_for_WB\examples\shape\.
1. Start from scratch using the provided control_arm.stp geometry file. Continue at chapter 3.3.4 Preparing the model.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Fig. 71
SIMULIA
Tosca Structure
2. Start the project with an imported geometry file. Use the ANSYS Workbench project archive control_arm.wbpz. Continue at chapter 3.3.4 Preparing
the model, step 15.
3. Start the project with an imported geometry file and defined boundary conditions. Use the ANSYS Workbench project archive control_arm_bc.wbpz.
Continue at chapter 3.3.5 Optimization preprocessing.
3.3.4
3. Double-click Geometry in
order to open the application
Design Modeler.
Select mm as unit and confirm.
www.3ds.com/tosca
SIMULIA
Tosca Structure
Shape Optimization with Tosca Extension for ANSYS/WB
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
www.3ds.com/tosca
9. Click Extrude.
10. If Extrude is clicked immediately after having sketched, the
correct sketch will be highlighted as Geometry. If not,
choose the correct sketch. Click
Apply.
11. Choose Slice Material
as Operation.
SIMULIA
Tosca Structure
Shape Optimization with Tosca Extension for ANSYS/WB
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
www.3ds.com/tosca
SIMULIA
Tosca Structure
Shape Optimization with Tosca Extension for ANSYS/WB
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
www.3ds.com/tosca
SIMULIA
Tosca Structure
Shape Optimization with Tosca Extension for ANSYS/WB
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
www.3ds.com/tosca
SIMULIA
Tosca Structure
Shape Optimization with Tosca Extension for ANSYS/WB
3.3.5
Optimization preprocessing
Now that the calculation put out all the requested solutions, an optimization
task can be set up.
It is not mandatory to solve any stresses before the optimization. Loads and
boundary conditions are enough. It is recommended though, since it can be
checked whether the analysis is correctly set up or not.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
www.3ds.com/tosca
SIMULIA
Tosca Structure
Shape Optimization with Tosca Extension for ANSYS/WB
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
www.3ds.com/tosca
SIMULIA
Tosca Structure
Shape Optimization with Tosca Extension for ANSYS/WB
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
www.3ds.com/tosca
SIMULIA
Tosca Structure
Shape Optimization with Tosca Extension for ANSYS/WB
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
3.3.6
Postprocessing
The Tosca Extension for ANSYS/Workbench offers some visualization
options in the Mechanical application. The optimization result can be displayed in different ways, single iterations can also be shown.
www.3ds.com/tosca
Besides the total nodal displacement, the directional nodal displacement can
be visualized as well. Right click on Solution in the Tree Outline and
then Insert | Deformation | Directional if you wish to visualize the
directional results.
SIMULIA
Tosca Structure
Shape Optimization with Tosca Extension for ANSYS/WB
use a Play and Stop button or regulate animation speed. All required buttons can be found in the Graph window. .
3.3.7
Troubleshooting
Wrong connection in Project Schematic
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Make sure the Tosca Optimizer has all the input it needs: Engineering
Data, Geometry, Model. Loads cannot be specified in a standalone
TOSCA Structure.shape system.
Volume II
User Manual
www.3ds.com/tosca
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
SIMULIA
Tosca Structure
Preface
www.3ds.com/tosca
Preface
The User Manual is the standard reference describing the available functionalities of all Tosca Structure modules.
chapter 1 Overview of Tosca Structure gives a brief overview of Tosca Structure. This includes a short description of each module (chapter 1.1 The Tosca
Structure Modules), the chronological sequence of the optimization process
with Tosca Structure (chapter 1.2 Overview of the Optimization Process) and
a diagram (chapter 1.3 Workflow for Optimization) showing the step-by-step
process of the optimization with useful links to the documentation. The chapter 2 Working with Tosca Structure shows how each module can be started
with or without a graphical user interface. The contents of these two sections
together with the manual vol.1 Start Manual give a sufficient description to
understand the process for a standard topology, shape and bead optimization. A more detailed description of the optimization process with the relevant
data flow can be found in chapter 12 Tosca Structure Control.
The chapter 3 The Model explains requirements for the optimization model. It
shows how the link between finite element model and optimization task is
established and how further model specifications like group or coordinate
system definition can be made.
chapter 4 Terms for Optimization explains terms required for the optimization
(objective and constraint) and their definition using the several front ends. It
further lists design responses (e.g. analysis results) allowed for the definition
of optimization targets and constraints.
A more detailed description of the functionalities available for topology optimization (chapter 5 Topology Optimization), shape optimization (chapter 6
Shape Optimization), bead optimization (chapter 7 Bead Optimization) and
sizing optimization (chapter 8 Sizing Optimization) discusses e.g. manufacturing constraints and typical optimizations tasks. Each command is
described only in the context of its functionality with other commands. A more
detailed description of the command syntax can be found in volume 3: Commands Manual.
The next chapter (chapter 9 Result Transfer and Validation Run) describes
how optimization results can be transferred to CAD for further processing of
the optimization results and how a validation run can be set up.
The possibilities available for analyzing the optimization results are shown in
chapter 10 Postprocessing of Optimization Results. The different solver-specific functionalities are described in chapter 11 Solver Specific Features
including shape optimization taking into account the lifetime of a component.
chapter 12 Tosca Structure Control shows the program flow of Tosca Structure in detail as well as configuration of the program and file structure of optimization results.
The chapter 13 Troubleshooting describes troubleshooting in case of
unwanted or premature termination of the program.
User Manual 2 - 3
SIMULIA
Tosca Structure
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
The Appendix chapter 14 Appendix summarizes the possibilities that are provided by Tosca Structure modules for specific functionalitites. It further lists
the program limits and predefined macros.
2 - 4 User Manual
SIMULIA
Tosca Structure
Overview of Tosca Structure
www.3ds.com/tosca
1.1
User Manual 2 - 5
SIMULIA
Tosca Structure
The Tosca Structure Modules
1.1.1
Abaqus CAE
Abaqus CAE allows users to setup and perform topology, shape or sizing
optimization tasks with Tosca Structure fully integrated into Abaqus CAE.
Optimization results can be visualized in the visualization module of CAE. For
details about the Tosca integration in Abaqus/CAE, Tosca for Abaqus, see the
Abaqus manuals provided with your Abaqus installation. All other graphical
user interfaces are treated within this documentation.
1.1.2
1.1.3
Tosca Structure.gui
1.1.4
2 - 6 User Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Tosca Structure.gui is the graphical user interface where other modules of the
optimization system can be started. Tosca Structure.gui includes the module
Tosca Structure.pre for interactive input of optimization parameters. For
details about Tosca Structure.gui see vol.1 chapter 2, Getting Started with
Tosca Structure.gui and vol.2 chapter 2.2, Working with the Graphical User
Interface Tosca Structure.gui. Tosca Structure.gui can be used as alternative
to Tosca ANSA environment.
SIMULIA
Tosca Structure
Overview of Tosca Structure
1.1.5
1.1.6
Tosca Structure.report
Tosca Structure.report automatically generates vtfx reports for quick navigation through the results of the optimization. It contains important graphical
information of the model and optimization results as well as tables of the process of significant values to be stored in an archive.
1.1.7
Tosca Structure.view
Tosca Structure.view is an efficient viewer for fast visualization of optimization
results and reports generated by Tosca Structure.report. For presentation
purposes a plug-in for Microsoft PowerPoint is available (see vol.2 chapter
10.2, Tosca Structure.view). Further, an integrated report generator transfers
Tosca Structure optimization results to MS Office and html documents.
Tosca Structure.smooth
Tosca Structure.smooth prepares the optimization results for import into a
CAD system or FE-preprocessor or a remeshing for a validation run (see
vol.2 chapter 9.1, Tosca Structure.smooth). This validation run is performed
automatically using Tosca ANSA environment.
www.3ds.com/tosca
1.1.8
User Manual 2 - 7
SIMULIA
Tosca Structure
Overview of the Optimization Process
1.2
OPTIMIZATION STEPS
PLANNING
PREPROCESSING
CHECK RUN
OPTIMIZATION LOOP
POSTPROCESSING
VALIDATION RUN
Fig. 1
Planning
The optimization and simulation tasks should be carefully thought out and formulated before beginning the optimization. All requirements like the optimization target, the necessary restrictions and the acceptable volume of the whole
project should be considered.
1.2.2
2 - 8 User Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
1.2.1
SIMULIA
Tosca Structure
Overview of Tosca Structure
www.3ds.com/tosca
1.2.3
Check Run
The check run should be performed before starting the optimization to avoid
wrong or missing definitions for the optimization task. Using Tosca ANSA
environment (see vol.2 chapter 2.1.2, Check Run) this step is included in the
task manager. With Tosca Structure.gui the check run is a normal optimization run with special settings (vol.2 chapter 2.2.2, Check Run).
1.2.4
Optimization Loop
The optimization can be started in Tosca ANSA environment (see vol.2 chapter 2.1.3), using Tosca Structure.gui (see vol.2 chapter 2.2.3) or Tosca Extension for ANSYS/Workbench (see vol.2 chapter 2.3.2) or by calling Tosca
Structure in a command shell (see vol.2 chapter 2.4.4). Tosca Structure first
starts a preprocessing step to check the definitions and write the complete
optimization model to the database. Then the optimization loop runs until the
stop criteria defined by the user is reached.
User Manual 2 - 9
SIMULIA
Tosca Structure
Overview of the Optimization Process
1.2.5
1.2.6
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
2 - 10 User Manual
SIMULIA
Tosca Structure
Overview of Tosca Structure
1.3
Preprocessing
Tosca ANSA environment
Tosca Structure.pre
Check Run
Start Optimization
chapter 13
Postprocessing
www.3ds.com/tosca
Tosca Structure.report
Tosca Structure.view
10.2
User Manual 2 - 11
SIMULIA
Tosca Structure
Workflow for Optimization
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Fig. 2
2 - 12 User Manual
SIMULIA
Tosca Structure
Working with Tosca Structure
2.1
www.3ds.com/tosca
User Manual 2 - 13
SIMULIA
Tosca Structure
Working with Tosca ANSA environment
Fig. 3
One big advantage over the classical workflow with Tosca Structure.gui is the
possibility to perform geometric definitions (like design variable constraints or
group selection) interactively. Further, consistency checks and updates of all
dependencies are performed for each step. At the end of a topology optimization the modified model with all boundary conditions and load cases can be
prepared automatically for the validation run.
Tosca ANSA environment can be started with the command
tosca_ansa_env in a TOSCA command shell. The start script can be
found in <install_dir>\bin\tosca_ansa_env.
2.1.1
Preprocessing
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
2 - 14 User Manual
SIMULIA
Tosca Structure
Working with Tosca Structure
ager tree view shows a logical sequence of definitions necessary for the
optimization task.
Fig. 4
www.3ds.com/tosca
First the link to the model has to be established. After loading the linked
model can be used for interactive definitions of groups or constraints on
design variables. Then optimization type dependent items for the optimization
task can be defined and are grouped into folders according to their context. A
detailed description of the setup of the optimization task can be found in vol.1
chapter 1.2, Topology Optimization with Tosca ANSA environment, vol.1
chapter 1.3, Shape Optimization with Tosca ANSA environment and vol.1
chapter 1.4, Bead Optimization with Tosca ANSA environment.
2.1.2
Check Run
Once the optimization task is completely defined, a check run should be
made. Tosca Structure then performs a complete syntax check of the optimization task to ensure a valid definition. Test runs for shape and bead optimization can be added to the CHECK INPUTS folder which will apply hypothetic
optimization displacements to the model to enable the user to check restrictions etc. visually. The test results can be visualized (VTF_VISUALIZATION)
using Tosca Structure.view.
User Manual 2 - 15
SIMULIA
Tosca Structure
Working with Tosca ANSA environment
2.1.3
Start Optimization
The optimization task defined in the task manager tree can now be started by
simply updating the RUN item in the task manager tree. Eventually required
settings can be entered in an editor window. When starting the optimization,
all dependencies are actualized automatically. It is possible to deactivate definitions in the tree which are then skipped for the optimization run.
2.1.4
Postprocessing
After the successful completion of the optimization run, the results have to be
carefully checked. In the postprocessing step of your optimization task you
can prepare your optimization results for a visual check with Tosca Structure.view (see chapter 10.1.3 Tosca Structure.report in Tosca Extension for
ANSYS/Workbench andchapter 10.2 Tosca Structure.view) which can be
directly accessed from the task manager (item VTF_VISUALIZATION). The
user can navigate through the several steps of the iterations to visualize the
changes in the model for one or more optimization relevant values. Further,
graphs of specific optimization terms like, e.g., values of the objective or constraints, can be added to the vtfx visualization archive. Additionally Tosca
Structure.view provides you with a plug-in for MS PowerPoint to create interactive presentations including your optimization results (see chapter 10.2.9
VTFX PlugIn for Office applications and Webbrowser).
Fig. 5
Then the smoothed structure can be prepared for a validation run (VALIDATE) by performing a reconstruct step to improve the quality of the surface
2 - 16 User Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
2.1.5
SIMULIA
Tosca Structure
Working with Tosca Structure
mesh, batch creation of a solid mesh and output of the optimized model in
your solver format. All loads and boundary conditions of the design space
model are transferred automatically to the new mesh. Finally, the finite element analysis (VALIDATION_RUN) can be started to evaluate stresses and
displacements.
Fig. 6
Satisfying optimization results can now be prepared by Tosca Structure.smooth for transfer into a CAD-system for further treatment in the design
process (Create a new SMOOTH_INSTANCE with suitable output format).
A more detailed description of this process and possible settings can be
found in vol.2 chapter 9.1, Tosca Structure.smooth.
2.2
www.3ds.com/tosca
Tosca Structure.gui simplifies the work process of Tosca Structure for the
user. The graphical user interface enables the following tasks to be completed: defining the optimization task (Tosca Structure.pre), starting the optimization in Tosca Structure, calculating iso surfaces, data smoothing and
User Manual 2 - 17
SIMULIA
Tosca Structure
Working with the Graphical User Interface Tosca Structure.gui
Fig. 7
Preprocessing
Tosca Structure.pre is used to define the settings for the optimization task
which are then stored in a parameter file. The optimization task can either be
created by a wizard, by defining the individual commands or by modifying an
existing parameter file. A tree view with a logical sequence of the commands
supports the user in the definition.
For details about the use of Tosca Structure.pre and tips for the user refer to
vol.1 chapter 2, Getting Started with Tosca Structure.gui. The parameters for
2 - 18 User Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
2.2.1
SIMULIA
Tosca Structure
Working with Tosca Structure
the optimization commands and their syntax are described in detail in vol.3
Commands Manual.
Fig. 8
2.2.2
Check Run
Once the optimization task is completely defined, a check run should be
made. Tosca Structure then performs a complete syntax check of the optimization task to ensure a valid definition. Eventually some test runs for shape
(see vol.2 chapter 6.9, Check run (TEST_SHAPE)) and bead optimization
(see vol.2 chapter 7.9, Check run (TEST_BEAD)) are made which will apply
hypothetic optimization displacements to the model to enable the user to
check restrictions etc. visually (e.g. using Tosca Structure.view).
www.3ds.com/tosca
2.2.3
Start Optimization
Optimization with Tosca Structure.bead, Tosca Structure.shape or Tosca
Structure.topology can be started on the "Start Tosca Structure" screen in
Tosca Structure.gui. The job name of the optimization job (chosen by a
parameter file), the start directory and if necessary the name of the FE solver
are defined here. Further (optional) settings can be made using the menu
"additional Parameters".
A protocol window, convergence plots and a small queuing system are available to support the user in his work. For more details about the optimization
User Manual 2 - 19
SIMULIA
Tosca Structure
Working with the Graphical User Interface Tosca Structure.gui
start refer to vol.1 chapter 2.1.3, Starting the Optimization and vol.2 chapter
12.2, Starting Tosca Structure.
Fig. 9
Postprocessing
The module Tosca Structure.report allows a preparation of the optimization
results for postprocessing by Tosca Structure.view (see more chapter 10.1
Generation of Postprocessing Data). The user can navigate through the several steps of the iterations to visualize the changes in the model for one or
more optimization relevant values. Further, graphs of specific optimization
terms like, e.g., values of the objective or constraints, can be added to the vtfx
visualization archive. Tosca Structure.view provides you with a plug-in for MS
PowerPoint to create interactive presentations including your optimization
2 - 20 User Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
2.2.4
SIMULIA
Tosca Structure
Working with Tosca Structure
results (see more chapter 10.2.9 VTFX PlugIn for Office applications and
Webbrowser).
Fig. 10
www.3ds.com/tosca
2.2.5
User Manual 2 - 21
SIMULIA
Tosca Structure
Working with Tosca Extension for ANSYS/Workbench
smoothing and data reduction and output formats (additional information see
vol.2 chapter 9.1, Tosca Structure.smooth).
Fig. 11
2.3
2 - 22 User Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Working with Tosca Structure
Fig. 12
www.3ds.com/tosca
One big advantage over the classical workflow with Tosca Structure.gui is the
possibility to perform geometric definitions (like design variable constraints or
group selection) interactively. At the end of a topology optimization the modified model with all boundary conditions and load cases can be prepared for
the validation run.
Tosca Extension for ANSYS/WB is fully included into ANSYS/WB.
User Manual 2 - 23
SIMULIA
Tosca Structure
Working with Tosca Extension for ANSYS/Workbench
2.3.1
Preprocessing
The preprocessing step in Tosca Extension for ANSYS/WB is used to set up
the complete optimization task which can then be stored in a parameter file.
The Tree Outline lists all definitions that are made for the optimization task.
2.3.2
Start Optimization
The optimization task defined in the Tree Outline can now be started by clicking Solve. It is possible to deactivate single definitions by suppressing them in
the Tree Outline. These definitions are then skipped for the optimization run.
2 - 24 User Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Fig. 13
SIMULIA
Tosca Structure
Working with Tosca Structure
2.3.3
Postprocessing
After the successful completion of the optimization run, the results have to be
carefully checked. The Tosca Extension for ANSYS/Workbench offers in the
Mechanical application some visualization options (see chapter 10.3 Postprocessing with Tosca Extension for ANSYS/Workbench).
Futher, a standard vtfx report for visualization with Tosca Structure.view is
available in your jobname directory.
2.3.4
www.3ds.com/tosca
Fig. 14
Then the smoothed structure can be prepared for a validation run. During the
two validation steps the smoothed surface model - which serves only for visu-
User Manual 2 - 25
SIMULIA
Tosca Structure
Working with Tosca Structure in the Command Shell
Fig. 15
2.4
2 - 26 User Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Satisfying optimization results can now be prepared by Tosca Structure.smooth for transfer into a CAD-system for further treatment in the design
process (Choose suitable output format).
A more detailed description of this process and possible settings can be
found in vol.2 chapter 9.1, Tosca Structure.smooth.
SIMULIA
Tosca Structure
Working with Tosca Structure
2.4.1
To increase the amount of output to the command shell set the parameter:
tosca810 --loglevel_stdout <new_loglevel>
www.3ds.com/tosca
2.4.2
Preprocessing
Once the FE model has been completed and checked, the optimization task
must be defined. The parameter files containing these definitions can be created with an editor. This is only recommended when single commands in an
existing parameter file need to be modified. Groups and coordinate systems
can be defined in the FE-model to simplify the creation of the optimization
task.
A more detailed description of the command syntax for parameter files can be
found in vol.3 Commands Manual.
Tosca ANSA environment can be started with the command
tosca_ansa_env, Tosca Structure.gui can be started with the command
tosca_gui in a TOSCA command shell. Tosca Extension for ANSYS/Workbench can be started from within ANSYS/Workbench.
The start script can be found in <install_dir>\bin\tosca_ansa_env
or in <install_dir>\bin\tosca_gui.
User Manual 2 - 27
SIMULIA
Tosca Structure
Working with Tosca Structure in the Command Shell
2.4.3
Check Run
Before starting the optimization, the FE model (jobname.ext) and the
parameter file (jobname.par) must already exist in the work directory. As part
of a routine check, the FE model should be analyzed and evaluated. Consequently, a test run has to be completed and checked with respect to the optimization task before beginning the optimization.
tosca810 jobname --solver solvername --type test1
(see vol.2 chapter 12.2.8, Testing the optimization process). It is worthwhile to
make different test runs depending on the optimization task. Once the test run
is completed, a visual check of the definition of the optimization task can follow.
2.4.4
Start optimization
Starting the optimization with the standard settings is done with the command
tosca810 jobname --solver solvername
Further command line options are described in chapter 12.2 Starting Tosca
Structure.
Postprocessing
Tosca Structure.report allows the preparation of optimization results for postprocessing using Tosca Structure.view.
The optimization results are written by Tosca Structure in a neutral format
(ONF). A converting module allows the creation of a report file containing
visualization sequences and graphs for specific results. Automatic generation
of a visual post processing file can be done with the command line option report, e.g.:
tosca810 jobname --report
The above automatically call Tosca Structure.report which generates a vtfxfile in the directory TOSCA_POST after a successful optimization.
More details regarding postprocessing can be found in chapter 10.1 Generation of Postprocessing Data. The vtfx-file can be viewed in Tosca Structure.view which allows visualization of the optimization results by an
animation over the iterations of the optimization. The sequences can be created with Tosca Structure.smooth or Tosca Structure.report. Call Tosca Structure.view with the command line:
tosca810 --view jobname/TOSCA_POST/<vtfx-file>
2 - 28 User Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
2.4.5
SIMULIA
Tosca Structure
Working with Tosca Structure
2.4.6
Result Transfer
Tosca Structure.smooth allows the preparation for the transfer of the optimization results into the design process (for more details see chapter 9.1 Tosca
Structure.smooth).
Tosca Structure.smooth is called up in a command shell with the command
tosca810 jobname --smooth
More details regarding postprocessing can be found in chapter 9 Result
Transfer and Validation Run. The vtfx-file can be viewed in Tosca Structure.view which allows visualization of the optimization results by an animation over the iterations of the optimization.
www.3ds.com/tosca
User Manual 2 - 29
SIMULIA
Tosca Structure
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
2 - 30 User Manual
SIMULIA
Tosca Structure
The Model
The Model
Each optimization task is based on one or more finite element analysis models. These models form the basis for the optimization, i.e. contain the nodes
or elements to be changed and the loads and boundary conditions for the calculation of important terms for the optimization (see vol.2 chapter 4, Terms for
Optimization). Further, node and element groups or coordinate systems in the
analysis files are available for further definitions in the optimization task. Additional files may contain objects for the definition of constraints or provide supplementary analysis results to be considered in the optimization.
This chapter deals with requirements for optimizable models and discusses
the loading of models. Further, the definition of groups and coordinate systems in your optimization environment is explained.
3.1
www.3ds.com/tosca
When defining a model for analyzing, the selection and definition of the loads
and boundary conditions should be constructed with special consideration
because an incorrectly defined or forgotten load or support may have a very
pronounced effect on the result of the optimized structure. The basic characteristics of the analysis model that can be optimized are described in detail in
vol.2 chapter 11, Solver Specific Features (optimizable element types, number of load cases and permitted boundary conditions, types of analysis, nonlinearities, etc.) and in vol.2 chapter 14.2, Limits of Tosca Structure.
Remark
One single finite element can consist of several laminates which is especially
common for shell elements to specify e.g. several cross sections, materials
etc. In Tosca Structure, this is called a "ply". Currently Tosca Structure supports only one single ply for each element and stops with an error message if
elements with multiple plies are found.
3.1.1
User Manual 2 - 31
SIMULIA
Tosca Structure
Models for Optimization
The available design space must exist as a FE model. The resolution of the
designed structures depends strongly on the selected discretization. A fine
mesh produces a structure with a higher resolution than a coarse mesh. On
the other hand, it will also substantially increase the processing time required.
A compromise between structural resolution and processing time needs to be
found.
3.1.2
3.1.3
2 - 32 User Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
In shape optimization, the boundaries or surfaces of a component are modified. At first the optimizer calculates the new coordinates of the design nodes
on the component surface based on the stress condition and then adjusts the
remaining FE mesh accordingly. The calculation of the new coordinates of the
nodes is not based on geometrical parameters, but rather on each individual
coordinate for the nodes. Generally, every FE model can serve as a basis for
shape optimization.
The mesh must be of such quality that the analysis results from the FE mesh
remain essentially unaffected. To assure this, most FE preprocessors have
checking routines. The user must define an adequate mesh density for a subsequent optimization, i.e., high stress gradients should not be present within
an element.
The mesh density must be set correctly in order to achieve smooth contours.
For example, smooth contours cannot be expected when a 90 degree curve
is meshed by only three elements. The finer the mesh density, the closer the
contour will be to optimum.
Tosca Structure.shape features an integrated efficient smoothing mesh algorithm. It is capable of adjusting the FE mesh to the optimized displacement of
the design nodes without re-meshing. It is possible that the FE model will collapse when there is a large optimized displacement of the design nodes due
to a poor mesh. This can be avoided by setting the mesh to an adequate density.
SIMULIA
Tosca Structure
The Model
3.1.4
3.2
www.3ds.com/tosca
Topological Description
PLANE_QUAD_4
PLANE_QUAD_8
PLANE_TRIANG_3
PLANE_TRIANG_6
SHELL_QUAD_4
SHELL_QUAD_8
SHELL_TRIANG_3
SHELL_TRIANG_6
SOLID_BRICK_8
SOLID_BRICK_20
SOLID_TETRA_4
SOLID_TETRA_10
SOLID_PYRAM_5
SOLID_PYRAM_13
User Manual 2 - 33
SIMULIA
Tosca Structure
Preprocessing FE Models for Optimization
SOLID_PENTA_15
Fig. 16
2 - 34 User Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Table 1
3.3
Topological Description
SIMULIA
Tosca Structure
The Model
The finite element model may be generated in every finite element preprocessor that can generate an input model for the supported finite element solvers.
Simplifications for the formulation of the optimization task (such as groups,
different properties, ...) may also be defined in many FE preprocessing systems that are not mentioned below (e.g. Hypermesh).
The optimization preprocessing of Tosca Structure is mainly based on group
information. Using Tosca ANSA environment, group definition can be made
by graphical selection of nodes and elements or already in the FE-preprocessor.
Using Tosca Structure.gui, all necessary information such as design nodes or
frozen elements should be defined as groups in the FE-preprocessor. These
groups may be read by Tosca Structure.pre and then be referenced in the further definitions of the parameter file.
3.3.1
Abaqus/CAE
The analysis model for the optimization procedure may be generated in the
standard way in Abaqus/CAE. All groups that are necessary for the optimization should be generated in Abaqus/CAE.
Currently, the use of parts and assemblies in the Abaqus input file is not supported by Tosca Structure. It is recommended to configure Abaqus/CAE such
that no parts & assemblies are written. To achieve this, the following parameter must be set in the configuration file abaqus_v6.env:
cae_no_parts_input_file=ON
Alternatively before writing the input deck, right click on the model in the
Model Database, select "Edit Attributes..." and activate "Do not
use parts and assemblies in input files".
www.3ds.com/tosca
3.3.2
The option DB has to be used to ensure that the complete finite element information is written into the file. The file name (Fname) and the extension (Ext)
User Manual 2 - 35
SIMULIA
Tosca Structure
Preprocessing FE Models for Optimization
If multiple load cases are used, the load cases can be stored in load case
files (file.s01, file.s02, ...). These files are generated using the following command:
LSWRITE, LSNUM
The solution strategy for multiple load cases has to be added to the CDB file:
/SOLU
LSREAD, 1
SOLVE
LSREAD, 2
SOLVE
...
Unix
ANSYS145 -P -P[PRODUCTVAR] < [INPUT FILE] > [OUTPUT FILE]
Errors are reported to the *.err file. In case of errors, the input file must be
modified.
2 - 36 User Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
FINISH
SIMULIA
Tosca Structure
The Model
3.3.3
www.3ds.com/tosca
User Manual 2 - 37
SIMULIA
Tosca Structure
Preprocessing FE Models for Optimization
For the export of a CDB File, the corresponding solution has to be activated
first. If the solution is active, Write ANSYS Input command can be selected
from the Tools menu.
Activate "Solution"
Enter <filename>.cdb
Fig. 18
2 - 38 User Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
For the selection of the filename in the ANSYS Workbench File Export, the
file extension can be specified: to prevent the standard Extension *.inp from
being used during export, one should switch to ALL FILES in the output file
dialog and specify the *.cdb extension manually.
SIMULIA
Tosca Structure
The Model
Fig. 19
www.3ds.com/tosca
With ANSYS version 14.0 and later, node groups can also be defined independent of hte geometry using Select Geometry | Select Mesh (Activate "show Mesh" before).
The name specified for the component in ANSYS Workbench is output to the
CDB file and may be used to reference the groups in the definition of the
Tosca Structure optimization task.
Fig. 20
User Manual 2 - 39
SIMULIA
Tosca Structure
Preprocessing FE Models for Optimization
Choose
"Method": Tetrahedron
"Algorithm": Patch Independent
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Fig. 21
2 - 40 User Manual
SIMULIA
Tosca Structure
The Model
If the minimum and maximum element sizes are chosen in a small range, a
homogeneous mesh is generated inside the volumetric parts, which is more
suitable for a topology optimization task.
Fig. 22
3.4
Loading FE Data
All FE models used for the optimization can be loaded using the
MODEL_LINK folder in the task tree of Tosca ANSA environment or the
FEM_INPUT command in Tosca Structure.gui. Here, several models can be
linked to your optimization task:
The ADD_FILE item refers to analysis files which may contain additional
geometry for definition of geometric constraints.
The COPY_FILE item allows to copy files to the working directory.
The LIFE_FILE item refers to an analysis model for a durability solver.
www.3ds.com/tosca
The FILE item refers to analysis files with always the same geometry
(node and element structure) which describe the design space.
User Manual 2 - 41
SIMULIA
Tosca Structure
Loading FE Data
The TEMPERATURE_FILE item refers to an analysis model for a temperature solver run.
Fig. 23
2 - 42 User Manual
=
=
=
=
id_read_files
fe_file_name_1
fe_file_name_2
fe_file_name_3
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
3.4.1
SIMULIA
Tosca Structure
The Model
END_
Working with Tosca ANSA environment, all three files can be entered into the
MODEL_LINK folder in a similar way.
The possibilities available to the user for loading the analysis model when
creating the optimization model depend on the chosen solver (see vol.2 chapter 10 and vol.2 chapter 11) and the option set (volume 3: OPTIONS). The
model data is loaded using an internal interface. After reading the model, the
following FE objects are available for further reference in the optimization
task:
Node groups
Element groups
Nodes
Elements
Coordinate systems
Materials
Properties
Element types
Boundary conditions (depending on the OPTIONS)
www.3ds.com/tosca
Load cases
Analysis results used as terms for objective or constraint, so called design
responses (DRESP), are built by referring the load case numbers for the
desired responses.
The load cases in the first file (fe_file_name_1) are numbered using the original load case numbers used in the finite element file.
The load cases in the second file (fe_file_name_2) are numbered using the
original load case numbers used in the finite element file plus 10.000.
The load cases in the third file (fe_file_name_3) are numbered using the
original load case numbers used in the finite element file plus 20.000 and etc.
E.g. the load cases 1, 3 and 4 in the first finite element file have the numbers
1, 3 and 4 in the parameter file, the load cases 1, 3 and 4 in the second finite
element file have the numbers 10001, 10003 and 10004 in the parameter file,
the load cases 1, 3 and 4 in the third finite element file have the numbers
20001, 20003 and 20004 in the parameter file and etc.
In vol.2 chapter 11 the different allowed analysis types for the specific solvers
are described. Furthermore, vol.2 chapter 4.5.2.1 describes how the load
case numbers for the different finite element solvers are applied in the design
response definitions (DRESP). This is especially important for the finite element input decks using no numbers when defining load cases. For the finite
element solvers using no numbers the general rule is that the load cases
User Manual 2 - 43
SIMULIA
Tosca Structure
Loading FE Data
have the numbers according to the order within they are defined. Meaning
that the load case number one will always have the load number of one for
Tosca Structure etc.
Remarks
1. A model link can only be made once for an optimization task, i.e. the
command FEM_INPUT can only be used once in a parameter file.
2. Several analysis files can be added, i.e. the item FILE can be repeated
several times. The first file in the list of files will be handled as master file,
which means that the configuration of the finite element model will be read
from this file. The second and all later referenced files will be used to
perform a finite element calculation. The model in these files has to be
identical to the original FE model. The files will be modified during the optimization.
3.4.2
LIFE_FILE
Is used to define input files for the durability solver (life_solver). Please see
vol.2 chapter 11.6, Shape Optimization Based on a Durability Analysis.
TEMPERATURE_FILE
This parameter allows Abaqus users to specify an Abaqus input file for a
sequential temperature analysis. First, a temperature calculation is carried
out, of which the results are used as boundary conditions for the following
finite element calculation.
The input file, which is used for the temperature calculation, can be specified
using the TEMPERATURE_FILE command. All model changes due to the optimization are also changed to the temperature model.
3.4.4
ADD_FILE
In certain circumstances it is useful to define additional nodes and elements
in the optimization model that are not required in the FE analysis. In this case,
it is practical to write the additional nodes and elements in a separate file.
This file can be read using the item ADD_FILE in the MODEL_LINK folder in
Tosca ANSA environment or the FEM_INPUT definition in Tosca Structure.gui.
For example, these additionally loaded elements can be used to define
restriction areas of any form. To simplify the selection of the elements in the
2 - 44 User Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
3.4.3
SIMULIA
Tosca Structure
The Model
parameter file, it is recommended to assign these elements with specific element properties, which can be used as selection criteria.
Remarks
1. The item ADD_FILE can be repeated several times. All nodes and
elements stored in the file referenced with this item are not available for the
optimization. This item can be used for the specification of neighbouring
elements for the definition of manufacturing constraints.
2. Tosca Structure can not manage double numbers. The user should be
aware of this and be sure that there is no conflict of numbers during file
loading (e.g. elements with identical numbers in the different files in the
MODEL_LINK or FEM_INPUT command).
3.4.5
COPY_FILE
The COPY_FILE command is the easiest way to copy a file into the working
directory of Tosca Structure. This could be an extra configuration file for your
FE-solver or another file that has no direct influence on Tosca Structure.
The item may be repeated several times.
Example:
If the file my_copy_file should be present in the working directory, e.g.
because it is required by the users solver or for use in a script call, it could be
copied as follows:
FEM_INPUT
www.3ds.com/tosca
ID_NAME
FILE
COPY_FILE
END_
3.4.6
= OPTIMIZATION_MODEL
= holeplate.bdf
= my_copy_file
Special FEM_INPUT-commands
The special extra commands: FILE_SOLVER_EXE,
FILE_CMDLINE,
FILE_ADD_CALL, LIFE_FILE_SOLVER_EXE, LIFE_FILE_CMDLINE,
LIFE_FILE_ADD_CALL, DEPENDENT_FILE are all related to the last FILE
or LIFE_FILE command. These are only be used in very advanced setups
and should normaly be avoided.
User Manual 2 - 45
SIMULIA
Tosca Structure
Loading FE Data
3.4.7
= ALL
END_
2 - 46 User Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Remarks
SIMULIA
Tosca Structure
The Model
www.3ds.com/tosca
3.5
Include Files
The parameter files can consist of several parts which can be encapsulated in
separate files. These files are referenced in the actual parameter file
(jobname.par) with the command INCLUDE. This is useful in cases where
the file is too large due to long selection lists used to define groups. The user
can save these group definitions in a separate file and link this with INCLUDE
at the relevant position. A second command INCLUDE can be used also in
the included file.
The INCLUDE files are searched for in the given directory. Should no directory be entered, a search is made in the current working directory or the subdirectory macros of the Tosca Structure installation directory.
Please Note:
The command INCLUDE is not required for your work with Tosca ANSA environment and thus is not available there.
3.6
User Manual 2 - 47
SIMULIA
Tosca Structure
Group Definition (GROUP_DEF, GROUP_AUTO_DEF)
In Tosca Structure two different types of groups exist: node groups and element groups. Groups can be defined manually using selection of objects or
using lists in Tosca Structure.gui or can be defined using graphical selection
in Tosca ANSA environment. Further, automatic node group definition is
available to define groups following specific geometric patterns like, e.g., on
surfaces of revolution. All groups from the FE input file(s) linked to the optimization task are also available for definitions in Tosca Structure.
Groups are uniquely defined and addressed with their user-defined names
(character string). The use of an identical name for a node group and an element group is not permitted.
3.6.2
2 - 48 User Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
3.6.1
SIMULIA
Tosca Structure
The Model
3.6.3
3.6.4
www.3ds.com/tosca
END_
Changing the TYPE to ELEM assembles the elements with the numbers listed
into the group. Further, a list of materials or properties can be specified using
the LIST_MAT or LIST_PROP entry for FORMAT to combine all nodes or elements related to the listed materials or properties.
In Combination with the command SELECT,... (see volume 3: SELECT or
vol.2 chapter 3.7, Selection of Objects in Tosca Structure.gui) more complex
group definitions are possible. To this end, the nodes (or elements) to be
included in the group must first be selected according to their numbers, geometric position, belonging to a certain area etc., sometimes using several
SELECT commands sequentially in order to collect specific nodes or elements
in the selection list.
Subsequently, the group is defined with GROUP_DEF. A typical command
sequence appears as follows:
SELECT,NODE,S,...
GROUP_DEF
ID_NAME
TYPE
FORMAT
= ndgr_name
= NODE
= SELECTED
END_
User Manual 2 - 49
SIMULIA
Tosca Structure
Group Definition (GROUP_DEF, GROUP_AUTO_DEF)
3.6.5
GROUP_AUTO_DEF
ND_GROUP
...
SEARCH_TYPE
....
END_
2 - 50 User Manual
= parent_group
= CONTINUOUS
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
The Model
dir Direction
-Snap Tolerance
2*Snap Tolerance
Search Area
Not Grouped
Fig. 24
+Snap Tolerance
Length
= parent_group
= DISCRETE
END_
dir Direction
www.3ds.com/tosca
Discrete Length
2*Tolereance 2
Search-Length
Discrete Length
Discrete Length
2*Tolerance 1
Member of Parent Group
Fig. 25
Not Grouped
Search Area
User Manual 2 - 51
SIMULIA
Tosca Structure
Group Definition (GROUP_DEF, GROUP_AUTO_DEF)
= parent_group
= CS_MULTI
END_
Y1
CS
1
Yparent
X1
CSparent
Xparent
Y2
X2
X 1 in CS 1 = X 2 in CS 2 = X parent in CS parent
Y 1 in CS 1 = Y 2 in CS 2 = Y parent in CS parent
Fig. 26
Remarks
1. Only currently active (selected) nodes are considered for the definition of
children groups when using GROUP_AUTO_DEF. Per default, all nodes
are selected at the beginning of the optimization. If - for specific reasons only a subset of nodes was active (selected) and if nowall nodes should be
considered for the children group definition, then all nodes must be activated (again) using SELECT, NODE, ALL before the GROUP_AUTO_DEF
2 - 52 User Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
CS 2
SIMULIA
Tosca Structure
The Model
3.7
www.3ds.com/tosca
User Manual 2 - 53
SIMULIA
Tosca Structure
Selection of Objects in Tosca Structure.gui
Shortcut
Type
Description
Select
Reselect
Add
Unselect
ALL
Select all
Select none
Invert
NONE
INV
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Table 2
2 - 54 User Manual
SIMULIA
Tosca Structure
The Model
MAT
ETYP
EPROP
ELGR
ELEM
NODES:
ND_ALL
ND_ANY
LAYER
SOLID
ELEM
Restrict
NODE
Location
Surface
Design
List
www.3ds.com/tosca
NDGR
Property
C
Fig. 27
Selection criteria
Almost all objects can be added to a selection list using numbers or names.
For nodes and elements a variety of selection criteria exists (Table 3). For
example, it is possible to select elements by their element property or mate-
User Manual 2 - 55
SIMULIA
Tosca Structure
Selection of Objects in Tosca Structure.gui
rial number defined in the analysis file. Thus element and node numbers do
not have to be explicitly known by the user.
Selection lists are useful tools that help the user to quickly define element and
node lists. Selection lists are required for group definitions.
.
ELGR
NDGR
ETYP
X
X
MAT
SOLID
EPROP
ETYP
NDGR
ELGR
NODE
ELEM
Table 3
CS
NR.
EPRO
P
SOLID
CS
MAT
Selection lists
NAME
Selection criteria
X
X
The following example serves to illustrate the effect of the selection commands. Each step is accompanied by a description of how the selection lists
change.
The aim of this detailed example is to select a node group by list entries for
which various assignments are applied (e.g. nodes to elements, element to
element properties).
The following steps are taken:
Direct selection of elements by specifying the element numbers (in the
example: elements 1, 3, 5).
Selection of elements using element properties (in the example: element
properties 3 and 5).
Selection of the nodes associated with the actually selected elements.
Step 1: Select element numbers directly:
2 - 56 User Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Examples
SIMULIA
Tosca Structure
The Model
- By specifying the list name ELEM, the element list is addressed. The
selection operator S initializes the element list (SELECT). The element
numbers are directly specified as selection criterion (elements 1 to 5 with
increments of 2). The elements 1, 3 and 5 are selected directly with their
numbers and written into the element list. All other lists remain
unchanged.
List
ELEM
Table 4
List entries
1, 3, 5
www.3ds.com/tosca
List
List entries
ELEM
1, 3, 5
EPROP
3, 5
Table 5
Now all elements with element properties that are currently in the element
property list should be added to the already existing element list.
SELECT, ELEM, A, EPROP
User Manual 2 - 57
SIMULIA
Tosca Structure
Selection of Objects in Tosca Structure.gui
List
List entries
ELEM
EPROP
3, 5
Table 6
- The node list is addressed and initialized. All nodes of the elements currently in the element list are included in the node list:
List
List entries
ELEM
EPROP
3, 5
NODES
Table 7
Remarks
1. To use the selection possibilities for element types, materials and coordinates in Tosca Structure, all quantities must previously be defined and
assigned in the FE analysis file.
2. Upon loading the analysis model, all loaded objects (nodes, elements,
coordinate systems, materials, element types, element properties) are
written into the corresponding lists. Initially, the lists SOLID, ELGR and
NDGR are empty.
2 - 58 User Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
The Model
3.8
The selection window (the right window in Fig. 28) allows the user to create,
edit or delete coordinate systems. An alternative way is to use the buttons in
CS_DEF group of Modules Buttons window. The button INFO opens the list of
defined coordinate systems that is basically equivalent to the selection window. The names of the buttons that create new coordinate systems depend
on the selected solver; they are described below in details.
www.3ds.com/tosca
Fig. 28
User Manual 2 - 59
SIMULIA
Tosca Structure
Coordinate Systems (CS_DEF)
Fig. 29
2 - 60 User Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
3.8.1
SIMULIA
Tosca Structure
The Model
Coordinate
system
type
Cartesian
Cylindrical
Spherical
solver
Abaqus
CS_DEF button
label
COORD database
Z RECTANGULAR
ORIENTATION_NODES_R
RECTANGULAR
ORIENTATION_NODES_DYN
Nastran
CORD1R
CORD_NODES_R
ANSYS
CS
LOCAL_NODES_DYN
Abaqus
CYLINDRICAL
ORIENTATION_NODES_C
Nastran
CORD1C
CORD_NODES_C
ANSYS
not supported
not supported
Abaqus
SPHERICAL
ORIENTATION_NODES_S
Nastran
CORD1S
CORD_NODES_S
ANSYS
not supported
not supported
In each case, after the command is chosen, the user selects three nodes
from the model that are used as follows:
the first node is the origin;
the axis that follows after the first one (i.e., Y- or X-axis) lies in the plane
defined by the three nodes, perpendicular to the first axis and closer to the
direction from the origin to the third node;
www.3ds.com/tosca
the direction from the origin to the second node is the direction of the first
axis that is X-axis (in case of NODES | RECTANGULAR (Abaqus), CS
(ANSYS) or ..._NODES_DYN (in selection window)) or Z-axis (otherwise);
User Manual 2 - 61
SIMULIA
Tosca Structure
Coordinate Systems (CS_DEF)
the last axis is perpendicular to the first and the second one, forming a positively oriented basis.
Fig. 30
In Tosca Structure.gui, the IDs of nodes should be entered in the corresponding fields, and also the fields Axis (x-axis or z-axis) and Plane (xy-plane or
xz-plane) should be specified. Then, the first chosen node (Node ID of
Origin field) is the origin, the second node (Node on Axis field)
defines the axis (specified in Axis field) as described above, and the third
node (Node in Plane field) is needed to define the plane according to
Plane field.
Example
A Cartesian coordinate system with the label, CS_12, should be defined by
the three nodes 101, 102 and 103. Node 101 is located at the origin of
CS_12, node 102 is on Z axis and node 103 is in XZ plane:
ID_NAME
CS_TYPE
DEF_TYPE
CS_AXIS
NODE_ORIGIN
NODE_AXIS
NODE_PLANE
2 - 62 User Manual
=
=
=
=
=
=
=
CS_12
RECTANGULAR
NODE
Z_XZ
101
102
103
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
CS_DEF
SIMULIA
Tosca Structure
The Model
END_
z
102
103
CS_12
101
x
Fig. 31
3.8.2
www.3ds.com/tosca
Fig. 32
The commands creating the coordinate systems are found under the buttons
CORD2 (Nastran), CORD (Abaqus) or LOCAL (ANSYS), as well as in the
context menu command New of the selection window for the coordinate systems:
User Manual 2 - 63
SIMULIA
Tosca Structure
Coordinate Systems (CS_DEF)
Coordinate
system
type
solver
Cartesian
Abaqus
Cylindrical
Spherical
CS_DEF button
label
COORD database
RECTANGULAR
ORIENTATION_R
OFFSET TO
NODES
ORIENTATION_OFFSET_TO_
NODES
Nastran
CORD2R
CORD_R
ANSYS
RECTANGULAR
LOCAL_R
Abaqus
CYLINDRICAL
ORIENTATION_C
Nastran
CORD2C
CORD_C
ANSYS
CYLINDRICAL
LOCAL_C
Abaqus
SPHERICAL
ORIENTATION_S
Nastran
CORD2S
CORD_S
ANSYS
SPHERICAL
LOCAL_S
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
After a command is chosen, the user should select three points from the
model. If a point close to an edge is clicked, the middle point of the edge is
chosen; otherwise, if the point is close to a node, this node is chosen. Please
take care not to select the edges in case you need the nodes. To do this,
choose a point between the edges going from the node you wish to choose,
sufficiently close to the node but not to any edge.
2 - 64 User Manual
SIMULIA
Tosca Structure
The Model
When all three nodes are chosen, the following dialog appears:
Fig. 33
This window contains the coordinates of the nodes that have just been chosen (A1..A3, B1..B3, C1..C3 fields). This coordinates may be modified; moreover, if it is needed to define the coordinate system using some points that
not necessarily coincide with nodes or middle points of edges, the easiest
way is to create a coordinate system using any three points and then to set
the correct values in the fields of this dialog window.
The three points are used as follows:
the first point (A1, A2, A3) is the origin;
the direction from the origin to the second point (B1, B2, B3) is the direction
of Z-axis;
www.3ds.com/tosca
X-axis lies in the plane defined by the three nodes, perpendicular to Z-axis
and closer to the direction from the origin to the third point (C1, C2, C3);
Y-axis is perpendicular to the other two, forming a positively oriented basis.
The field RID defines the reference coordinate system (by default, it is set to
0 indicating the global coordinate system). Pressing "?" key in this field opens
the list of all defined coordinate systems. The values in A1..C3 fields are
interpreted as the points with the corresponding coordinates with respect to
the coordinate system that has ID equal to RID field, with RID = 0 corresponding to the global coordinate system.
Choosing Abaqus or ANSYS as the solver allows (but not requires) the specification of one rotation angle using "rotation axis" field: choosing an axis (1 to
3, i.e., X to Z) in this field and then an angle in degrees in "rotation angle" field
leads to the rotation of the new coordinate system around the specified axis
(the "new" one, i.e., calculated basing on the chosen points).
User Manual 2 - 65
SIMULIA
Tosca Structure
Coordinate Systems (CS_DEF)
3.8.3
Fig. 34
Then, the coordinates of the origin (with respect to the coordinate system
specified in Reference CS field) and the three rotation angles are to be chosen. The directions of the axes of the coordinate system are constructed in
the following manner:
first, the axes X, Y, Z of the reference coordinate system are taken;
then, the axes are rotated around Z-axis by the first angle in Rotation
fields (labeled with 3): axes X, Y, Z = Z are produced;
finally, these axes are rotated around X by the third angle (field labeled
with 1): axes X = X, Y, Z are produced that give the directions for the
coordinate system axes.
All rotations are performed in positive (counter-clockwise) directions; the values of the angles are in degrees.
Examples
A Cartesian coordinate system with the name CS_14 should be defined relative to the global Cartesian coordinate system CS_0. The point of origin of the
new coordinate system should have the coordinates (30, 20, 0). Then, a
cylindrical coordinate system CS_15 should be defined relative to CS_14 with
the origin at the point (60, 5, 0). CS_15 should be rotated 15 around Z axis:
The result coordinate system CS_15 defines a cylindrical coordinate system
with origin (90,25,0) with respect to the global Cartesian coordinate system
CS_0. The polar axis through the new origin is rotated by 15 around the z-
2 - 66 User Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
the resulting axes are rotated around Y by the second angle (field labeled
with 2): axes X, Y = Y, Z are produced;
SIMULIA
Tosca Structure
The Model
axis. The longitudinal axis is parallel to the original z-axis through the new origin:
CS_DEF
ID_NAME
CS_TYPE
DEF_TYPE
CS_REF
ORIGIN_123
ROTATION_321
=
=
=
=
=
=
CS_14
RECTANGULAR
LOCAL
CS_0
30,20,0
0,0,0
END_
CS_DEF
ID_NAME
CS_TYPE
DEF_TYPE
CS_REF
ORIGIN_123
ROTATION_321
=
=
=
=
=
=
CS_15
CYLINDRICAL
LOCAL
CS_14
60,5,0
15,0,0
END_
y
y
CS_15 z
15
CS_14
20
60
www.3ds.com/tosca
z
CS_0
Fig. 35
3.8.4
30
User Manual 2 - 67
SIMULIA
Tosca Structure
Solids (Geometric Primitives)
3.9
Fig. 36
3.9.1
2 - 68 User Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
In some applications, it is required that the nodes stay in a certain region, or,
conversely, are not allowed to enter a certain region during the shape or bead
optimization. In Tosca Structure, such regions can be defined by geometric
primitives: in two dimensions, rectangles, circles or circular segments; in
three dimensions, bricks, cylinders and cylinder segments are supported. The
type of the geometric primitive depends on the coordinate system it is defined
with.
In the figure, the cylindrical segment 0 r 10 , 0 90 , 5 z 10 in the
cylindrical coordinate system C2 and the cube 5 x 10 , 5 y 10 ,
5 z 10 in the Cartesian coordinate system R1 are shown, as represented
in Tosca ANSA environment:
SIMULIA
Tosca Structure
The Model
Fig. 37
www.3ds.com/tosca
Choosing CS_DEF in CS field and pressing "?" key in CS_DEF field opens
the list of all defined coordinate systems. The fields VAL_1_MIN,
VAL_1_MAX,.., VAL_3_MAX define the extents of the geometric primitive in
each coordinate. For Cartesian coordinate systems, the coordinates are x, y
and z; for cylindrical coordinate systems, they are r, phi and z.
The list of all defined SOLIDs is opened by the button SOLID in RESTRICTION panel of Modules Buttons in Tosca ANSA environment.
3.9.2
User Manual 2 - 69
SIMULIA
Tosca Structure
Solids (Geometric Primitives)
tion or Restricted), the coordinate system and the extents of the geometric
primitive in each coordinate are edited. See the previous subsection for more
information about these fields.
The field ID_NAME defines the name of the geometric primitive, so that it can
be referenced in the DVCON_SHAPEcommand (see vol.2 chapter 6.3.3).
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Remarks
Another usage of geometric primitives in Tosca Structure is in SELECT command. In this case, the nodes that lie inside a geometric primitive defined
using a SOLID command are selected. Node selection in solids is independent of the mesh density of the FE model, only depending of geometric
dimensions. This selection method is more complicated than other methods
but is highly recommended for models with varying mesh density.
2 - 70 User Manual
SIMULIA
Tosca Structure
Terms for Optimization
Overview
To optimize anything you need to know what to optimize. Do you want to minimize stresses? Or maximize all eigenvalues?
The two above statements are too unclear for defining an optimization.
Therefore, we usually reduce the what to well defined terms, say: Minimize
the maximal nodal stresses of load case 1 and 2, or maximize the sum of the
first 5 eigenvalues.
The goal or objective of an optimization is usually called the objective function
(OBJ_FUNC), e.g. when you want to minimize or maximize some well
defined terms. You may also want to enforce certain values, for example a
displacement of a given node must not exceed a certain value. This would be
defined through a CONSTRAINT.
In Tosca Structure the objective function depends upon at least one term or
more, whereas a constraint always depends on exactly one term.
These terms or responses are in Tosca Structure called design responses or
DRESP. DRESPs are the fundamental definitions of the optimization problem. In Tosca ANSA environment the DRESPs are available under the
OBJ_FUNC_ITEM_1 item and the CONSTRAINTS item.
Most DRESP definitions depend on a node or element group, but not all e.g.
eigenfrequencies (DRESP, TYPE=DYN_FREQ). This node or element group
may also consist of one single item, say one node, e.g. displacement in Xdirection of a node (DRESP, TYPE=DISP_X). The optimization problem is
summarized in the OPTIMIZE command and the dependencies can be visualized in following way:
www.3ds.com/tosca
4.1
User Manual 2 - 71
SIMULIA
Tosca Structure
Objective Function
4.1.1
Mathematical formulation
An optimization problem can be stated as:
min ( ( U ( x ), x ) )
s.t. i ( U ( x ), x ) 0
s.t.
gi ( x ) 0
ref
= min
w ( ( ( U ( x ), x ) ) ) i )
i=1 i i
ref
= max
w ( ( ( U ( x ), x ) ) ) i )
i=1 i i
s.t.
i ( U ( x ), x ) 0
s.t.
gi ( x ) 0
The MINMAX formulation should always be used for controller based optimization. For sensitivity based optimization MIN or MAX are prefered because
they tend to converge better and faster. Note remark in next section regarding
default reference value and shape optimization.
4.2
Objective Function
The objective function defines the values to be maximized or minimized during optimization. This function may depend analysis results, geometric values
or combinations of those.
2 - 72 User Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
= minmax { w i ( i ( U ( x ), x ) i ) }
SIMULIA
Tosca Structure
Terms for Optimization
4.2.1
Overview
The objective function depends upon results of the finite element analysis
such as compliance, displacements, stresses, reaction forces, internal forces,
eigenfrequencies or properties of the finite element model such asmaterial
volume or nodal positions. These results are combined to scalar values using
the so called design responses. Initially, one or several responses for the
objective function have to be defined using the command DRESP. These
responses are then added to the objective:
DRESP (scalar value)
DRESP (scalar value)
DRESP (scalar value)
......................
Fig. 38
OBJ_FUNC
Weight and reference values can be applied in the combination using the
command OBJ_FUNC.
OBJ_FUNC
ID_NAME
DRESP
DRESP
DRESP
DRESP
...
TARGET
=
=
=
=
=
...
id_name_1,
id_name_2,
id_name_3,
id_name_4,
WEIGHT,
WEIGHT,
WEIGHT,
WEIGHT,
REFERENCE
REFERENCE
REFERENCE
REFERENCE
The ID_NAME of the OBJ_FUNC must be referenced in the OPTIMIZE command to activate the objective function.
The WEIGHT and REFERENCE values are optional. The default weighting
ref
factor is w i = 1 and the default reference value is i
= 0 , except for controller based shape optimization, see Remark. See also equations in chapter
4.1.1 Mathematical formulation. Because of the default values the user has
not to define WEIGHT and REFERENCE for the most common optimization
formulations.
The command TARGET can be set to MIN, MAX or MINMAX indicating if the
objective function is minimized or maximized or a min-max formulation is
used.
www.3ds.com/tosca
END_
User Manual 2 - 73
SIMULIA
Tosca Structure
Objective Function
ref
ti = wi ( i i )
If constraints are defined in optimization task these are also included in
optimization_report.csv and optimization_status_all.csv.
Remark
1. For controller based shape optimization (chapter 6 Shape Optimization)
ref
the reference value ( i ) has a special meaning. The reference value is
the value around which Tosca Structure homogenizes the stress around.
ref
Thus, a value i
= 0 usually does not make sense and Tosca Struc-
2 - 74 User Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
In above example first the total objective function is listed for each iteration
as MINIMIZE_MAX_MISES. The objective function is always the first colomn.
Then each DRESP in the
1 = DRESP_MAX_MISES1 and 2 =
DRESP_MAX_MISES2
is
listed
as
OBJ_FUNC_DRESP:DRESP_MAX_MISES1 and OBJ_FUNC_DRESP:
DRESP_MAX_MISES2. After each DRESP the terms are listed:
OBJ_FUNC_TERM:DRESP_MAX_MISES1
and
OBJ_FUNC_TERM:
DRESP_MAX_MISES2. The terms include weight and reference value and
are given as:
SIMULIA
Tosca Structure
Terms for Optimization
ref
2. Also, for controller based shape optimization the user must either set all
REFERENCE-values or none at all (automatic reference value calculation).
3. Please note that the reference value for the MINMAX function differs from
the above definition by eigenfrequency optimization for the sensitivity
based algorithm, see for example chapter 7.6.2.5 Maximize band gaps.
4. Please note that the reference value for von Mises stresses in topology
optimization differs from the above definition (see also vol.2 chapter 4:
Reference stress for objective function).
The design responses (DRESP) listed in OPTIMZE will be summed up taking
into account the individual weighting and reference values (see also chapter
4.1.1 Mathematical formulation) if TARGET is set to MIN or MAX.
A min-max formulation is applied if TARGET is set to MINMAX. Then the
design responses (DRESP) are dealt with individually in a multidisciplinary
optimization taking into account the individual weighting and reference values.
www.3ds.com/tosca
4.2.2
User Manual 2 - 75
SIMULIA
Tosca Structure
Objective Function
ID_NAME
DRESP
DRESP
...
TARGET
= ...
= ...
= ...
= MIN (or MAX)
END_
where the DRESP definitions are referring to the desired responses for the
objective function using the ID name of the defined responses. The defined
responses which should be minimized (or maximized) have to be valid design
responses (see chapter 4.4 Design Responses).
4.2.3
END_
where the DRESP definitions are referring to the desired design responses
for the objective function using the ID name of the defined responses. The
defined responses that should be minimized have to be valid design
responses (see also chapter 4.4 Design Responses).
2 - 76 User Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
ID_NAME
DRESP
DRESP
...
TARGET
SIMULIA
Tosca Structure
Terms for Optimization
Fig. 39
Fig. 40
www.3ds.com/tosca
In addition to the target definition for the objective function definition, the user
also has to define the design responses for the objective function combined
by the target. These terms then will be minimized or maximized.
User Manual 2 - 77
SIMULIA
Tosca Structure
Objective Function
Fig. 41
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
2 - 78 User Manual
SIMULIA
Tosca Structure
Terms for Optimization
Fig. 42
Constraints
Normally, optimization tasks have some restrictions. These restrictions limit
the values of the design responses or linear combinations of the design
responses. If the constraint is not fulfilled the optimization result is not feasible.
Tosca Structure allows inequality constraints in all sensitivity based algorithms. Equality constraints are only allowed in the controller based
approaches.
This means that the item EQ_VALUE defining the equality value may only be
used for controller based optimization. LE_VALUE and GE_VALUE are to be
used for the upper and lower values of constraints in sensitivity based optimization algorithms.
An equality constraint is given as (see also vol.2 chapter 4.1.1, Mathematical
formulation):
www.3ds.com/tosca
4.3
User Manual 2 - 79
SIMULIA
Tosca Structure
Constraints
where is the value of the design response. Inequality constraints are given
as (see also chapter 4.1.1 Mathematical formulation):
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
The <magnitude> can be defined as ABS or REL, short for absolute or relative value of the design response in the constraint. When using the relative
value the design response is normalized with respect to the initial value of the
design response (design response value of optimization iteration 0).
2 - 80 User Manual
SIMULIA
Tosca Structure
Terms for Optimization
Fig. 43
For the definition of a constraint within the Tosca Structure.gui the design
response which should be constraint has to be defined previously. Please
www.3ds.com/tosca
User Manual 2 - 81
SIMULIA
Tosca Structure
Constraints
Fig. 44
2 - 82 User Manual
=
=
=
=
=
=
<ID_NAME>
<DRESP>
<MAGNITUDE>
<EQ-TARGET>
<LE-TARGET>
<GE-TARGET>
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Fig. 45
SIMULIA
Tosca Structure
Terms for Optimization
The <ID_NAME> must be referenced in the OPTIMIZE command for the constraint to be activated. Only one of the constraint items EQ_VALUE,
LE_VALUE and GE_VALUE may be defined. They define the constraint value
.
Fig. 46
Remark
www.3ds.com/tosca
1. In the above plot CONSTRAINT_NORM are all constraints plottet, normalized. CONSTRAINT_NORM is a special normalization so all fullfiled
constraints are < 1.0. This also applies to GE_EQUAL constraints.
4.4
Design Responses
Most design responses are only available for certain analysis types. Others
are independent of the analysis type because they are directly linked to the
geometry of the FE-model. Each design response represents one scalar
value which can be extracted from the model information (like the volume) or
from the FE-results.
All design responses always consist of one single scalar value. So although
you reference a node or element group in the DRESP definition, Tosca Structure will use a group operator (GROUP_OPER) to either use the maximal
User Manual 2 - 83
SIMULIA
Tosca Structure
Design Responses
(MAX), minimal (MIN) or sum of the values (SUM) to combine the responses
to a single value. (see also chapter 4.5.1 Group operations for design
responses)
Although Tosca Structure can handle more load cases within one design
response, it is best practice to use one design response for each load case.
This is done with the item LC_SET:
LC_SET = <ANALYSIS_TYPE>, <LOADCASE_NR>,<SUBSTEP>
If more load cases or sub-steps are referenced in the LC_SET item the maximum (MAX) or minimum (MIN) value will be used within the design response,
depending on the setting of load case selection (LC_SEL). If LC_SEL is not
set explicitly, a default value is used according to the type of the design
response. Using Tosca Structure.gui LC_SEL no longer needs to be defined
manually. Again, this is done to obtain exactly one single value. See also
chapter 4.5.2.1 Load case specification (LC_SET). Command in parameter
file:
DRESP
ID_NAME
DEF_TYPE
TYPE
VAR_OPER
UPDATE
GROUP_OPER
EL_GROUP
ND_GROUP
ELEM
NODE
LC_SET
LC_SEL
=
=
=
=
=
=
=
=
=
=
=
=
.....
.....
.....
.....
.....
.....
.....
.....
.....
.....
.....
.....
2 - 84 User Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
END_
SIMULIA
Tosca Structure
Terms for Optimization
Fig. 47
www.3ds.com/tosca
Allowed objective functions and constraints are shown in the Tosca ANSA
environment, see Fig. 47.
User Manual 2 - 85
SIMULIA
Tosca Structure
Design Responses
a)
b)
Fig. 48
Fig. 49
2 - 86 User Manual
Add a design response to the project and define the desired settings
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Terms for Optimization
4.4.1
STRAIN_ENERGY
uT Ku
TOPO
OBJ_FUNC
CONSTRAINT
Table 8
SHAPE
BEAD
SIZING
C*,S*
C,S
S*
Compliance has a large popularity within scientific publications, and compliance is of large importance in engineering applications even though the
expression may not be widely known outside the optimization community.
Compliance may be expressed as the overall flexibility or softness of a
structure given by the sum of elastic or strain energy in a structure. Thus,
compliance can be seen as a stiffness measure or more correctly the reciprocal of stiffness.
To maximize the global stiffness we therefore minimize compliance. Compliance is defined in Tosca Structure by the sum of strain energy of all elements.
www.3ds.com/tosca
Remarks:
1. In certain cases including prescribed displacements or thermal fields "minimizing compliance" will result in a stiff structure. If a load case is driven by
prescribed displacements or a thermal field the elastic energy / compliance
will only decrease if the structure is made softer. If only prescribed
displacements are present without external loading, the strain energy
should be maximized to obtain optimal results:
R u
max --------------
2
with R=reaction force and u* = nodal prescribed displacements.
If both external loading and prescribed displacements are present, a new
energy stiffness measure is introduced (see chapter 4.4.2 Energy stiffness
User Manual 2 - 87
SIMULIA
Tosca Structure
Design Responses
measure). The "standard" strain energy does not lead to optimal results:
P
u R
u
---------+ -------------2
2
with P=external loading and u = corresponding nodal deflections of the
loaded nodes.
2. Compliance is equal to the overall strain energy. Therefore the strain
energy for all elements is required. Any other element group is not allowed,
because in such cases the optimization problems are not self-adjoint.
3. If no LC_SET is specified (no load case is selected from the existing load
cases) Tosca Structure will always read the last sub-step for each load
case in case of non-linear loading.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
2 - 88 User Manual
SIMULIA
Tosca Structure
Terms for Optimization
Fig. 50
www.3ds.com/tosca
User Manual 2 - 89
SIMULIA
Tosca Structure
Design Responses
Fig. 51
2. To choose load case click Add LC. In the field Load case number enter 2.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
2 - 90 User Manual
SIMULIA
Tosca Structure
Terms for Optimization
4. Click Add Dresp and choose the previously defined design response for
compliance.
Fig. 52
Fig. 53
www.3ds.com/tosca
User Manual 2 - 91
SIMULIA
Tosca Structure
Design Responses
When done, add an objective function to the project. Select Minimize sum as
Target and select the previously defined design response in a new tab.
Fig. 54
OBJ_FUNC
ID_NAME
DRESP
TARGET
END_
4.4.2
=
=
=
=
=
=
compliance
STRAIN_ENERGY
SYSTEM
STATIC,2,
ALL_ELEMENTS
SUM
= MY_OBJ_FUNC
= compliance
= MIN
2 - 92 User Manual
c = P u R u
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
DRESP
ID_NAME
TYPE
DEF_TYPE
LC_SET
EL_GROUP
GROUP_OPER
END_
SIMULIA
Tosca Structure
Terms for Optimization
SHAPE
BEAD
SIZING
OBJ_FUNC
CONSTRAINT
Table 9
Pu
min ----------
2
where P is the external loading and u is the corresponding nodal deflections
of the loaded nodes.
If a load case is driven by prescribed displacements the elastic energy / compliance will only decrease if the structure is made softer. If only prescribed
displacements are present without external loading, the strain energy should
be maximized to obtain optimal results:
www.3ds.com/tosca
R u
max --------------
2
where u* are the nodal prescribed displacements being different from zero
and R are the corresponding nodal reaction forces.
The physical strain energy with both external load and prescribed displacements is described as follows but may not lead to optimal stiffness results:
P u R u
= ---------- + -------------2
2
The new stiffness measure (ENERGY_STIFF_MEASURE) combines the first
two approaches in the following optimization formulation :
P u R u
min ---------- --------------
2
2
User Manual 2 - 93
SIMULIA
Tosca Structure
Design Responses
Remarks:
1. Energy stiffness measure should always be minimized (TARGET = MIN) in
the objective function independent upon external loading, prescribed
displacement and thermal loading. This requires less user effort compared
to total strain energy !
2. Energy stiffness measure should always be applied to ALL_ELEMENTS.
3. Thermal loading is allowed as long the thermal loading is independent
upon material distribution
4. Energy stiffness measure can also be applied in a min-max optimization
formulation (TARGET = MINMAX).
5. The energy stiffness measure is also allowed in constraints.
6. If only external loading is present in a given loadcase then the energy stiffness measure (TYPE = ENERGY_STIFF_MEASURE) is equal to the total
strain energy (TYPE = STRAIN_ENERGY) also called the compliance.
7. If only prescribed displacements are present in a given loadcase then the
energy stiffness measure (TYPE = ENERGY_STIFF_MEASURE) is equal
to the minus total strain energy (TYPE = STRAIN_ENERGY) also called
the compliance.
8. If both external loading and prescribed displacements are present in a
given loadcase then the energy stiffness measure (TYPE =
ENERGY_STIFF_MEASURE) is not equal to the total strain energy (TYPE
= STRAIN_ENERGY).
9. The energy stiffness measure is not a physical energy measure!
2 - 94 User Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
10.The energy stiffness measure is not available for the controller based optimization strategy.
SIMULIA
Tosca Structure
Terms for Optimization
4.4.2.1
Fig. 55
www.3ds.com/tosca
User Manual 2 - 95
SIMULIA
Tosca Structure
Design Responses
Fig. 56
2. To choose load case click Add LC. In the field Load case number enter 2.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
2 - 96 User Manual
SIMULIA
Tosca Structure
Terms for Optimization
4. Click Add Dresp and choose the previously defined design response for
energy stiffness measure.
Fig. 57
=
=
=
=
=
...
SYSTEM
ENERGY_STIFF_MEASURE
ALL_ELEMENTS
SUM
END_
www.3ds.com/tosca
4.4.3
ui
ROT_X, ROT_Y,ROT_Z
DISP_X_ABS, DISP_Y_ABS,
DISP_Z_ABS
u i2
DISP_ABS
u x2 + u y2 + u z2
User Manual 2 - 97
SIMULIA
Tosca Structure
Design Responses
TOPO
SHAPE
BEAD
SIZING
OBJ_FUNC
S*
CONSTRAINT
S*
Table 10
Displacements and rotations are the primary variables in the FEM solution.
They are also very often the main interest of the FEM-analyst, e.g. the maximal displacement. Displacements and rotations should be defined using a
nodal id, although node groups may also be referenced. Large node groups
can lead to major performance issues, see chapter 4.5.1 Group operations
for design responses.
Displacements and rotations can also be referenced in a local coordinate system.
See also chapter 4.5 Combined Terms.
Remark
1. It is always strongly recommended that the user defines design elements
attached to nodes used in displacement definitions or reaction definitions
(DRESP) as frozen elements. This stabilizes the optimization iterations and
often leads to a significant lower number of optimization iterations.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
2 - 98 User Manual
SIMULIA
Tosca Structure
Terms for Optimization
www.3ds.com/tosca
Fig. 58
User Manual 2 - 99
SIMULIA
Tosca Structure
Design Responses
Fig. 59
Fig. 60
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
In Tosca Extension for ANSYS/WB an objective function containing a displacement has to be set up in two steps. At first, add and define a design
response containing the displacement. Therefore add a design respone to
the project, choose Displacement as Category and Absolute as Response
Type.
SIMULIA
Tosca Structure
Terms for Optimization
In order to select the node: activate a nodal selection first by clicking Show
mesh and Select mesh. Then select the desired node graphically.
Fig. 61
Fig. 62
ID_NAME
TYPE
CS_REF
DEF_TYPE
LC_SET
NODE
END_
=
=
=
=
=
=
disp_x_abs
DISP_X_ABS
CS_1
SYSTEM
STATIC, 2,
10
www.3ds.com/tosca
DRESP
SIMULIA
Tosca Structure
Design Responses
4.4.4
Reaction force
REACTION_FORCE_ABS
F =
REACTION_FORCE_X,
REACTION_FORCE_Y,
REACTION_FORCE_Z
F =
Ke ui
Ke ui
REACTION_FORCE_X_ABS,
REACTION_FORCE_Y_ABS,
REACTION_FORCE_Z_ABS
F =
Ke ui
REACTION_MOMENT_ABS
F =
REACTION_MOMENT_X,
REACTION_MOMENT_Y,
REACTION_MOMENT_Z
F =
Ke ui
Ke ui
REACTION_MOMENT_X_ABS,
REACTION_MOMENT_Y_ABS,
REACTION_MOMENT_Z_ABS
F =
Ke ui
TOPO
SHAPE
BEAD
SIZING
OBJ_FUNC
CONSTRAINT
Table 11
The reaction forces and the reaction moments can only be defined as a
DRESP (design response) in the sensitivity based bead and topology optimization.
Remarks
1. A reference coordinate system (CS_REF) cannot be used for the reaction
force responses defined using REACTION_FORCE_ABS and
REACTION_MOMENT_ABS.
2. The reaction force, reaction moment, internal force and/or internal moment
in a given DOF of a node applied in the optimization formulation has to
2 - 102 User Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Terms for Optimization
have stiffness in the DOF direction similar to the DOF direction of the reaction force or internal force used in the optimization formulation. Meaning
that at least one of the elements surrounding the node has to have stiffness
in the DOF direction similar to the reaction force or internal force direction
applied in the optimization formulation.
Hence, this criterion is also physical meaningful since a structure having no
stiffness in a given direction will always have zero reaction force in this
direction.
3. Differences between reaction forces can be defined using group operations.
4. Examples for combinations of reaction forces can be found in chapter
4.5.1.4 Group operations for reaction forces/moments.
www.3ds.com/tosca
Apply New |
STRAINTS item.
Fig. 63
SIMULIA
Tosca Structure
Design Responses
Fig. 64
Fig. 65
= my_reac
= SYSTEM
= REACTION_FORCE_Y
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Terms for Optimization
NODE
LC_SET
GROUP_OPER
CS_REF
END_
4.4.5
=
=
=
=
112072
ALL,2,All
Max
CS_0
Internal force
INTERNAL_FORCE_ABS
F =
INTERNAL_FORCE_X,
INTERNAL_FORCE_Y,
INTERNAL_FORCE_Z
F =
Ke ui
Ke ui
INTERNAL_FORCE_X_ABS,
INTERNAL_FORCE_Y_ABS,
INTERNAL_FORCE_Z_ABS
F =
Ke ui
INTERNAL_MOMENT_ABS
F =
INTERNAL_MOMENT_X,
INTERNAL_MOMENT_Y,
INTERNAL_MOMENT_Z
F =
Ke ui
Ke ui
INTERNAL_MOMENT_X_ABS,
INTERNAL_MOMENT_Y_ABS,
INTERNAL_MOMENT_Z_ABS
F =
Ke ui
www.3ds.com/tosca
SHAPE
BEAD
SIZING
OBJ_FUNC
CONSTRAINT
Table 12
SIMULIA
Tosca Structure
Design Responses
The internal forces and the internal moments can be defined as a DRESP
(design response) in the sensitivity based bead and topology optimization.
The internal forces as DRESPs are supported for Abaqus, ANSYS, Marc,
MSC Nastran.
a)
b)
Fig. 66
As previously shown the internal forces are defined by nodes and elements.
Meaning that the design response is defined in the following way:
ID_NAME
DEF_TYPE
TYPE
CS_DEF
GROUP_OPER
ND_GROUP
NODE
EL_GROUP
ELEM
LC_SET
=
=
=
=
=
=
=
=
=
=
.....
SYSTEM
.....
.....
MAX or
.....or
.....or
.....or
.....or
.....
SUM
use the
use the
use the
use the
NODE-definition
ND_GROUP-definition
ELEM-definition
ELEM_GROUP-definition
END_
Remarks
1. The reaction force, reaction moment, internal force and/or internal moment
in a given DOF of a node applied in the optimization formulation has to
2 - 106 User Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
DRESP
SIMULIA
Tosca Structure
Terms for Optimization
have stiffness in the DOF direction similar to the DOF direction of the reaction force or internal force used in the optimization formulation. Meaning
that at least one of the elements surrounding the node has to have stiffness
in the DOF direction similar to the reaction force or internal force direction
applied in the optimization formulation.
Hence, this criterion is also physical meaningful since a structure having no
stiffness in a given direction will always have zero reaction force in this
direction.
2. Internal forces are only supported for elements having node numbers. If
the element is not defined by nodes (e.g. some weld element) then the
internal forces of this element can not be applied in the optimization.
3. Both node(s) and element(s) always have to be defined for internal forces.
4. See also the tables of supported element types (chapter 11 Solver Specific
Features) for a list of elements which can be used for internal forces.
5. A reference coordinate system (CS_REF) can not be used for the internal
force responses defined using INTERNAL_FORCE_ABS and
INTERNAL_MOMENT_ABS.
6. Internal forces are supported for Abaqus, ANSYS, Marc and MSC Nastran.
7. Internal forces are not supported for PERMAS.
8. Examples for combinations of internal forces can be found in chapter
4.5.1.5 Group Operations for Internal Forces.
www.3ds.com/tosca
SIMULIA
Tosca Structure
Design Responses
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Fig. 67
SIMULIA
Tosca Structure
Terms for Optimization
Fig. 68
www.3ds.com/tosca
DRESP
ID_NAME
DEF_TYPE
TYPE
EL_GROUP
ND_GROUP
LC_SET
GROUP_OPER
CS_REF
END_
4.4.6
=
=
=
=
=
=
=
=
internal_force_response
SYSTEM
INTERNAL_FORCE_Y
EL_INTERNAL_GROUP
ND_INTERNAL_GROUP
ALL,1,All
Sum
CS_0
Eigenfrequency
DYN_FREQ
fj
SIMULIA
Tosca Structure
Design Responses
DYN_FREQ_KREISSEL
kf j
1
--- ln
e ,
k j
30
by default k = ---------f min
( 4 f M K ) = 0
TOPO
SHAPE
BEAD
SIZING
OBJ_FUNC
S*
C, S*
S*
CONSTRAINT
S*
S*
S*
Table 13
kf j
30
1
--- ln
e , by default k = ---------
f min
k j
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Terms for Optimization
The
Kreisselmaier-Steinhauser
formulation
is
defined
by
DYN_FREQ_KREISSEL in the design response. For this design response
mode tracking is not needed.
For the other optimization tasks mode tracking is often necessary because
the modes and thereby the eigenfrequencies may switch during the optimization.
www.3ds.com/tosca
SIMULIA
Tosca Structure
Design Responses
Fig. 69
SIMULIA
Tosca Structure
Terms for Optimization
Fig. 70
www.3ds.com/tosca
Fig. 71
=
=
=
=
freq_kreissel
DYN_FREQ_KREISSEL
SYSTEM
MODAL,ALL,1-5
SIMULIA
Tosca Structure
Design Responses
LC_SEL
END_
= MIN
Mode tracking is activated using the optimization parameter MODETRACKING= ON. The second item in MODETRACKING defines the node group
which is used for the mode tracking. The node group can improve performance when the node group is small. If no node group is defined all nodes in
the model will be applied as default. This is reasonable for small to medium
sized finite element models. By default the mode tracking applies for 5
modes. This can be changed by the item MODENUMBERS =
<number_modes>. This number should not be set too high otherwise the
CPU-time might have a significant increase.
Using the parameter MODETRACK_REFERENCE for the Modal Assurance
Criterion (MAC) allows the user to define the reference modes applied when
tracking the modes during the optimization iterations. If the parameter
MODETRACK_REFERENCE is set to INITIAL then the reference modes are
set to be the modes of the initial optimization iteration throughout the entire
optimization history. If the parameter MODETRACK_REFERENCE is set to
PREVIOUS then the reference modes are always set to be the modes of the
previous optimization iteration.
Typically, setting MODETRACK_REFERENCE to INITIAL is the most consistent comparison in the modetracking. However, some initial modes may
change significantly or completely disappear during the optimization iterations and thereby, the INITIAL comparison may fail. When INITIAL as setting
for MODETRACK_REFERENCE is failing then the only option is to apply
PREVIOUS even though the comparison might not be so consistent as INITIAL.
4.4.7
Equivalent stress
SIG_1
SIG_2
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
MODETRACKING
=<ON/OFF>, <NODE_GROUP>
MODENUMBERS
=<NUMBER_MODES>
MODETRACK_REFERENCE =INITIAL | PREVIOUS
SIMULIA
Tosca Structure
Terms for Optimization
SIG_3
SIG_11
11
SIG_22
22
SIG_33
33
SIG_12
12
SIG_23
23
SIG_13
13
SIG_ABS_123
max ( 1 , 2 , 3 )
SIG_ABS_3
SIG_MISES
SIG_TRESCA
1--2
2
2
{ ( 1 2 ) + ( 2 3 ) + ( 1 3 ) }
2
max ( 1 2 , 2 3 , 3 1 )
SIG_BELTRAMI
SIG_GALILEI
SIG_KUHN
SIG_MARIOTTE
www.3ds.com/tosca
SIG_SANDEL
2
[ 1 + 2 + 3
1---
2
2
2 -----------------2- ( 1 2 + 2 3 + 1 3 ) ]
1 + 2
SIG_SAUTER
1 2 + 2 3 + 3 1
SIG_DRUCKER_PRAGER
STRAIN_ENERGY
1 T
c = --- u Ku
2
SIMULIA
Tosca Structure
Design Responses
STRAIN_ENERGY_
DENSITY
1 T
c = ------- u Ku
2V
DAMAGE_LC
DAMAGE
SIG_CONTACT_SHEAR
SIG_CONTACT_
SHEAR_X
SIG_CONTACT_
SHEAR_Y
SIG_CONTACT_TOTAL
STRAIN_ELASTIC
1 + 2
p + 1 + 2
2
2
2
2
- ( e ) + ( e ) + ( e )
-11
22
33
3
2
2
2
+2 ( e ) + ( e ) + ( e )
12
13
23
STRAIN_PLASTIC
1--2
2
2
2
2
- ( p ) + ( p ) + ( p )
-11
22
33
3
2
2
2
+2 ( p ) + ( p ) + ( p )
12
13
23
1--2
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIG_CONTACT_PRESSU
RE
SIMULIA
Tosca Structure
Terms for Optimization
STRAIN_TOTAL
2 2
2
2
- [ 11 + 22 + 33
-3
2
2
2
+2 ( 12 + 13 + 23 ) ]
ABQ_ND_PEEQ
1--2
Analysis types: Any analysis type with stress output or fatigue result
TOPO
OBJ_FUNC
SHAPE
BEAD
SIZING
CONSTRAINT
www.3ds.com/tosca
Table 14
The equivalent stresses are the main input for the shape optimization controller algorithm. All values, whether nodal, from gauss points or elements, are
interpolated to the nodes. Equivalent stress is only allowed in the objective
function by controller based shape optimization.
Typical optimization tasks:
1. Minimize maximal von Mises stress (see vol.2 chapter 6.6.1, Minimization
of maximum equivalent stress)
2. Minimize maximal damage (fatigue analysis)
3. Minimize contact pressure in a contact region (see vol.2 chapter 6.7.2,
Minimization of contact pressure)
Equivalent stresses are always read for ALL_NODES to give the user the
most appropriate output. This will give some warnings for nodes which do not
SIMULIA
Tosca Structure
Design Responses
have any equivalent stress values, e.g., nodes on elements which are not in
contact when evaluating SIG_CONTACT_... .
Remark:
Plastic strain values (TYPE = STRAIN_PLASTIC) are calculated by Tosca
Structure and may differ slightly from your solver results.
4.4.8
( vMises )
SIG_TOPO_MISES = Max -------------------------2 y
( f ( i ) y )
The vMises is the elemental centroidal von Mises stress, y is the reference
stress and f ( i ) is a factor for interpolating the stresses of the elements having intermediate densities (given by the topology optimization, see vol.2
chapter 4: Stress interpolation).
Only von Mises stress can be applied in topology optimization.
Analysis type: Static linear and non-linear (contact) analysis (no geometrical and material non-linearities in element group)
TOPO
OBJ_FUNC
CONSTRAINT
BEAD
SIZING
Weighted centroidal von Mises stress for topology optimization (C = controller, S = sensitivity)
Remarks
Stress applied in topology optimization cannot directly be compared to the
von Mises stress given as output from the finite element solver. Only for solid
elements ( = 1 ) the von Mises stresses given by Tosca Structure stresses
is equal to the von Mises stresses as output from the FE-solver (see vol.2
chapter 4: Stress interpolation).
Please note:
Topology optimization using stresses as DRESP is implemented as a prerelease feature at Tosca Structure version 7.2.0.
Consequently, this newly developed feature may not yet be applied to all possible practical scenarios. Thus, we appreciate your feedback since this feature is still under development.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Table 15
SHAPE
SIMULIA
Tosca Structure
Terms for Optimization
Stress calculation
The von Mises stress is calculated in the elemental centroid for avoiding
stress singularities which might be present in the initial model or appear in the
non-smoothed topology optimized structures.
singular
stresses
Fig. 72
Singular stresses caused by the initial model (left) and by a nonsmooth topology optimized structure (right)
www.3ds.com/tosca
where <reference stress 1> and <reference stress 2> correspond to ref . The reference stress values should not be chosen too low as
this might cause numerical singularities. This corresponds to
2
2
( vMises )
( vMises )
+
If the user does not define a reference stress in the objective function command then Tosca Structure automatically determines a reference stress,
which is generated in the initial optimization iteration and is written to
TOSCA.OUT.
Constraint value
A limitation on the stresses can be formed for a DRESP of type
SIG_TOPO_MISES used in a constraint definition with the LE_VALUE
parameter:
SIMULIA
Tosca Structure
Design Responses
CONSTRAINT
ID_NAME
DRESP
MAGNITUDE
LE_VALUE
=
=
=
=
STRESS_CONSTRAINT
DRESP_STRESS_ID
ABS
<stress_constraint>
END_
( vMises )
Max -----------------------------2- con con
( f ( i ) con )
Remarks
1. ref is equal to the reference value when the DRESP defined by
SIG_TOPO_MISES is applied in the objective function. The reference
stress ref can be changed by modifying the reference value in the objective.
2. con is equal to LE_VALUE (or GE_VALUE) when the DRESP defined by
SIG_TOPO_MISES is applied in a constraint.
3. A DRESP being TYPE = SIG_TOPO_MISES can only be applied once in
the objective function or as constraint!.
4. Note that a reference stress or constrained stress which is too low might
cause numerical singularities.
The factor f ( i ) describes a function for the interpolation of stresses depending of the density i of the element i.
The interpolation is needed because during the topology optimization the
densities of the elements are modified and can have a minimum value close
to zero. Stress values calculated by the solver for transition or soft elements
(i.e. elements with low density) have no real physical meaning for the
stresses and must be weighted by a factor to allow for a successful optimization convergence.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Stress interpolation
SIMULIA
Tosca Structure
Terms for Optimization
.
Different densities of several elements
during topology optimization
Void
Initial
Fig. 73
Optimized
Thus, the stress measure SIG_TOPO_MISES applied in topology optimization cannot be directly compared to the von Mises stresses seen as output
from the finite element solver. Only for solid elements ( = 1 ) the
www.3ds.com/tosca
E ( i )
------------- f ( i )
E0
SIMULIA
Tosca Structure
Design Responses
( vMises )
vMises
f ( i = 1 ) = 1 -------------------------2 = ------------------( f ( i ) y )
y2
2
vMises
-------------------- = 1 DRESP = vMises = con
2
con
Element group
The element group for the stress measure can consist of both design and
non-design elements.
Frequently, the initial model for the optimization contains non-physical modeling around loaded nodes and boundary conditions, respectively. The user
should avoid including stresses from stress singularities caused by external
loaded nodes or by boundary conditions. These singularities are eliminated
by excluding these elements from the group used for calculating the DRESP.
The user should exclude elements with loaded nodes and boundary conditions to avoid stress singularities.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Fig. 74
SIMULIA
Tosca Structure
Terms for Optimization
Pyramidal 5 and 13 node elements as well as shell elements are not supported.
Remark:
1. Shear and volume locking in the finite element yield wrong results not only
in the finite element analysis but can also cause optimization convergence
problems when such stress responses are included in the optimization
formulation. Especially, the linear 4 node tetrahedral elements should be
avoided. Instead it is recommended to use the quadratic10 node tetrahedral element or the linear 8 node hexahedral element.
Loadcases
Several loadcases can be defined for the stress measure.
Static linear analysis is supported. For static non-linear analysis only contact
is supported. Thus, geometrical non-linearities (like large deformation) and
non-linear materials are not supported.
www.3ds.com/tosca
Not yet available with Tosca ANSA environment 13.2.x. Stresses as design
responses are only supported for ANSA version 13.3.0 and later.
SIMULIA
Tosca Structure
Design Responses
Fig. 75
Fig. 76
=
=
=
=
=
TOPO_STRESS_DESIGN_ELEMENTS
SIG_TOPO_MISES
SYSTEM
<element_group>
<loadcases>
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Add a design response to the project first, then chose Stress/Strain as Category and SIG_Topo_Mises as Response Type.
SIMULIA
Tosca Structure
Terms for Optimization
The design response for stresses is applied in the objective function as the
following:
OBJ_FUNC
ID_NAME = OBJ_FUNCTION_ID
DRESP
= SIG_TOPO_MISES,<weight_fact_1>, <ref_stress_1>
...........
TARGET = MIN
END_
www.3ds.com/tosca
Fig. 77
SIMULIA
Tosca Structure
Design Responses
and select the perviously defined von Mises stress design response, set Type
to Absolute, Category to Less or equal and set the desired value.
Fig. 78
=
=
=
=
=
TOPO_STRESS_DESIGN_ELEMENTS
SIG_TOPO_MISES
SYSTEM
<element_group>
<loadcases>
END_
STRESS_CONSTRAINT
TOPO_STRESS_DESIGN_ELEMENTS
ABS
<stress constraint>
END_
Remarks
1. Each design response definition of type SIG_TOPO_MISES may only be
applied once in either the objective or constraint definition. If stresses
should be considered both in constraint or the objective (or several
stresses should be combined) for each use one separate design response
has to be defined.
2. Different optimization settings (STRESS_DRESP_OPT = ON) are applied for
updating the design variables (=relative densities) when DRESP is TYPE =
SIG_TOPO_MISES.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
ID_NAME
DRESP
MAGNITUDE
LE_VALUE
SIMULIA
Tosca Structure
Terms for Optimization
www.3ds.com/tosca
4.4.9
Center of gravity
CENTER_GRAVITY_X
x dV
x G = ---------------- dV
CENTER_GRAVITY_Y
y dV
y G = ---------------- dV
CENTER_GRAVITY_Z
xz dV
z G = ------------------- dV
TOPO
OBJ_FUNC
SHAPE
BEAD
SIZING
SIMULIA
Tosca Structure
Design Responses
TOPO
CONSTRAINT
Table 16
SHAPE
BEAD
SIZING
Fig. 79
The center of gravity and the moments of inertia can be calculated in the global coordinate system or/and a user defined local
Cartesian coordinate system. The calculation in the local coordinate system involves both a translation of the origin and a rotation of the coordinate system.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Terms for Optimization
Remarks
1. Only elements of the element group (EL_GROUP) listed in the tables of
supported element types (chapter 11 Solver Specific Features) will be
applied in the calculation of center of gravity.
2. The physical density defined in finite element input deck will be used in the
calculation for the center of gravity.
3. The moments of inertia for shell and membrane elements are calculated as
true 3D elements in Tosca Structure using the thickness defined in the
properties of the shell and membrane elements in the finite element deck.
Some finite element solvers and postprocessors calculate the moments of
inertia for shell and membrane elements as 2D elements without thickness.
4. The physical density defined in finite element input deck will be used in the
calculation for the center of gravity and in the calculation for the moments
of inertia.
5. Internally, Tosca Structure calculates the center of gravity and the moments
of inertia using more digits than can be observed in the finite element input
deck. A slight difference (<1%) between the center of gravity and the
moments of inertia calculated using Tosca Structure and the finite element
solver might be present.
www.3ds.com/tosca
6. When Tosca Structure calculates the center of gravity and the moments of
inertia only the elements shown in the tables of supported element types
(chapter 11 Solver Specific Features) are included in the calculation. This
might lead to a significant difference between the center of gravity and the
moments of inertia calculated by Tosca Structure and the center of gravity
and the moments of inertia calculated by the finite element solver, e.g. if
several beam elements are included in the calculation of the center of
gravity and the moments of inertia.
7. The coordinate system for the center of gravity and the moments of inertia
is always interpreted as a Cartesian (rectangular) coordinate system, even
if a cylindrical or spherical coordinate system was defined. To get close to a
non-Cartesian coordinate system you can define adequate "box
constraints" using several constraints (e.g. in x- and y-direction for a cylindrical coordinate system).
Definition
The design response (DRESP) for the center of gravity in the x-direction is
defined like
DRESP
SIMULIA
Tosca Structure
Design Responses
ID_NAME
DEF_TYPE
TYPE
EL_GROUP
CS_REF
=
=
=
=
=
...
SYSTEM
CENTER_GRAVITY_X
...
...
END_
=
=
=
=
=
...
SYSTEM
CENTER_GRAVITY_Y
...
...
END_
...
SYSTEM
CENTER_GRAVITY_Z
...
...
END_
= DRESP_COG_Y_GLOBAL
= SYSTEM
= CENTER_GRAVITY_Y
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
ID_NAME
DEF_TYPE
TYPE
EL_GROUP
CS_REF
SIMULIA
Tosca Structure
Terms for Optimization
EL_GROUP
= ALL_ELEMENTS
END_
E.g., the definition of the design response (DRESP) for the center of gravity
for the y-direction of the substructure called EL_GROUP_2 is calculated in
the local coordinate system number 23 like the following:
DRESP
ID_NAME
DEF_TYPE
TYPE
EL_GROUP
CS_REF
=
=
=
=
=
DRESP_COG_X
SYSTEM
CENTER_GRAVITY_X
EL_GROUP_2
CS_23
END_
INERTIA_YY
www.3ds.com/tosca
INERTIA_ZZ
Ix =
( y2 + z2 ) dV
Iy =
( x2 + z2 ) dV
Iz =
( x2 + y2 ) dV
INERTIA_XY
I xy = I yx = xy dV
INERTIA_XZ
I xz = I zx = xz dV
INERTIA_YZ
I yz = I zy = yz dV
TOPO
OBJ_FUNC
SHAPE
BEAD
SIZING
SIMULIA
Tosca Structure
Design Responses
TOPO
CONSTRAINT
Table 17
SHAPE
BEAD
SIZING
The moments of inertia can be applied as DRESP (topology, sizing and bead
optimization) and as VARIABLE (topology, sizing, shape and bead optimization). The moments of inertia are defined using INERTIA_XX, INERTIA_XY
(INERTIA_YX), INERTIA_XZ (INERTIA_ZX), INERTIA_YY, INERTIA_YZ
(INERTIA_ZY) and INERTIA_ZZ, respectively.
Mathematically, the moments of inertia about the origin of the coordinate system are given by the above integrals which can be calculated in a global or a
local coordinate system as shown in Fig. 79. The local coordinate system is
defined using CS_REF. The volume for which the moments of inertia are calculated is defined using EL_GROUP.
Remarks
1. Only the elements of the element group (EL_GROUP) listed in the tables of
supported element types (chapter 11 Solver Specific Features) will be
applied in the calculation of moments of inertia.
2. The product of inertia with respect to any two orthogonal axes is zero if
either of the axes is an axis of symmetry.
3. The physical density defined in finite element input deck will be used in the
calculation of the moments of inertia.
DRESP
ID_NAME
DEF_TYPE
TYPE
EL_GROUP
CS_REF
=
=
=
=
=
...
SYSTEM
INERTIA_XX
...
...
END_
The design response (DRESP) for the moment of inertia about the line
through the origin, parallel to the Y-axis is defined like
DRESP
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
The design response (DRESP) for the moment of inertia about the line
through the origin, parallel to the X-axis is defined like
SIMULIA
Tosca Structure
Terms for Optimization
ID_NAME
DEF_TYPE
TYPE
EL_GROUP
CS_REF
=
=
=
=
=
...
SYSTEM
INERTIA_YY
...
...
END_
The design response (DRESP) for the moment of inertia about the line
through the origin, parallel to the Z-axis is defined like
DRESP
ID_NAME
DEF_TYPE
TYPE
EL_GROUP
CS_REF
=
=
=
=
=
...
SYSTEM
INERTIA_ZZ
...
...
END_
The design response (DRESP) for the moment of inertia describing the coupling between the rotation parallel to the X-axis and the rotation parallel to the
Y-axis yields
DRESP
ID_NAME
DEF_TYPE
TYPE
EL_GROUP
CS_REF
= ...
= SYSTEM
= INERTIA_XY
(Alternatively, TYPE =INERTIA_YX)
= ...
= ...
www.3ds.com/tosca
END_
The design response (DRESP) for the moment of inertia describing the coupling between the rotation parallel to the X-axis and the rotation parallel to the
Z-axis yields
DRESP
ID_NAME
DEF_TYPE
TYPE
EL_GROUP
CS_REF
= ...
= SYSTEM
= INERTIA_XZ
(Alternatively, TYPE = INERTIA_ZX)
= ...
= ...
END_
SIMULIA
Tosca Structure
Design Responses
The design response (DRESP) for the moment of inertia describing the coupling between the rotation parallel to the Y-axis and the rotation parallel to the
Z-axis yields
DRESP
ID_NAME
DEF_TYPE
TYPE
EL_GROUP
CS_REF
= ...
= SYSTEM
= INERTIA_YZ
(Alternatively, TYPE = INERTIA_YZ)
= ...
= ...
END_
Examples of commands
E.g. the design response (DRESP) for the moment of inertia of the entire
structure (ALL_ELEMENTS) about the line through the origin of the global
coordinate system, parallel to the Y-axis is defined like
DRESP
ID_NAME
DEF_TYPE
TYPE
EL_GROUP
=
=
=
=
DRESP_INERTIA_YY_GLOBAL
SYSTEM
INERTIA_YY
ALL_ELEMENTS
END_
DRESP
ID_NAME
DEF_TYPE
TYPE
EL_GROUP
CS_REF
END_
=
=
=
=
=
DRESP_INERTIA_YY_LOCAL
SYSTEM
CENTER_GRAVITY_X
EL_GROUP_2
CS_23
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
E.g. The definition of the design response (DRESP) for the moment of inertia
of the substructure called EL_GROUP_2 is calculated about the line through
the origin of the local coordinate system number 23, parallel to the Y-axis is
like the following
SIMULIA
Tosca Structure
Terms for Optimization
4.4.11 Volume
VOLUME
Ve
TOPO
OBJ_FUNC
CONSTRAINT
Table 18
SHAPE
BEAD
S
C, S
SIZING
S
www.3ds.com/tosca
SIMULIA
Tosca Structure
Design Responses
Fig. 80
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Terms for Optimization
=
=
=
=
=
volume
SYSTEM
VOLUME
DESIGN_ELEMS
Sum
4.4.12 Weight
WEIGHT
we
CONSTRAINT
www.3ds.com/tosca
Table 19
SHAPE
BEAD
SIZING
S
The weight term is the same as the volume term except you have the possibility of constraining your optimization result to have a certain physical weight.
Tosca Structure requires that the density of all elements is defined in the input
deck. Additionally, only supported element types are used in the weight calculation.
for
the
element
group
SIMULIA
Tosca Structure
Design Responses
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Terms for Optimization
Add a design response to the project, select Base as Category and Weight as
Response Type. Then choose the predefined Named Selection by setting
Scoping Method to Named Selection.
Fig. 81
=
=
=
=
=
weight
SYSTEM
WEIGHT
DESIGN_ELEMS
Sum
4.4.13 DENSITY_MEASURE
DENSITY_MEASURE
4
------------------Volume
Volume
Nel
4
( 1 ) dv --------
( 1 e )
N el e = 1 e
where e is the relative density in each element of the given user defined
element group and N el is the number of elements in the defined element
group, respectively.
www.3ds.com/tosca
SIMULIA
Tosca Structure
Design Responses
CONSTRAINT
Table 20
SHAPE
BEAD
SIZING
0.5
1.0
1.0
0.0
min
DRESP DENSITY_MEASURE yields the value 1.0 for the intermediate density
0.5 of all elements.
DRESP DENSITY_MEASURE yields the value 0.0 for the intermediate density
1.0 of all elements.
DRESP DENSITY_MEASURE yields the value 4 min ( 1 min ) 4 min for the
intermediate minimum density min of all elements.
Fig. 82
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Terms for Optimization
Or
www.3ds.com/tosca
CONSTRAINT
ID_NAME
= DENSITY_MEASURE_constraint
DRESP
= DRESP_ DENSITY_MEASURE
MAGNITUDE = ABS
LE_VALUE
= 0.05
END_
REMARKS
1. The DRESP DENSITY_MEASURE is only for advanced applications. In
particular, it is aimed at advanced dynamic applications like modal eigenfrequency analysis and frequency response analysis
2. The weighting factor has to be carefully chosen when applying the DRESP
DENSITY_MEASURE in the objective function. Otherwise, only one of the
objective terms would be optimized.
SIMULIA
Tosca Structure
Design Responses
3. The constraint value has to be carefully chosen when applying the DRESP
DENSITY_MEASURE as constraint. Otherwise, there might be no feasible
solution.
4. The constraint value for DRESP DENSITY_MEASURE cannot be lower than
4 minimum density (DENSITY_LOWER) which is default
4 0.001 ( 1 0.001 ) 0.004 .
5. Normally, the DRESP DENSITY_MEASURE yields a significant higher
number of optimization iterations.
SHAPE
BEAD
SIZING
OBJ_FUNC
CONSTRAINT
=
=
=
=
=
DRESP_BEAD_HEIGHT
SYSTEM
DESIGN_NODES
BEAD_HEIGHT
MAX
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Table 21
SIMULIA
Tosca Structure
Terms for Optimization
CONSTRAINT
ID_NAME
DRESP
MAGNITUDE
EQ_VALUE
END_
4.5
=
=
=
=
bead_height
dresp_bead_height
ABS
10.
Combined Terms
For getting the scalar value of a design response or a variable it is necessary
to combine values derived from model properties or analysis results. This
could be done getting the maximum or minimum value within a number of
load cases or a number of group entities or creating response combinations
like relative values, differences or mean values. In Tosca Structure combination of values can be performed in several ways:
1. The simplest way to combine terms is using a weighted sum for the objective function, or using a MINMAX formulation with the different weighting of
the design responses. See chapter 4.2 Objective Function for more information.
www.3ds.com/tosca
Remark:
If several of these possibilities to combine values are applied, Tosca Structure
operates as follows:
1. First the value over all entities of the group for one load case is calculated.
This means that a loop over all entities of the group is executed and then
the value of the inner loop is calculated with the operator specified in
SIMULIA
Tosca Structure
Combined Terms
4.5.1
=
=
=
=
= <group_entities_for_combination>
= <group_entities_for_combination>
= MAX | MIN | SUM | COUNT
END_
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Terms for Optimization
2. In Tosca ANSA environment, the operator can only be changed using the
commands from Module Buttons toolbar that deal with design responses
(variables).
3. Maximal 500 design responses are allowed. Therefore, the maximal
number of nodes for GROUP_OPER = MAX is restricted to 500, as internally there is created one design response for each node.
4. For sensitivity based optimization the objective function built from design
responses combining several entities (nodes) will be replaced by a subsitute expression built from the single design responses. For TARGET=MAX
this means that the sum of the single design responses is optimized. For
an example see chapter 4.5.1.3 Group Operations for Displacements.
5. Not all group operators make sense for all kind of design responses. An
overview which group operators are admitted for specific design responses
can be found in chapter 4.5.3 Design response combination.
=
=
=
=
=
=
DRESP_MAX_MISES
SYSTEM
SIG_MISES
EVER
DESIGN_NODES
MAX
www.3ds.com/tosca
END_
=
=
=
=
=
DRESP_SUM_ENERGY
SYSTEM
STRAIN_ENERGY
EVER
ALL_ELEMENTS
SIMULIA
Tosca Structure
Combined Terms
GROUP_OPER
= SUM
END_
Fig. 83
A structure loaded with three loads in the nodes 15, 16 and 17,
respectively. The displacements of the three nodes should be
minimized or applied in a set of constraints using
GROUP_OPER=MAX or GROUP_OPER=SUM.
ID_NAME
TYPE
FORMAT
LIST_BEGIN
15, 16, 17
= DISP_NODES
= NODE
= LIST
END_
GROUP_OPER = MAX
Based upon the node group a design response for the displacements in ydirections are defined in a DRESP using GROUP_OPER=MAX yielding
DRESP
ID_NAME
DEF_TYPE
= DRESP_DISP_MAX
= SYSTEM
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
GROUP_DEF
SIMULIA
Tosca Structure
Terms for Optimization
TYPE
LC_SET
ND_GROUP
GROUP_OPER
=
=
=
=
DISP_Y
STATIC,1,
DISP_NODES
MAX
END_
Internally, Tosca Structure generates three DRESPs. One DRESP for the displacement of node 15, one DRESP for the displacement of node 16 and one
DRESP for the displacement of node 17.
If one then applies the DRESP in the objective yielding:
OBJ_FUNC
ID_NAME
DRESP
TARGET
= MIN_DISP_MAX
= DRESP_DISP_MAX
= MIN
END_
Tosca Structure then sums up the three displacements like the following:
minimize { 0 } = minimize { u 15 + u 16 + u 17 }
Remark:
If you want to minimize the maximum of the three displacements you need to
define an objective function with target MIN_MAX operating on three design
responses (one for each node).
minimize { 0 } = max { u 15 ;u 16 ;u 17 }
GROUP_OPER = SUM
www.3ds.com/tosca
Based upon the node group a design response for the displacements in ydirections are defined in a DRESP using GROUP_OPER=SUM yielding
DRESP
ID_NAME
DEF_TYPE
TYPE
LC_SET
ND_GROUP
GROUP_OPER
END_
=
=
=
=
=
=
DRESP_DISP_SUM
SYSTEM
DISP_Y
STATIC,1,
DISP_NODES
SUM
Internally, Tosca Structure generates one DRESP consisting of the sum of the
displacements of the nodes 15, 16 and 17.
If one then applies the DRESP in the objective yielding:
SIMULIA
Tosca Structure
Combined Terms
OBJ_FUNC
ID_NAME
DRESP
TARGET
END_
= MIN_DISP_SUM
= DRESP_DISP_SUM
= MIN
Tosca Structure then sum up the three displacements like the following;
minimize { 0 } = minimize { u 15 + u 16 + u 17 }
Alternative definition of objective function
Alternatively, one could also define three DRESPs for each node like the following:
DRESP
ID_NAME
DEF_TYPE
TYPE
NODE
LC_SET
GROUP_OPER
=
=
=
=
=
=
DRESP_DISP_1
SYSTEM
DISP_Y
15
STATIC,1
MAX or SUM
=
=
=
=
=
=
DRESP_DISP_2
SYSTEM
DISP_Y
16
STATIC,1
MAX or SUM
=
=
=
=
=
=
DRESP_DISP_3
SYSTEM
DISP_Y
17
STATIC,1
MAX or SUM
END_
DRESP
ID_NAME
DEF_TYPE
TYPE
NODE
LC_SET
GROUP_OPER
END_
ID_NAME
DEF_TYPE
TYPE
NODE
LC_SET
GROUP_OPER
END_
And then add the three design response in the objective function:
OBJ_FUNC
ID_NAME
DRESP
DRESP
= MIN_DISP_SUM
= DRESP_DISP_1
= DRESP_DISP_2
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
DRESP
SIMULIA
Tosca Structure
Terms for Optimization
DRESP
TARGET
= DRESP_DISP_3
= MIN
END_
minimize { 0 } = minimize { u 15 + u 16 + u 17 }
Remark:
Consequently, it can be concluded that all three ways of defining the optimization leads to the same objective function. In this case it is strongly recommended to combine the displacements using GROUP_OPER = SUM which
results in a much better performance.
Use in Constraints
Initially, a node group is defined containing the nodes 15, 16 and 17 (see Fig.
83) yielding
GROUP_DEF
ID_NAME
TYPE
FORMAT
LIST_BEGIN
15, 16, 17
= DISP_NODES
= NODE
= LIST
END_
GROUP_OPER = MAX
Based upon the node group a design response for the displacements in ydirections are defined in a DRESP using GROUP_OPER=MAX yielding
www.3ds.com/tosca
DRESP
ID_NAME
DEF_TYPE
TYPE
LC_SET
ND_GROUP
GROUP_OPER
=
=
=
=
=
=
DRESP_DISP_MAX
SYSTEM
DISP_Y
STATIC,1,
DISP_NODES
MAX
END_
Internally, Tosca Structure generates three DRESPs. One DRESP for the displacement of node 15, one DRESP for the displacement of node 16 and one
DRESP for the displacement of node 17.
If one then applies the DRESP in a constraint yielding:
CONSTRAINT
ID_NAME
DRESP
= CONSTRAINT_MAX
= DRESP_DISP_MAX
SIMULIA
Tosca Structure
Combined Terms
MAGNITUDE
LE_VALUE
END_
= ABS
= <value>
Tosca Structure then generates three displacement constraints like the following;
u 15 u
u 16 u
u 17 u
GROUP_OPER = SUM
Based upon the node group a design response for the displacements in ydirections are defined in a DRESP using GROUP_OPER=SUM yielding
DRESP
ID_NAME
DEF_TYPE
TYPE
LC_SET
ND_GROUP
GROUP_MAX
END_
=
=
=
=
=
=
DRESP_DISP_SUM
SYSTEM
DISP_Y
STATIC,1,
DISP_NODES
SUM
Internally, Tosca Structure generates one DRESP consisting of the sum of the
displacements of the nodes 15, 16 and 17.
CONSTRAINT
ID_NAME
DRESP
MAGNITUDE
LE_VALUE
END_
=
=
=
=
CONSTRAINT_MAX
DRESP_DISP_MAX
ABS
<value>
Tosca Structure then generates a single displacement constraint like the following;
u 15 + u 16 + u 17 u
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Terms for Optimization
=
=
=
=
=
=
DRESP_DISP_1
SYSTEM
DISP_Y
15
STATIC,1
MAX or SUM
=
=
=
=
=
=
DRESP_DISP_2
SYSTEM
DISP_Y
16
STATIC,1
MAX or SUM
=
=
=
=
=
=
DRESP_DISP_3
SYSTEM
DISP_Y
17
STATIC,1
MAX or SUM
DRESP
ID_NAME
DEF_TYPE
TYPE
NODE
LC_SET
GROUP_OPER
END_
DRESP
ID_NAME
DEF_TYPE
TYPE
NODE
LC_SET
GROUP_OPER
END_
www.3ds.com/tosca
=
=
=
=
CONSTRAINT_1
DRESP_DISP_1
ABS
<value>
=
=
=
=
CONSTRAINT_2
DRESP_DISP_2
ABS
<value>
= CONSTRAINT_3
= DRESP_DISP_3
SIMULIA
Tosca Structure
Combined Terms
MAGNITUDE
LE_VALUE
END_
= ABS
= <value>
Tosca Structure then generates three displacement constraints like the following;
u 15 u
u 16 u
u 17 u
.....
SYSTEM
.....
MAX or SUM
.....or use the NODE-definition
.....or use the ND_GROUP-definition
.....
END_
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
ID_NAME
DEF_TYPE
TYPE
GROUP_OPER
ND_GROUP
NODE
LC_SEL
SIMULIA
Tosca Structure
Terms for Optimization
The picture at Fig. 84 shows a structure where the reaction forces in the ydirection of the three nodes 31, 32, 33 should be applied in a set of constraints.
Fig. 84
Use in Constraints
Initially, a node group is defined containing the nodes 31, 32 and 33 (see Fig.
84) yielding
GROUP_DEF
ID_NAME
TYPE
FORMAT
LIST_BEGIN
31, 32, 33
= REAC_NODES
= NODE
= LIST
END_
www.3ds.com/tosca
GROUP_OPER = MAX
Based upon the node group a design response for the reaction force in ydirections are defined in a DRESP using GROUP_OPER=MAX yielding
DRESP
ID_NAME
DEF_TYPE
TYPE
LC_SET
ND_GROUP
GROUP_OPER
=
=
=
=
=
=
DRESP_REAC_MAX
SYSTEM
REACTION_FORCE_Y
STATIC,1,
REAC_NODES
MAX
END_
SIMULIA
Tosca Structure
Combined Terms
Internally, Tosca Structure generates three DRESPs. One DRESP for the
reaction force of node 31, one DRESP for the reaction force of node 32 and
one DRESP for the reaction force of node 33.
If one then applies the DRESP in a constraint yielding:
CONSTRAINT
ID_NAME
DRESP
MAGNITUDE
LE_VALUE
END_
=
=
=
=
CONSTRAINT_MAX
DRESP_REAC_MAX
ABS
<value>
Tosca Structure then generates three reaction force constraints like the following;
R 31 R*
R 32 R*
R 33 R*
GROUP_OPER = SUM
Based upon the node group a design response for the reaction force in ydirections are defined in a DRESP using GROUP_OPER=SUM yielding
=
=
=
=
=
=
DRESP_REAC_SUM
SYSTEM
REACTION_FORCE_Y
STATIC,1,
REAC_NODES
SUM
Internally, Tosca Structure generates one DRESP consisting of the sum of the
reaction forces of the nodes 31, 32 and 33.
If one then applies the DRESP in a constraint yielding:
CONSTRAINT
ID_NAME
DRESP
MAGNITUDE
LE_VALUE
END_
=
=
=
=
CONSTRAINT_MAX
DRESP_REAC_MAX
ABS
<value>
Tosca Structure then generates a single reaction force constraint like the following;
R 31 + R 32 + R 33 R*
2 - 154 User Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
DRESP
ID_NAME
DEF_TYPE
TYPE
LC_SET
ND_GROUP
GROUP_OPER
END_
SIMULIA
Tosca Structure
Terms for Optimization
=
=
=
=
=
=
DRESP_REAC_1
SYSTEM
REACTION_FORCE_Y
31
STATIC,1
MAX or SUM
=
=
=
=
=
=
DRESP_REAC_2
SYSTEM
REACTION_FORCE_Y
32
STATIC,1
MAX or SUM
=
=
=
=
=
=
DRESP_REAC_3
SYSTEM
REACTION_FORCE_Y
33
STATIC,1
MAX or SUM
DRESP
ID_NAME
DEF_TYPE
TYPE
NODE
LC_SET
GROUP_OPER
END_
DRESP
ID_NAME
DEF_TYPE
TYPE
NODE
LC_SET
GROUP_OPER
END_
www.3ds.com/tosca
=
=
=
=
CONSTRAINT_1
DRESP_REAC_1
ABS
<value>
=
=
=
=
CONSTRAINT_2
DRESP_REAC_2
ABS
<value>
= CONSTRAINT_3
= DRESP_REAC_3
SIMULIA
Tosca Structure
Combined Terms
MAGNITUDE
LE_VALUE
END_
= ABS
= <value>
Tosca Structure then generates three reaction force constraints like the following;
R 31 R*
R 32 R*
R 33 R*
Consequently, it can be concluded that there is fundamental difference in the
constraints if a node group (ND_GROUP) consisting of more than one node
is applied and the choice of GROUP_OPER.
Fig. 85
A structure loaded with three loads. The internal forces of the two
nodes 65 and 66 and elements 33, 34, 37 and 38 should be
applied in a set of constraints using GROUP_OPER=MAX or
GROUP_OPER=SUM.
Use in Constraints
Initially, a node group is defined containing the nodes 65 and 66 (see Fig. 85)
yielding
GROUP_DEF
ID_NAME
TYPE
FORMAT
LIST_BEGIN
= FORCE_NODES
= NODE
= LIST
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
The picture at Fig. 85 shows a structure where the internal forces in the ydirection of the two nodes 65 and 66 for elements 33, 34, 37 and 38 should
be applied in a set of constraints.
SIMULIA
Tosca Structure
Terms for Optimization
65, 66
END_
and a element group is defined containing the elements 33, 34, 37 and 38
(see Fig. 85) yielding
GROUP_DEF
ID_NAME
= FORCE_ELEM
TYPE
= ELEM
FORMAT
= LIST
LIST_BEGIN
33, 34, 37, 38
END_
GROUP_OPER = MAX
Based upon the node group and the element group a design response for the
internal force in y-directions are defined in a DRESP using
GROUP_OPER=MAX yielding
DRESP
ID_NAME
DEF_TYPE
TYPE
LC_SET
ND_GROUP
EL_GROUP
GROUP_OPER
=
=
=
=
=
=
=
DRESP_FORCE_MAX
SYSTEM
INTERNAL_FORCE_Y
STATIC,1,
FORCE_NODES
FORCE_ELEM
MAX
END_
www.3ds.com/tosca
Internally, Tosca Structure generates two DRESPs. One DRESP for the internal force of node 65 for element 33 and 34, and one DRESP for the internal
force of node 66 for element 37 and 38.
If one then applies the DRESP in a constraint yielding:
CONSTRAINT
ID_NAME
DRESP
MAGNITUDE
LE_VALUE
END_
=
=
=
=
CONSTRAINT_MAX
DRESP_FORCE_MAX
ABS
<value>
Tosca Structure then generates two internal force constraints like the following;
F 65 F*
F 66 F*
SIMULIA
Tosca Structure
Combined Terms
GROUP_OPER = SUM
Based upon the node group a design response for the internal force in ydirections are defined in a DRESP using GROUP_OPER=SUM yielding
DRESP
ID_NAME
DEF_TYPE
TYPE
LC_SET
ND_GROUP
EL_GROUP
GROUP_OPER
END_
=
=
=
=
=
=
=
DRESP_FORCE_SUM
SYSTEM
INTERNAL_FORCE_Y
STATIC,1,
FORCE_NODES
FORCE_ELEM
SUM
Internally, Tosca Structure generates one DRESP consisting of the sum of the
internal forces of the nodes 65 and 66 for the elements 33, 34, 37 and 38.
If one then applies the DRESP in a constraint yielding:
CONSTRAINT
ID_NAME
DRESP
MAGNITUDE
LE_VALUE
END_
=
=
=
=
CONSTRAINT_MAX
DRESP_FORCE_MAX
ABS
<value>
Tosca Structure then generates a single internal force constraint like the following;
F 65 + F 66 F*
Alternatively, one could also define two DRESPs for each node like the following:
GROUP_DEF
ID_NAME
TYPE
FORMAT
LIST_BEGIN
33, 34
= FORCE_ELEM_1
= ELEM
= LIST
END_
DRESP
ID_NAME
DEF_TYPE
TYPE
= DRESP_FORCE_1
= SYSTEM
= INTERNAL_FORCE_Y
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Terms for Optimization
NODE
EL_GROUP
LC_SET
GROUP_OPER
END_
=
=
=
=
65
FORCE_ELEM_1
STATIC,1
MAX or SUM
GROUP_DEF
ID_NAME
TYPE
FORMAT
LIST_BEGIN
37, 38
END_
= FORCE_ELEM_2
= ELEM
= LIST
DRESP
ID_NAME
DEF_TYPE
TYPE
NODE
EL_GROUP
LC_SET
GROUP_OPER
=
=
=
=
=
=
=
DRESP_FORCE_2
SYSTEM
INTERNAL_FORCE_Y
66
FORCE_ELEM_2
STATIC,1
MAX or SUM
END_
www.3ds.com/tosca
=
=
=
=
CONSTRAINT_1
DRESP_FORCE_1
ABS
<value>
CONSTRAINT
ID_NAME
DRESP
MAGNITUDE
LE_VALUE
END_
=
=
=
=
CONSTRAINT_2
DRESP_FORCE_2
ABS
<value>
Tosca Structure then generates two internal force constraints like the following;
F 65 F*
F 66 F*
SIMULIA
Tosca Structure
Combined Terms
4.5.2
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Terms for Optimization
www.3ds.com/tosca
SIMULIA
Tosca Structure
Combined Terms
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Fig. 86
SIMULIA
Tosca Structure
Terms for Optimization
www.3ds.com/tosca
Fig. 87
If more than one FE input file is used, then the numbering of load cases is not
necessarily unique because the numbering of load cases might start with 1 in
each input file. For avoiding this problem, the GUI offers the possibility to
select the name of the file that contains the load case to be used in the design
response definition. The load cases in the first referenced file in the
FEM_INPUT command (see chapter 3.4 Loading FE Data and FEM_INPUT)
will then get their original numbers. If there is a second file referenced in the
FEM_INPUT command, then 10000 will be added to its load case numbers;
e.g., load case 11 in the second file will be referenced as load case 10011. If
a third file is referenced, 20000 will be added to its load case numbers, and
so on.
SIMULIA
Tosca Structure
Combined Terms
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Fig. 88
SIMULIA
Tosca Structure
Terms for Optimization
www.3ds.com/tosca
4.5.3
TOPO
SHAPE
OBJ_FUNC
S*
CONSTRAINT
S*
Table 22
BEAD
SIZING
S*
S*
SIMULIA
Tosca Structure
Combined Terms
Creating response combinations like relative values, differences or mean values requires operations on a number of previously extracted design
responses. For sensitivity based topology optimization, only weighted sums
are admitted in objective function and constraint definitions. For controller
based shape optimization, a large variety of other operators are admissible.
All operators are available to create new responses for monitoring of optimization results. Weighted sums operate on one to 10 variables defined by the
item VARIABLE. All other operators combine (operate on) one to four variables whereas the order of the variables is significant. For a complete list of
available operators refer to the detailed description of the DRESP command.
DRESP
ID_NAME
DEF_TYPE
VAR_OPER
VAR_A
VAR_B
=
=
=
=
=
.....
OPER
SUB or
.....
.....
SUB_ABS or ...
END_
and
DRESP
ID_NAME
= .....
DEF_TYPE
= OPER
VAR_OPER
= COMBINE
VARIABLE
= ....., .....
VARIABLE
= ....., .....
....................
Remark:
1. Please note: maximal 500 Design responses are allowed.
2. For sensitivity based topology optimization design responses can only be
combined using DEF_TYPE = OPER if they refer to the same loadcases.
Combination of design responses with OPER cannot be done for two separate loadcases. Nevertheless for shape optimization design responses for
different loadcases may be combined.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
END_
SIMULIA
Tosca Structure
Terms for Optimization
TYPE
The allowable types for
displacements and rotations
DISP_X
DISP_Y
DISP_Z
ROT_X
ROT_Y
ROT_Z
GROUP_OPER
The allowable
definition types for
displacements
and rotations
VAR_OPER
The allowable
operators for
displacements
and rotations
MAX
MIN
SUM
SUB
SUB_ABS
COMBINE
DISP_ABS
MAX
SUB
SUB_ABS*
ROT_ABS
MAX
SUB_ABS*
MAX
MIN
---
DISP_X_ABS
DISP_Y_ABS
DISP_Z_ABS
ROT_X_ABS
ROT_Y_ABS
ROT_Z_ABS
* For these VAR_A and VAR_B have to have the same DRESP type. E.g.
the DRESP type for VAR_A and VAR_B is TYPE = DISP_ABS yielding
u =
( u x1 u x2 ) + ( u y1 u y2 ) + ( u z1 u z2 )
www.3ds.com/tosca
Remarks
1. For TYPE=DISP_ABS with VAR_OPER=SUB both VAR_A and VAR_B are
TYPE=DISP_ABS. For this case the displacement of DRESP is calculated
as following:
l def =
SIMULIA
Tosca Structure
Combined Terms
I ini =
as initial length.
Thereby n pos = n pos1 n pos2 , for n = x,y,z
and u n = u n1 u n2 , for n = x, y, z ,
where pos1 and pos2 are the coordinates of the nodes and u the
displacements.
The DRESP can also be negative and gives the stretch between two nodes
(i.e. the difference between the two notes in deformed and undeformed
configuration).
2. GROUP_OPER is default GROUP_OPER = MAX.
3. A node group (ND_GROUP) has to be applied in the DRESP when more
than one node is required.
4. Maximal 500 DRESPs can be defined. Therefore, the maximal number of
nodes for GROUP_OPER = MAX is 500 or less as in this case one design
response is created for each group member.
5. If possible, define design responses for displacements for single nodes
(allows better control). Often 1 representative node is sufficient for the task.
6. The maximal number of nodes for GROUP_OPER = SUM us unlimited.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Terms for Optimization
Reaction forces
TYPE
The allowable types for
reaction forces
REACTION_FORCE_X
REACTION_FORCE_Y
REACTION_FORCE_Z
REACTION_MOMENT_X
REACTION_MOMENT_Y
REACTION_MOMENT_Z
REACTION_FORCE_ABS
REACTION_MOMENT_ABS
REACTION_FORCE_X_ABS
REACTION_FORCE_Y_ABS
REACTION_FORCE_Z_ABS
REACTION_MOMENT_X_ABS
REACTION_MOMENT_Y_ABS
REACTION_MOMENT_Z_ABS
GROUP_OPER
The allowable
definition types for
reaction forces
VAR_OPER
The allowable
operators for
reaction forces
MAX
MIN
SUM
SUB
SUB_ABS
COMBINE
MAX
SUB_ABS*
MAX
MIN
---
* For these VAR_A and VAR_B have to have the same DRESP type.
E.g. the DRESP type for VAR_A and VAR_B is
TYPE = REACTION_FORCE_ABS yielding
R =
( R x1 R x2 ) + ( R y1 R y2 ) + ( R z1 R z2 )
www.3ds.com/tosca
Internal forces
TYPE
The allowable types for
internal forces
INTERNAL_FORCE_X
INTERNAL_FORCE_Y
INTERNAL_FORCE_Z
INTERNAL_MOMENT_X
INTERNAL_MOMENT_Y
INTERNAL_MOMENT_Z
INTERNAL_FORCE_ABS
INTERNAL_MOMENT_ABS
GROUP_OPER
The allowable
definition types for
internal forces
VAR_OPER
The allowable
operators for
internal forces
MAX
MIN
SUM
SUB
SUB_ABS
COMBINE
MAX
SUB_ABS*
SIMULIA
Tosca Structure
Combined Terms
TYPE
The allowable types for
internal forces
INTERNAL_FORCE_X_ABS
INTERNAL_FORCE_Y_ABS
INTERNAL_FORCE_Z_ABS
INTERNAL_MOMENT_X_ABS
INTERNAL_MOMENT_Y_ABS
INTERNAL_MOMENT_Z_ABS
GROUP_OPER
The allowable
definition types for
internal forces
MAX
MIN
VAR_OPER
The allowable
operators for
internal forces
---
* For these VAR_A and VAR_B have to have the same DRESP type.
E.g. The DRESP type for VAR_A and VAR_B is
TYPE = INTERNAL_FORCE_ABS yielding
2
( F x1 F x2 ) + ( F y1 F y2 ) + ( F z1 F z2 )
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
F =
SIMULIA
Tosca Structure
Terms for Optimization
Modal eigenfrequencies
GROUP_OPER
The allowable
definition types
TYPE
DYN_FREQ
MAX
MIN
VAR_OPER
The allowable
operators
SUB
SUB_ABS
COMBINE
TYPE
The allowable types for
frequency response
FS_DISP_X_ABS
FS_DISP_Y_ABS
FS_DISP_Z_ABS
FS_DISP_ABS
www.3ds.com/tosca
FS_PHASE_X
FS_PHASE_Y
FS_PHASE_Z
FS_VELOCITY_X
FS_VELOCITY_Y
FS_VELOCITY_Z
FS_ACCEL_X
FS_ACCEL_Y
FS_ACCEL_Z
GROUP_OPER
The allowable
definition types for
frequency
response
VAR_OPER
The allowable
operators for
frequency
response
MAX
MIN
SUB_ABS*
MAX
MIN
---
* For these VAR_A and VAR_B have to have the same DRESP type.
E.g. the DRESP type for VAR_A and VAR_B is TYPE = FS_DISP_X_ABS
yielding
A x =
( u R, x1 u R, x2 ) + ( u I, y1 u I, y2 )
SIMULIA
Tosca Structure
Combined Terms
Objective:
Constraint:
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
In the window that appears, the combined design responses and their weighing factors are entered:
SIMULIA
Tosca Structure
Terms for Optimization
Pressing "?" key in a VARIABLE_<n> field opens the list of all defined design
responses:
www.3ds.com/tosca
Note that the window DRESP/VARIABLE that lists all available design
responses is also opened by the button DRESP/VARIABLE found in
OBJ_FUNC/CONSTRAINTS panel of Modules Buttons toolbar.
SIMULIA
Tosca Structure
Combined Terms
Fig. 89
Remarks
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Terms for Optimization
Fig. 90
Figure Fig. 90 shows two forces defined in different coordinates system and
different directions called DRESP_1 and DRESP_2 which can be combined
to a DRESP which can be applied in the optimization like the following:
DRESP
ID_NAME
= .....
DEF_TYPE
= OPER
VAR_OPER
= COMBINE
VARIABLE
= ....., .....
VARIABLE
= DRESP_1, 0.6
VARIABLE
= DRESP_2, -0.8
VARIABLE
= ....., .....
....................
END_
Remarks
www.3ds.com/tosca
SIMULIA
Tosca Structure
Combined Terms
=
=
=
=
=
.....
OPER
SUB_ABS
DRESP_1
DRESP_2
i
i, rel = -----0
VARIABLE
ID_NAME
DEF_TYPE
TYPE
ND_GROUP
LC_SET
GROUP_OPER
UPDATE
END_
VARIABLE
ID_NAME
DEF_TYPE
TYPE
ND_GROUP
LC_SET
=
=
=
=
=
=
=
von_mises
SYSTEM
SIG_MISES
ALL_NODES
ALL,1,All
Max
EVER
=
=
=
=
=
von_mises_first
SYSTEM
SIG_MISES
ALL_NODES
ALL,1,All
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Now, if we use this term in the objective function all nodal von Mises stresses
will be divided by the von Mises stress from the first iteration.
To define the above statement use the following commands:
SIMULIA
Tosca Structure
Terms for Optimization
GROUP_OPER
UPDATE
END_
DRESP
ID_NAME
DEF_TYPE
VAR_OPER
VAR_A
VAR_B
END_
= Max
= FIRST
=
=
=
=
=
relative_von_mises
OPER
DIV
von_mises
von_mises_first
Example 2:
In a second example, the sum of the von Mises stress from two load cases,
say LC1 and LC2, should be used as the design response:
www.3ds.com/tosca
The above is NOT a sum of the stress tensors upon which the von Mises criteria is calculated. It is simply a sum of the two resulting values of the von
Mises stress for each node.
The scalar summation can be done using following commands:
DRESP
ID_NAME
DEF_TYPE
TYPE
ND_GROUP
LC_SET
GROUP_OPER
END_
DRESP
ID_NAME
DEF_TYPE
TYPE
ND_GROUP
LC_SET
GROUP_OPER
END_
DRESP
ID_NAME
DEF_TYPE
VAR_OPER
VAR_A
VAR_B
=
=
=
=
=
=
von_mises_LC1
SYSTEM
SIG_MISES
ALL_NODES
ALL,1,All
Max
=
=
=
=
=
=
von_mises_LC2
SYSTEM
SIG_MISES
ALL_NODES
ALL,2,All
Max
=
=
=
=
=
scalar_sum_von_mises
OPER
ADD
von_mises_LC1
von_mises_LC2
SIMULIA
Tosca Structure
Logging and Monitoring
END_
4.6
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
All defined design responses are logged to the log-file TOSCA.OUT. The
design responses used in objective function or constraints are also written in
the file optimization_report.csv. In Tosca Structure.gui these can be monitored graphically during and after optimization using the Convergence
Plot button in Tosca Structure.gui.
SIMULIA
Tosca Structure
Topology Optimization
Topology Optimization
At the beginning of the conventional design process, the design engineer
often defines the shape and the topology of new components using the experience and the results gained from existing designs. This results in an evolution process that might lead to an optimum design after several manual
design iterations and a long process development time.
Nowadays it is necessary to shorten the development process of new components, and at the same time develop fundamentally new designs. Therefore,
optimization tools are necessary for replacing the natural evolution process
by an automatic procedure.
With Tosca Structure, it is possible to carry out topology and shape optimization in the existing CAE environment.
www.3ds.com/tosca
Fig. 91
5.1
General Information
Topology optimization is a tool to generate a new design proposal and is often
used within the concept phase for a determining a new conceptual design for
a component.Starting with the design area (which represents the maximum
allowed area for the component) and with the boundary conditions, such as
loads, fixtures and manufacturing conditions, the optimization system will
determine a new material distribution by removing and adding material in the
design area. This design proposal should fulfill all mechanical requirements
and often represents a weight-optimal design proposal.
SIMULIA
Tosca Structure
The Optimization Task
For the optimization, the following constraints and objectives can be applied:
stiffness (compliance and displacements);
eigenfrequencies;
internal and reaction forces;
weight, volume;
center of gravity;
moment of inertia.
In addition, a number of manufacturing constraints can be applied ensuring
that the design proposal can be produced, e.g., with casting or stamping. Different casting constraints can be defined, like member size constraints, freezing of parts, symmetry and different coupling constraints.
As result, the optimization creates a design proposal with the information
regarding the material layout. This design proposal has to be interpreted and
has to be used for a more detailed analysis. For supporting this step, the
Tosca Structure system supports the generation of a verification model within
Tosca ANSA environment. This means that a new model based on the results
of the topology optimization can be created easily without the necessity of
applying the loads and boundary conditions manually to the verification
model. All load cases and boundary conditions of the original optimization
model are also transferred automatically to the verification model.
With the results of the verification run, it is possible to perform a normal FE
postprocessing step within the postprocessing environment suitable for your
solver, or a CAD model can be generated that then can be transferred back to
your CAD system.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
5.2
SIMULIA
Tosca Structure
Topology Optimization
5.2.1
www.3ds.com/tosca
SIMULIA
Tosca Structure
The Optimization Task
Objective function
Maximize stiffness
Table 23
Constraint
Volume constraint
All other types of objective functions and constraints can be applied using the
sensitivity based algorithm.
The following table describes which terms and response types are valid for
the objective function and the constraints.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Center of gravity
SIMULIA
Tosca Structure
Topology Optimization
Several constraints and several terms for the objective function can be specified.
5.2.2
www.3ds.com/tosca
1. Question: Which file(s) contains the FE- model for the optimization?
Procedure: Link file(s) to optimization task.
TAE: MODEL_LINK | FILE, select Edit, then choose your model file.
GUI: Choose your model file in FEM_INPUT.
WB: Right click the Geometry cell of the static or modal system and select
Import Geometry. Add mesh and load cases later in the Mechanical
apllication.
Design Area
2. Question: Which part of the FE model should be selected as the design
space?
Procedure: Assign an element group to the design area.
TAE: DESIGN_AREA, select Edit, then choose a predefined group or
select a new group.
GUI: Choose or define the element group for the selected design area
(volume 3: GROUP_DEF) and define the design variables (volume 3:
DV_TOPO).
WB: Add a Topology | Design Area and assign a part of the geometry graphically or by Named Selection.
SIMULIA
Tosca Structure
The Optimization Task
3. Question: Are there elements in the design space which have to have
certain restrictions (e.g. symmetry and manufacturing restrictions)? How
can these restrictions be described?
Procedure: Define design variable constraints for element group.
TAE: DESIGN_AREA | DV_CONSTRAINTS, select New | <type of restriction>, choose predefined group or select new group for this restriction. If
needed, define link conditions using Modules Buttons toolbar.
GUI: Choose or define element groups with restrictions (volume 3:
GROUP_DEF). Define the restrictions using DVCON_TOPO command.
WB: Click Topology and choose a desired restriction. Then assign a part
of the geometry.
4. Question: Are there certain symmetry conditions that should be fulfilled?
Procedure: Create a symmetry coupling condition.
TAE: DESIGN_AREA | DV_CONSTRAINTS, select New |
SYMMETRY_CONTROL.
GUI: Create a LINK_TOPO condition and reference it in the restriction
command (volume 3: DVCON_TOPO).
WB: Select Topology | Symmetry and fill out the corresponding input
boxes.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Objective Function
SIMULIA
Tosca Structure
Topology Optimization
GUI: Define the design response (volume 3: DRESP) and assign it to the
constraint (volume 3: CONSTRAINT).
WB: Select Optimization | Design Response and define the available options for this Design Response. Then add a Optimization |
Constraint and assign the predefined Design Response.
Optimization Task
7. Question: Are all of the command definitions listed above complete and
ready for the optimization job?
Procedure: If necessary, make the additional definitions and prepare the
optimization job.
TAE: Automatically prepared by task manager.
GUI: Reference all definitions above in OPTIMIZE.
WB: All active (not Suppressed) definitions will be used automatically in
the Optimize command and the following optimization.
8. Question: Are you using controller or sensitivity based optimization
strategy?
Procedure: Choose the corresponding strategy.
TAE: Chosen in the beginning when the task is created
(TOPOLOGY_OPTIMIZATION_CONTROLLER or
TOPOLOGY_OPTIMIZATION_SENSITIVITY).
GUI: Set the correct value to either TOPO_CONTROLLER or
TOPO_SENSITIVITY in OPTIMIZE subcommand STRATEGY.
WB: Choose the desired Strategy in the Analysis Settings in the
Tree Outline.
www.3ds.com/tosca
Stop Condition
9. Question: Should the stop condition be modified?
Procedure: Modify stop condition
TAE: GLOBAL_STOP_CONDITION, select Edit and change the number of
iterations.
GUI: STOP.
WB: An iteration based stop condition can be defined as Max design
cycles in Analysis Settings in the Tree Outline.
Completion
10.Question: Is all required data specified?
Procedure: If yes, finish the definition of the optimization problem and
save your definition.
TAE: OUTPUT, choose Edit, enter the jobname
SIMULIA
Tosca Structure
Design Area
Fig. 92
5.3
Design Area
5.3.1
Design variables
For each optimization problem, the design variables represent the values to
be changed during the optimization. The densities of the elements are the
design variables for the topology optimization in Tosca Structure. The densities change during the optimization in order to fulfill the optimization goals.
The density of each individual element in the design space is a design variable in topology optimization. The Youngs modulus of each element is coupled with the density (see e.g. vol.2 chapter 5.10, References).
Valid design elements are 2D and 3D elements, including shell elements.
Bars can be used as design variables, but not within mixed groups. The list of
valid element types for the topology optimization is given in vol.2 chapter 11,
Solver Specific Features for the different FE solvers.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
During an optimization, only part of the model may be changed. This part is
defined as design area.
SIMULIA
Tosca Structure
Topology Optimization
Fig. 93
In order to choose the design element group, the command Edit should be
applied on the item DESIGN_AREA. Then, pressing "?" key in GROUP_DEF
field (after the field EL_GROUP is set to GROUP_DEF) opens the window SET
HELP where all existing groups are listed; if needed, a new element group
can be created by using New command of this window.
Design variable definition in Tosca Structure.gui
www.3ds.com/tosca
Fig. 94
The resulting command is the DV_TOPO command. For further details please
refer to DV_TOPO in the command manual.
DV_TOPO
ID_NAME
= dv_design_elem
SIMULIA
Tosca Structure
Design Area
EL_GROUP
= design_elem
END_
Fig. 95
The RESTART File containing the initial material distribution must be located
in the start directory of the optimization job. The format of the RESTART File
has to be ONF (Optmization Neutral File). The initial material distribution is
extracted from the datablock 740 with the title MAT_PROP_NORMALIZED.
When using a material distribution of a previous optimization run (file
TP_XXX.onf ) for the new optimization it is recommended to rename the file
(e.g. to INITIAL_MAT.onf) . Otherwise name conflicts with the running optimization (with newly generated material distribution files TP_YYY.onf) may lead
to confusion in the postprocessing: the start file TP_XXX.onf may be considered and shown as last iteration (if XXX is larger as the last iteration in the
actual optimization).
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
DV_TOPO
SIMULIA
Tosca Structure
Topology Optimization
5.3.2
www.3ds.com/tosca
SIMULIA
Tosca Structure
Design Area
Fig. 96
SIMULIA
Tosca Structure
Topology Optimization
Fig. 97
www.3ds.com/tosca
Fig. 98
SIMULIA
Tosca Structure
Design Area
ID_NAME
EL_GROUP
CHECK_TYPE
= frozen_area
= frozen_grp
= FROZEN
END_
Fig. 99
The manufacturing constraints are helpful and necessary to ensure that the
design is manufacturable, and thus the results of the topology optimization
are acceptable and the transfer of the results is easy.
In many cases where bending and torsion loads are applied, the topology
optimization results in models with hollow areas or models with undercuts
that make the manufacturing close to infeasible.
In order to convert the result of non-restricted topology optimization into a
manufacturable design, a lot of manual changes are necessary. These
changes might modify the mechanical properties dramatically. The solution
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Topology Optimization
www.3ds.com/tosca
Fig. 100 Difference between two optimization results: without manufacturing constraints (left) and with casting constraint to prevent undercuts (right)
The formation of cavities and undercuts during the topology optimization can
be prevented by using the casting constraint in the design variable constraint
definition. This simplifies significantly the transfer of topology optimization
results into manufacturable components. Solutions are limited as in the case
of all other kinds of restrictions. Usually, it is better to carry out the optimization without manufacturing restrictions first, and then to perform a second
optimization with manufacturing restrictions.
For a definition of a demold restriction, two element groups are needed. The
first group ("casting group") consists of the elements where the restriction is
active; it should be a subset of the design element group. The second one is
the "check group": when it is checked if an element is allowed to be removed,
this test is performed with respect to the elements in the check group.The
check group should include all elements of the casting group.
The check if a removal of an element results in a hole or an undercut requires
that the check direction is specified. Since only one check direction for an element is allowed, casting groups of two different demold restrictions must not
intersect. There are four types of the check for undercuts and cavities:
SIMULIA
Tosca Structure
Design Area
= deformation angle
r = base radius
Fig. 101 Pull cone with a deformation angle centered at element enlarged
by base radius r.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
A pull direction vector (PULL_DIR) has to be defined for the types 1-3. The
deformation angle (ANGLE) defines the necessary angle needed for ejection.
Values between 0 and 20 are permitted. Checking the pull direction is made
with the help of a pull cone starting at the centroid of the respective element.
That the pull direction is maintained is checked using the pull cone with a certain base radius.This radius is based on the average element size and is usually determined from the model.
SIMULIA
Tosca Structure
Topology Optimization
The specification of this RADIUS is optional and is only necessary for models
that have elements of very different sizes. If a value is specified, it should be
larger than approximately 50% of the average element edge length.
Members of the specified element group are only modified if they can be
removed from the model in the pull direction, so that internal cavities and
recesses cannot be formed.
www.3ds.com/tosca
SIMULIA
Tosca Structure
Design Area
Remarks
1. The check type SURFACE is useful for models where the pull direction is not
already known.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Topology Optimization
www.3ds.com/tosca
SIMULIA
Tosca Structure
Design Area
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Topology Optimization
Remark
1. This constraint for the design variables is only active if the definition is
referenced in the OPTIMIZE command. This is done using the parameter
DVCON = cast_restrictrion in OPTIMIZE command.
www.3ds.com/tosca
SIMULIA
Tosca Structure
Design Area
Remarks
1. For 2D models, the definition of a manufacturing constraint leads to a
significant reduction of the possible solution space. If this option is used in
combination with 2D models, an additional definition for the step width
should be added using the OPT_PARAM command (the parameter
SPEED=SLOW has to be defined).
2. Breakouts might occur if there are thin walls parallel to the pull direction.
These areas should be excluded from the restriction group.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Topology Optimization
www.3ds.com/tosca
SIMULIA
Tosca Structure
Design Area
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Topology Optimization
Thin trusses in the resulting structure are often undesirable, depending on the
manufacturing process. Defining a minimum thickness avoids the creation of
small substructures in the final result.
The minimum member size control technique also ensures the mesh independence of the results. A coarse mesh and a fine mesh lead to the same
optimized topology if the minimum member sizes for both cases are set to the
www.3ds.com/tosca
SIMULIA
Tosca Structure
Design Area
same absolute size. Please note that the size in both cases should be larger
than the average element edge length.
Fig. 112 Optimized engine support with and without MINIMUM member
size restriction
Remarks
1. It is not possible to ensure the accurate minimum thickness of the structures. For some cases, the results contain parts with a diameter smaller
than the defined minimum member size.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
2. The CPU-time for the calculation increases quadratically with the minimum
member size. To save calculation time, the restriction should only be
defined in the areas of the model where thin parts should be avoided. To
identify these areas, the first step is to perform an optimization without
restrictions.
SIMULIA
Tosca Structure
Topology Optimization
www.3ds.com/tosca
For the definition of the minimum member size, the element group and the
desired minimum thickness should be entered in MEMBER_SIZE_CONTROL
dialog, using MEMBER_SIZE = MIN.
SIMULIA
Tosca Structure
Design Area
=
=
=
=
no restriction
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
END_
SIMULIA
Tosca Structure
Topology Optimization
Normally, the maximum member size control is also a minimum member size
control. In the restriction area, the resulting structure contains trusses mainly
of the given defined diameter. Generally, no thinner trusses exist. Usually, the
combination of a maximum member size control and a minimum member size
control is not required.
www.3ds.com/tosca
Fig. 117 Plate designed with and without maximum member size control
SIMULIA
Tosca Structure
Design Area
For the definition of the maximum member size, the element group and the
desired maximum thickness as well as the minimum thickness and the minimum distance between trusses (DISTANCE field) should be entered in
MEMBER_SIZE_CONTROL dialog, using MEMBER_SIZE = MAX.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Topology Optimization
=
=
=
=
=
=
www.3ds.com/tosca
SIMULIA
Tosca Structure
Design Area
Remarks
1. The maximum member size restriction will usually not create thin parts in
the area of boundary conditions and loads in the optimized structure. A
reduction in these areas may result in collapsing the structure.
2. The specified maximum diameter should not be smaller than twice the
average element edge length because smaller values will create elements
only connected by one or two nodes (point or line contact).
3. The CPU-time for the calculation increases quadratically with the maximum
member size. To save calculation time, the restriction should only be
defined in the areas of the model where the thick parts are present. To
identify these areas, the first step is to perform an optimization without
restrictions.
4. The maximum member size constraint can only be used with the sensitivity
based algorithm. Maximum member size constraints with the controller
algorithm are not supported.
Fig. 121 Beam without symmetry (left) and with reflection symmetry (right)
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Topology Optimization
Fig. 122 Example of point symmetry (left) and rotational symmetry (right)
www.3ds.com/tosca
Fig. 123 Example of cyclic symmetry (left) and a link condition (right)
SIMULIA
Tosca Structure
Design Area
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Topology Optimization
(DIRECTION_1..DIRECTION_3); the field TRANSLATION is the translation distance. Note that although the origin has no influence, it should be
specified because Tosca Structure requires that the direction is an axis of a
coordinate system. In this case, this coordinate system is created automatically by Tosca ANSA environment.
In each case, EL_GROUP is the element group that the symmetry condition
applies to.
www.3ds.com/tosca
SIMULIA
Tosca Structure
Design Area
The frozen elements of one area are also considered as frozen for the linked
areas if Frozen checkbox is checked.
LINK_TOPO
ID_NAME
CS
TYPE
TRANSLATION
ANGLE
END_
DVCON_TOPO
ID_NAME
EL_GROUP
CHECK_TYPE
CHECK_LINK
=
=
=
=
END_
More than one symmetry condition can be defined for an element group.
Geometrically, different combinations have to be feasible.
Defining a symmetry condition in Tosca Extension for ANSYS/Workbench
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Add a Symmetry Control to the project by clicking Topology | Symmetry Control. Options like the type of symmetry or directions can be set in
the corresponding Details View window.
SIMULIA
Tosca Structure
Topology Optimization
www.3ds.com/tosca
It is possible within this order that one constraint weakens the modification of
another restriction.
E.g., a combination of reflection symmetry and a casting restriction defined by
a pull direction which is not parallel to the reflection symmetry axis is questionable geometrically and the user is not allowed to specify such a restriction.
SIMULIA
Tosca Structure
Design Area
The combination of a maximum member size and a pull direction is not recommended for the controller based algorithm. It is possible that the optimization does not converge, depending on the finite element mesh.
Minimum member size control and maximum member size control can be
combined if the radius of the minimum member size is larger than the
radius of the maximum member size (!). This can be done because the
minimum member size control is processed before the maximum member
size control. The optimizer creates thick supports that are broken up in the
second step. Parallel double supports can often be seen with this combination. The choice of a radius for the maximum member size which is larger
than the radius of the minimum member size does not influence the combination.
END_
The element group for a certain restriction should be a subset of the design
element group. If this is not the case, Tosca Structure will stop the optimization.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
...
DVCON
...
SIMULIA
Tosca Structure
Topology Optimization
5.4
Objective Function
The objective function describes the optimization target. In general, one scalar value (sometimes combined from other scalars) is to be maximized or
minimized.
5.4.1
Overview
The OBJECTIVE FUNCTION is the function, which value can be maximized
or minimized during the optimization. This function depends on the results of
the FE analysis. Therefore, the values of interest must be derived from the FE
results in order to define an objective function and functional constraints. The
results of the FE analysis (total displacement, energy, etc.) for determining
the objective function and functional constraints are called design
responses. A single value from the design response must be specified for the
definition of the objective function using the command DRESP (DESIGN
RESPONSE). For Details about design responses refer to vol.2 chapter 4.4,
Design Responses. General comments about the definition of objective functions can be found in vol.2 chapter 4.2, Objective Function.
5.4.2
Eigenfrequency terms
for objective
+C k
+ ( V V )
+f k
--- ln
k
j = 1 e
kf j
www.3ds.com/tosca
The following tables describe which design response types are valid as the
terms of an objective function that is to be minimized or maximized:
SIMULIA
Tosca Structure
Objective Function
+u i
+R i
+F i
+ i
+M i
+M i
+ u i
+ R i
2
+ F i
2
+ u x + u y + u z
+ R x + R y + R z
+ F x + F y + F z
+ ( u i ,1 u i ,2 )
+ ( R i ,1 R i ,2 )
+ ( F i ,1 F i ,2 )
+ ( u i ,1 u i ,2 )
+ ( R i ,1 R i ,2 )
+ ( F i ,1 F i ,2 )
Center of gravity
terms for objective
Moment of inertia
terms for objective
+i i
+I ij
In this table, the indices i and j indicate a direction of an axis (x, y or z) of the
global or a local coordinate system. The compliance, eigenfrequencies, displacements and forces can be based upon results from different load cases.
The reference values marked with "*" are defined in DRESP parameter of
OBJ_FUNC command. By default, the reference values are zero. The reference values can be set individually for each term in the objective function.
The weight factors are defined by the user in DRESP parameter of
OBJ_FUNC command. The weight factors are set individually for each term of
the objective function. By default, the weight factors are set to 1.
In the example below, the weight factor is set to 1.5 and the reference value is
set to 4.0:
OBJ_FUNC
...
DRESP
...
END_
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
( vMises )
+Max ----------------------------2- ref
( f ( i ) ref )
SIMULIA
Tosca Structure
Topology Optimization
Remarks
1. A minimization optimization task can be converted into a maximization optimization task (or vice versa) by changing the sign of the weighting factors
in the definition of the objective function.
5.4.3
Compliance terms in
Min-Max
Eigenfrequency terms
in Min-Max
( C k C k )
( V V )
1
-----------------
fk fk
( u i u i )
( )
( R i R i )
(M M )
2
( u i u i )
2
( R i R i )
( u x + u y + u z u )
((u u ) u )
( R x + R y + R z R )
((R R ) R )
2
( ( u i ,1 u i ,2 ) u i )
( ( R i ,1 R i ,2 ) R i )
i ,1
i ,2
i ,1
i ,2
www.3ds.com/tosca
SIMULIA
Tosca Structure
Constraints
Moment of inertia
terms in Min-Max
i C i C
I ij I ij
( vMises )
Max ----------------------------2- ref
( f ( i ) ref )
where the index i and j are indicating one of the x-y-z-directions. The compliance, eigenfrequencies, displacements and reaction forces can be from different load cases.
The REFERENCE values marked with the star "*" are defined by the use in
the DRESP command in OBJ_FUNC. Normally, the reference values are zero.
Hence, by default all reference values are set to zero. The reference can be
set individually for each term in the objective function.
The WEIGHT factors are defined by the user in the DRESP command in
OBJ_FUNC. The weight factors can be different for each individual term in the
objective function. By default the weighting factors are all set to one. Hence,
by default all weighting factors are set to one.
The reference value and weight factor can be changed, e.g. to 2.5 and 14.0
for response id_dresp in the following way:
OBJ_FUNC
...
DRESP
...
The main difference between the scheme in vol.2 chapter 5.4.2 and the present scheme is the way the frequency terms are defined in the objective.
5.5
Constraints
Constraints are fundamental parts of the definition for an optimization task,
see also vol.2 chapter 4.3. The purpose of having constraints is to ensure that
the optimized design is feasible. The following two tables describe which
design response types are valid as constraints. These design responses can
be constrained using equality constraint, lower equal constraint or greater
equal constraint as explained in vol.2 chapter 4.3. Note, that the equality constraint is only allowed for the controller based topology optimization. The
lower equal or greater equal constraints are allowed for the sensitivity based
approach as explained in vol.2 chapter 5.2.1. The constraint values can be
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
END_
SIMULIA
Tosca Structure
Topology Optimization
defined as absolute values or relative with respect to the corresponding values of the optimization start model. Moreover, for the sensitivity based
approach new combinations using VAR_OPER or GROUP_OPER for the
DRESP can also be applied in the constraints as described in vol.2 chapter
4.3:
C k C k
V V
[ V V ]
[ C l C l ]
Eigenfrequency terms
for constraints
f k f k
f l f l
f k f l f
www.3ds.com/tosca
[ f k f l f ]
SIMULIA
Tosca Structure
Constraints
u i u i
R i R i
F i F i
u i u i
R i R i
F i F i
i i
M i M i
M i M i
i i
M i M i
M i M i
2
u i u i
R i R i
2
F i F i
2
[ u i u i ]
[ R i R i ]
[ F i F i ]
u x + u y + u z u
2
R x + R y + R z R
F x + F y + F z F
2
[ u x + u y + u z u ]
2
2
2
2
2
2
[ R x + R y + R z R ] [ F x + F y + F z F ]
u i ,1 u i ,2 u i
R i ,1 R i ,2 R i
F i ,1 F i ,2 F i
u i ,1 u i ,2 u i
R i ,1 R i ,2 R i
F i ,1 F i ,2 F i
( u i ,1 u i ,2 ) u i
( R i ,1 R i ,2 ) R i
[ ( u i ,1 u i ,2 ) u i ]
2
( F i ,1 F i ,2 ) F i
2
[ ( R i ,1 R i ,2 ) R i ] [ ( F i ,1 F i ,2 ) F i ]
2
i ,1 u i ,1 + i ,2 u i ,2 + u i
( vMises )
Max ----------------------------2- ref ref
( f ( i ) ref )
Center of gravity
terms for
constraints
Moment of inertia
terms for
constraints
i i i i
I ij I ij
i i i i
I ij I ij
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
i ,1 u i ,1 + i ,2 u i ,2 + u i
SIMULIA
Tosca Structure
Topology Optimization
Remark
1. Constraints defined using relative values always refer to the design
response of the start model for the optimization. Please note that the
element densities in the optimization start model may be modified
compared to your original model (e.g. when no volume constraint is
present they are set to 50% of the original density). Take this into account
when defining, e.g., relative displacement or frequency constraints. This
behaviour can be controlled by the user with the parameter
DENSITY_INITIAL in the OPT_PARAM command.
5.5.1
www.3ds.com/tosca
Fig. 129. shows the design domain consisting of three different materials.
Two volume constraints are applied in the design domain. The elements on
the left side have the volume constraint of 20%, and the elements on the right
side have the volume constraint of 40%.
Fig. 129 Design domain consisting of three different materials. The stiffness of the structure is optimized under two material volume constraints.
SIMULIA
Tosca Structure
Constraints
= DESIGN_VARIABLES
= ALL_ELEMENTS
END_
Then, using the groups ELEM_LEFT (left part of the model) and
ELEM_RIGHT (right part of the model), two separate design responses are
defined:
DRESP
ID_NAME
DEF_TYPE
TYPE
EL_GROUP
GROUP_OPER
=
=
=
=
=
DRESP_VOL_TOPO_LEFT
SYSTEM
VOLUME
ELEM_LEFT
SUM
=
=
=
=
=
DRESP_VOL_TOPO_RIGHT
SYSTEM
VOLUME
ELEM_RIGHT
SUM
END_
DRESP
ID_NAME
DEF_TYPE
TYPE
EL_GROUP
GROUP_OPER
END_
Afterwards, these design responses are applied in the relative volume constraints:
ID_NAME
DRESP
MAGNITUDE
LE_VALUE
=
=
=
=
VOLUME_CONSTRAINT_LEFT
DRESP_VOL_TOPO_LEFT
REL
0.2
=
=
=
=
VOLUME_CONSTRAINT_RIGHT
DRESP_VOL_TOPO_RIGHT
REL
0.4
END_
CONSTRAINT
ID_NAME
DRESP
MAGNITUDE
LE_VALUE
END_
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
CONSTRAINT
SIMULIA
Tosca Structure
Topology Optimization
Remark
1. It is not allowed for the element groups with different volume constraints to
have common elements. In other words, each element can be used in no
more than one volume constraint.
The compliance is minimized in the objective in order to maximize the stiffness:
DRESP
ID_NAME
DEF_TYPE
TYPE
EL_GROUP
GROUP_OPER
=
=
=
=
=
DRESP_SUM_ENERGY
SYSTEM
STRAIN_ENERGY
ALL_ELEMENTS
SUM
END_
OBJ_FUNC
ID_NAME
DRESP
TARGET
= MAXIMIZE_STIFFNESS
= DRESP_SUM_ENERGY
= MIN
END_
=
=
=
=
=
TOPOLOGY_OPTIMIZATION
DESIGN_VARIABLES
MAXIMIZE_STIFFNESS
VOLUME_CONSTRAINT_LEFT
VOLUME_CONSTRAINT_RIGHT
END_
www.3ds.com/tosca
Nastran
ANSYS
Marc
PERMAS
SIMULIA
Tosca Structure
Typical Tasks for Static Analysis
Fig. 130 The solution for the optimization problem shown in Fig. 129.
5.6
5.6.1
min
U
i = 1, n
i = 1, n Vol
= vol_restrict
with U being the strain energy, Vol the element volume and vol_restrict the
value of the volume constraint.
Necessary definitions
The user has to define two design responses in order to set up the optimization problem:
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
The optimization problem can be solved with the controller based approach
(which needs about 15 iterations to solve the problem) and with the sensitivity
approach (where the number of iterations is not previously known).
The controller based approach works with equality constraints, so that the
problem looks like:
SIMULIA
Tosca Structure
Topology Optimization
1. The design response for the sum of the strain energy over all elements (if
not all elements are selected, then the problem will not represent the maximization of the total stiffness).
2. The design response for the relative volume defined as the sum of volumes
of elements multiplied with their relative densities and divided through the
original volume.
3. The strain energy can be used as an objective function term. The answer
to the question whether to minimize or to maximize the sum of the strain
energy depends on the loading types and boundary conditions, respectively. If the loads for the model are applied as external forces or pressure,
then the objective function has to be minimized. If only prescribed displacements are assigned and no external forces, then the objective function has
to be maximized. If simultaneously prescribed displacements and external
loading are assigned then a new energy stiffness measure
ENERGY_STIFF_MEASURE is available for stiffness optimization using
sensitivity based topology optimization.
4. The relative material volume is used in the equality constraint, so that the
optimization results the stiffest model that has the specified material
volume (and thus weight). Without the constraint, the stiffest structure will
use as much material as possible.
The commands in the parameter file for this problem look like:
DRESP
www.3ds.com/tosca
ID_NAME
DEF_TYPE
TYPE
UPDATE
EL_GROUP
GROUP_OPER
=
=
=
=
=
=
DRESP_SUM_ENERGY
SYSTEM
STRAIN_ENERGY
EVER
ALL_ELEMENTS
SUM
=
=
=
=
=
=
DRESP_VOL_TOPO
SYSTEM
VOLUME
EVER
ALL_ELEMENTS
SUM
END_
DRESP
ID_NAME
DEF_TYPE
TYPE
UPDATE
EL_GROUP
GROUP_OPER
END_
OBJ_FUNC
ID_NAME
= maximize_stiffness
SIMULIA
Tosca Structure
Typical Tasks for Static Analysis
DRESP
TARGET
= DRESP_SUM_ENERGY
= MIN
END_
CONSTRAINT
ID_NAME
DRESP
MAGNITUDE
EQ_VALUE
=
=
=
=
volume_constraint
DRESP_VOL_TOPO
REL
0.45
=
=
=
=
=
topology_optimization
design_variables
maximize_stiffness
volume_constraint
TOPO_CONTROLLER
END_
OPTIMIZE
ID_NAME
DV
OBJ_FUNC
CONSTRAINT
STRATEGY
END_
Remark
1. The same optimization task can be solved using the sensitivity based
topology optimization. Then, the relative material volume constraint should
be set to "less or equal", i.e., LE_VALUE parameter should be used instead
of EQ_VALUE parameter.
Defining the stiffness optimization task in Tosca ANSA environment
Please refer to vol.2 chapter 5, Topology Optimization section where an
example similar to this one is described.
Realization with the Tosca Structure.gui
5.6.2
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Topology Optimization
The sensitivity based approach works with an inequality constraint, and the
optimization problem is
min ( u i )
i = 1, n Vol vol_restrict
with u i being the displacement in a given coordinate or the total displacement, Vol the element volume and vol_restrict the value of the volume constraint.
Necessary definitions
The user has to define two design responses in order to set up the optimization problem:
1. The design response for the displacement of the given node. The displacement in a given direction (x, y or z) or the absolute value of the displacement is chosen according to the value of TYPE parameter. Please refer to
vol.2 chapter 4.4.3, Displacement and rotation for details.
www.3ds.com/tosca
2. The design response for the relative volume defined as the sum of volumes
of elements multiplied with their relative densities and divided through the
original volume.
3. The objective function is the minimization of the displacement design
response. If more than one node is used in the design response definition,
an individual design response is created for each node. In this case, a
large number of nodes leads to many objective function terms. The target
of the objective function is to minimize the nodal displacement of a single
node, or, if more than one node is specified in the displacement design
response, the target should be set to the minimization of the largest
displacement. Please check the TOSCA.OUT file for the list of generated
design responses.
4. The relative material volume is used in the inequality constraint, so that the
optimization results the stiffest model that has the material volume (and
thus weight) less than a certain value. Without the constraint, the stiffest
structure will use as much material as possible.
The commands in the parameter file for this problem look like:
DRESP
ID_NAME
DEF_TYPE
TYPE
= DRESP_DISP_X
= SYSTEM
= DISP_X
SIMULIA
Tosca Structure
Typical Tasks for Static Analysis
UPDATE
NODE
GROUP_OPER
LC_SET
LC_SEL
=
=
=
=
=
EVER
557
MAX
STATIC,2,ALL
MAX
=
=
=
=
=
=
DRESP_VOL_TOPO
SYSTEM
VOLUME
EVER
ALL_ELEMENTS
SUM
END_
DRESP
ID_NAME
DEF_TYPE
TYPE
UPDATE
EL_GROUP
GROUP_OPER
END_
OBJ_FUNC
ID_NAME
DRESP
TARGET
= maximize_stiffness
= DRESP_DISP_X
= MIN
END_
CONSTRAINT
ID_NAME
DRESP
MAGNITUDE
LE_VALUE
=
=
=
=
volume_constraint
DRESP_VOL_TOPO
REL
0.45
=
=
=
=
=
topology_optimization
design_variables
maximize_stiffness
volume_constraint
TOPO_SENSITIVITY
END_
ID_NAME
DV
OBJ_FUNC
CONSTRAINT
STRATEGY
END_
=
=
=
=
=
DRESP_DISP_X_1
SYSTEM
DISP_X
EVER
557
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
OPTIMIZE
SIMULIA
Tosca Structure
Topology Optimization
GROUP_OPER
LC_SET
LC_SEL
= MAX
= STATIC,2,ALL
= MAX
END_
DRESP
ID_NAME
DEF_TYPE
TYPE
UPDATE
NODE
GROUP_OPER
LC_SET
LC_SEL
=
=
=
=
=
=
=
=
DRESP_DISP_X_2
SYSTEM
DISP_X
EVER
1997
MAX
STATIC,1,ALL
MAX
=
=
=
=
=
=
DRESP_VOL_TOPO
SYSTEM
VOLUME
EVER
ALL_ELEMENTS
SUM
=
=
=
=
maximize_stiffness
DRESP_DISP_X_1
DRESP_DISP_X_2
MINMAX
=
=
=
=
volume_constraint
DRESP_VOL_TOPO
REL
0.45
=
=
=
=
=
topology_optimization
design_variables
maximize_stiffness
volume_constraint
TOPO_SENSITIVITY
END_
DRESP
ID_NAME
DEF_TYPE
TYPE
UPDATE
EL_GROUP
GROUP_OPER
END_
OBJ_FUNC
ID_NAME
DRESP
DRESP
TARGET
www.3ds.com/tosca
END_
CONSTRAINT
ID_NAME
DRESP
MAGNITUDE
LE_VALUE
END_
OPTIMIZE
ID_NAME
DV
OBJ_FUNC
CONSTRAINT
STRATEGY
SIMULIA
Tosca Structure
Typical Tasks for Static Analysis
END_
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
www.3ds.com/tosca
Topology Optimization
Fig. 132 Selecting the nodes for the displacement design response
SIMULIA
Tosca Structure
Typical Tasks for Static Analysis
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Topology Optimization
Details View window. Further options like the direction (Respone Type)
can be selected and the desired node(s) has to be defined.
5.6.3
www.3ds.com/tosca
Aim of this optimization task is to obtain the structure with maximal stiffness
subject to the constraint on the difference of the displacements of two nodes.
This relative displacement constraint is used in the stiffness optimization task
of the shift fork model (see Fig. 135).
SIMULIA
Tosca Structure
Typical Tasks for Static Analysis
min ( U )
u 1 u 2 u max Difference
Vol vol_restrict
with U being the sum of the strain energy over all elements, u 1 and u 2 the
displacements of the nodes in a given direction (x, y or z), Vol the relative
material volume, vol_restrict the value of the volume constraint and
u maxDifference the constraint value.
Necessary definitions
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Topology Optimization
www.3ds.com/tosca
Fig. 136 Definition of the constraint as combined term within the Tosca
ANSA environment
First, create a COMBINED_ITEM design response with VAR_OPER =
SUB_ABS. Then, create the individual design responses for each of the two
displacements. In order to do it, press "?" key in VARIABLE_1 field and press
New button in the appeared dialog, then choose TOSCA_DRESP. In the dialog,
choose TARGET = NODE, TYPE = DISP_Z (in case of the displacement in zdirection), then enter the node ID (NID field) and the load case(s) (LC_SET
field). Click OK and then double click on the name of the design response in
TOSCA HELP window so that this design response is entered in VARIABLE_1
field of the COMBINED_ITEM design response. Repeat the steps for the second displacement entered in VARIABLE_2 field.
For more details, see Fig. 136.
SIMULIA
Tosca Structure
Typical Tasks for Static Analysis
=
=
=
=
=
=
DISP_TIP_RIGHT
DISP_Z
SYSTEM
STATIC,1,
Max
TIP_RIGHT
=
=
=
=
=
=
DISP_TIP_LEFT
DISP_Z
SYSTEM
STATIC,1,
Max
TIP_LEFT
END_
DRESP
ID_NAME
TYPE
DEF_TYPE
LC_SET
GROUP_OPER
ND_GROUP
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
DRESP
SIMULIA
Tosca Structure
Topology Optimization
END_
DRESP
ID_NAME
DEF_TYPE
VAR_OPER
VAR_A
VAR_B
=
=
=
=
=
DISP_DIFFERENCE
OPER
SUB_ABS
DISP_TIP_RIGHT
DISP_TIP_LEFT
=
=
=
=
=
=
DRESP_SUM_ENERGY_LC1
STRAIN_ENERGY
SYSTEM
STATIC,1
SUM
ALL_ELEMENTS
END_
DRESP
ID_NAME
TYPE
DEF_TYPE
LC_SET
GROUP_OPER
EL_GROUP
END_
OBJ_FUNC
ID_NAME
TARGET
DRESP
= MY_OBJ_FUNC
= MIN
= DRESP_SUM_ENERGY_LC1
END_
CONSTRAINT
ID_NAME
MAGNITUDE
DRESP
LE_VALUE
=
=
=
=
DISP_DIFF_CONSTRAINT
ABS
DISP_DIFFERENCE
0.1
=
=
=
=
=
DRESP_VOL_TOPO
VOLUME
SYSTEM
SUM
ALL_ELEMENTS
=
=
=
=
VOL_CONSTRAINT
REL
DRESP_VOL_TOPO
0.3
DRESP
www.3ds.com/tosca
END_
CONSTRAINT
ID_NAME
TYPE
DEF_TYPE
GROUP_OPER
EL_GROUP
END_
ID_NAME
MAGNITUDE
DRESP
LE_VALUE
SIMULIA
Tosca Structure
Typical Tasks for Static Analysis
END_
5.6.4
Fig. 137 Box model with spot-weld elements; 2 load cases (Force 1 and
Force 2) are applied
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
The aim of this optimization is to minimize the internal force of spot-weld elements. Both the relative material volume constraint and a displacement constraint are used. A simple box model with 16 spot-weld elements is optimized.
SIMULIA
Tosca Structure
Topology Optimization
www.3ds.com/tosca
( m in Vol )
F node F Limit
node=1m
u node u Limit
node=1k
with Vol being the relative material volume of the design area, F node the
nodal force in an element in a given direction, F Limit the constraint force,
u node the nodal displacement and u Limit the restriction for the nodal displacement.
Necessary definitions
Four design responses are needed in order to set up the optimization task.
1. The first design response is the relative material volume of the design
area. This relative material volume design response is then used in the
objective function that is to be minimized.
2. The second design response is the maximum internal force over the nodes
of a given node group belonging to the elements mentioned in the given
element group.
SIMULIA
Tosca Structure
Typical Tasks for Static Analysis
3. The third and fourth design responses are the displacements of the loaded
nodes that are then used in constraints. These design responses are
defined as the total displacements for each load case and the appropriate
loaded node.
Defining an internal force constraint in Tosca ANSA environment
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Topology Optimization
www.3ds.com/tosca
32 nodes are connected to the cweld elements. Since there are two load
cases, 64 design responses are produced in Tosca Structure.
Fig. 139 Defining the internal force constraint in Tosca ANSA environment
SIMULIA
Tosca Structure
Typical Tasks for Static Analysis
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Topology Optimization
www.3ds.com/tosca
SIMULIA
Tosca Structure
Typical Tasks for Static Analysis
Fig. 144 Internal force constraint values during the optimization process
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Fig. 143 Objective function (relative material volume) during the optimization process
SIMULIA
Tosca Structure
Topology Optimization
www.3ds.com/tosca
Fig. 146 Result of the optimization under force constraints in the spot weld
elements
The result of the optimization is shown in Fig. 146.
Definition summary (incomplete)
DRESP
ID_NAME
= DRESP_VOLUME
SIMULIA
Tosca Structure
Typical Tasks for Static Analysis
TYPE
DEF_TYPE
GROUP_OPER
EL_GROUP
=
=
=
=
VOLUME
SYSTEM
Sum
ALL_ELEMENTS
END_
OBJ_FUNC
ID_NAME
TARGET
DRESP
= MINIMIZE_VOLUME
= MIN
= DRESP_VOLUME, ,
END_
GROUP_DEF
ID_NAME
TYPE
FORMAT
LIST_BEGIN
5291, 4055, 5295,
5501, 4026, 5505,
5186, 4685, 5190,
5396, 4656, 5400,
= CWELD_NODES
= NODE
= LIST
4051,
4030,
4681,
4660,
5299,
5509,
5194,
5404,
4047,
4034,
4677,
4664,
5303,
5513,
5198,
5408,
4043,
4038,
4673,
4668
END_
GROUP_DEF
ID_NAME
TYPE
FORMAT
LIST_BEGIN
100000-100015
= CWELD_ELEMENTS
= ELEM
= LIST
END_
ID_NAME
TYPE
DEF_TYPE
GROUP_OPER
EL_GROUP
ND_GROUP
=
=
=
=
=
=
DRESP_INT_FORCE_ABS
INTERNAL_FORCE_ABS
SYSTEM
Max
CWELD_ELEMENTS
CWELD_NODES
=
=
=
=
CONSTRAINT_INT_FORCE_ABS
DRESP_INT_FORCE_ABS
ABS
15
END_
CONSTRAINT
ID_NAME
DRESP
MAGNITUDE
LE_VALUE
END_
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
DRESP
SIMULIA
Tosca Structure
Topology Optimization
DRESP
ID_NAME
DEF_TYPE
TYPE
NODE
LC_SET
GROUP_OPER
=
=
=
=
=
=
DRESP_DISP_LC11
SYSTEM
DISP_ABS
3900
ALL,11,All
Max
=
=
=
=
=
=
DRESP_DISP_LC12
SYSTEM
DISP_ABS
4530
ALL,12,All
Max
=
=
=
=
MAX_DISP_LC11
ABS
DRESP_DISP_LC11
0.003
=
=
=
=
MAX_DISP_LC12
ABS
DRESP_DISP_LC12
0.003
=
=
=
=
=
=
=
=
TOPOLOGY_OPTIMIZATION
DESIGN_VARIABLES
MINIMIZE_VOLUME
MAX_DISP_LC11
DVCON_FROZEN
TOPO_SENSITIVITY
MAX_DISP_LC12
CONSTRAINT_INT_FORCE_ABS
END_
DRESP
ID_NAME
DEF_TYPE
TYPE
NODE
LC_SET
GROUP_OPER
END_
CONSTRAINT
ID_NAME
MAGNITUDE
DRESP
LE_VALUE
END_
CONSTRAINT
ID_NAME
MAGNITUDE
DRESP
LE_VALUE
www.3ds.com/tosca
END_
OPTIMIZE
ID_NAME
DV
OBJ_FUNC
CONSTRAINT
DVCON
STRATEGY
CONSTRAINT
CONSTRAINT
END_
OPT_PARAM
SIMULIA
Tosca Structure
Typical Tasks for Static Analysis
ID_NAME
= MY_PARAMETERS
OPTIMIZE
= TOPOLOGY_OPTIMIZATION
DENSITY_UPDATE = CONSERVATIVE
STOP_CRITERION_DENSITY = 0.001
END_
5.6.5
min Vol
i = 1, n
u j u restrict,j
j =1...m
Fig. 147 Model of a support structure with fixtures (right) and 4 loads (left)
Necessary definitions
Two design responses are needed:
1. The first design response is the design response representing the relative
material volume of the design area. This design response is the objective
function that is to be minimized.
2. The second design response is the displacement of the loaded node. The
absolute displacement is used in this case. Alternatively, the displacement
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
where Vol is the relative material volume of an element in the design area, u j
is the nodal displacement and u restrict ,j is the restriction for the nodal displacement of the node j.
A model for the minimization of the relative material volume under the displacement of the loaded node is presented in the example below:
SIMULIA
Tosca Structure
Topology Optimization
www.3ds.com/tosca
in the direction of the load (in the example it is Z-direction of a local coordinate system) can be used. The restriction to one direction reduces the
number of load cases generated by the optimization system because using
absolute displacement leads to the need of 3 additional load cases in order
to calculate the sensitivities while the displacement in Z-direction only
requires one additional pseudo-load case for the calculation of the sensitivities. The constraint is then defined as an inequality constraint with an
absolute value for the displacement value.
SIMULIA
Tosca Structure
Typical Tasks for Static Analysis
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Fig. 148 Objective function (relative material volume) during the optimization process
SIMULIA
Tosca Structure
Topology Optimization
www.3ds.com/tosca
SIMULIA
Tosca Structure
Typical Tasks for Static Analysis
=
=
=
=
=
DRESP_VOLUME
SYSTEM
design_elem
Sum
VOLUME
END_
OBJ_FUNC
ID_NAME
DRESP
TARGET
= MINIMIZE_VOLUME
= DRESP_VOLUME, ,
= MIN
END_
DRESP
ID_NAME
TYPE
DEF_TYPE
GROUP_OPER
NODE
=
=
=
=
=
MAX_DISPLACEMENT
DISP_ABS
SYSTEM
Max
300
END_
CONSTRAINT
ID_NAME
DRESP
MAGNITUDE
LE_VALUE
= DISPLACEMENT_CONSTRAINT
= MAX_DISPLACEMENT
= ABS
= 8.5
5.6.6
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
END_
SIMULIA
Tosca Structure
Topology Optimization
Design elements are shown in blue, the elements in red are defined as nondesign elements due to loads and boundary conditions.
The optimization target is to minimize the maximum von Mises stress with a
volume constraint of 30%.
Initial model
Optimized model
The following diagram shows the difference between the maximum elemental
centroidal von Mises stress calculated by the FE solver and the stress interpolated by Tosca Structure.
Stress
www.3ds.com/tosca
Optimization Iteration
Fig. 151 Comparing the interpolated von Mises Stress in the topology optimization and the von Mises stress calculated by the solver.
SIMULIA
Tosca Structure
Typical Tasks for Static Analysis
5.6.7
Design elements are shown in blue, the elements in red are defined as nondesign elements due to loads and boundary conditions.
The optimization setup is to minimize material volume having a constraint on
theMaximum von Mises stress..
Optimized model
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Initial model
SIMULIA
Tosca Structure
Topology Optimization
The following diagram shows the difference between the maximal elemental
centroidal Von Mises stress from solver and from Tosca Structure:.
Stress
Optimization Iteration
Fig. 152 Comparing the interpolated von Mises Stress in the topology optimization and the von Mises stress calculated by the solver.
www.3ds.com/tosca
5.7
SIMULIA
Tosca Structure
Typical Optimization Tasks for Modal Analysis
In chapter 5.7.4 Constraining an eigenfrequency is shown how an eigenfrequency can be applied in a constraint, e.g. when maximizing the stiffness
under the condition that the first eigenfrequency is above 100 Hz or when
minimizing the mass under the condition that the eigenfrequencies are be
below or above certain specified values.
Fig. 153 Optimizing all the lowest eigenfrequencies using the Kreisselmaier-Steinhauser formulation (b) and the single lowest eigenfrequency using mode tracking (a)
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
5.7.1
SIMULIA
Tosca Structure
Topology Optimization
TYPE = DYN_FREQ_KREISSEL
LC_SET = MODAL, ALL, ALL
END_
OBJ_FUNC
ID_NAME = maximize_eigenfrequencies
DRESP = all_lowest_eigenfrequencies
TARGET = MAX
END_
www.3ds.com/tosca
END_
SIMULIA
Tosca Structure
Typical Optimization Tasks for Modal Analysis
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Topology Optimization
Fig. 155 Defining an eigenfrequency design response for first 5 eigenfrequencies in Tosca Structure.gui
www.3ds.com/tosca
Defining an design response with certain eigenfrequencies in Tosca Extension for ANSYS/Workbench
SIMULIA
Tosca Structure
Typical Optimization Tasks for Modal Analysis
Fig. 156 Defining a Design Response with the first five eigenfrequencies
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
5.7.2
SIMULIA
Tosca Structure
Topology Optimization
www.3ds.com/tosca
Fig. 157 Define additional optimization parameters in the Analysis Settings, e.g. Modetracking and Number of Modes
SIMULIA
Tosca Structure
Typical Optimization Tasks for Modal Analysis
Defining an objective function for a minimization of a specific eigenfrequency in Tosca ANSA environment
To add a new objective term for the optimization, apply New | command on
OBJ_FUNC item. It opens the following dialog:
Fig. 158 Defining a design response for the first eigenfrequency in Tosca
ANSA environment
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
In this dialog, choose TYPE = DYN_FREQ and then select the appropriate
load cases in LC_SET field either directly (note that the 3rd parameter is the
eigenfrequency number, so that 1 corresponds to the smallest eigenfrequency) or by pressing "?" key in LC_SET field and using the window that
appears.
SIMULIA
Tosca Structure
Topology Optimization
button and setting Analysis Type to MODAL, entering the load case ID and
the numbers of eigenmodes (e.g., 1) in Eigenmode/Subcase field.
Fig. 159 Defining an eigenfrequency design response for the first eigenfrequency in Tosca Structure.gui
www.3ds.com/tosca
SIMULIA
Tosca Structure
Typical Optimization Tasks for Modal Analysis
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Then call the predefined Design Response within an Objective Function. Therefore click Optimization | Objective Function, select
Maximize sum as Target and call the Design Response that contains
the eigenfrequency.
SIMULIA
Tosca Structure
Topology Optimization
5.7.3
www.3ds.com/tosca
DRESP
ID_NAME = eigenfrequency_3
DEF_TYPE = SYSTEM
TYPE = DYN_FREQ
LC_SET = MODAL, ALL, 3
END_
DRESP
ID_NAME = eigenfrequency_4
DEF_TYPE = SYSTEM
TYPE = DYN_FREQ
LC_SET = MODAL, ALL, 4
END_
OBJ_FUNC
DRESP = eigenfrequency_1, 1.0, 150.0
DRESP = eigenfrequency_2, 1.0, 150.0
SIMULIA
Tosca Structure
Typical Optimization Tasks for Modal Analysis
Fig. 162 Defining a design response and a reference value for the first
eigenfrequency in Tosca ANSA environment
Defining an objective function for a band gap maximization in Tosca Structure.gui
First, one needs to create 4 design responses as follows. Create a new
design response and then set DefType = System, Category = Base and Type
= DYN_FREQ. Choose the load cases by pressing Add LC button and setting Analysis Type to MODAL, entering the load case ID and the numbers of
eigenmodes (1 for first term, 2 for the second one, etc.) in Eigenmode/Subcase field.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Four design responses are created and added as the objective function terms
using the command New | EIGENFREQUENCY on OBJ_FUNC item. See vol.2
chapter 5.7.2, Maximizing the eigenfrequency of a certain eigenmode for
details. The reference value (REF_VALUE = 150) should be set for each
objective function term. The only difference between the terms is the mode
number represented by the third parameter in LC_SET field (1 for the first
design response, 2 for the second one, etc.).
SIMULIA
Tosca Structure
Topology Optimization
Once the design responses are defined, create an OBJ_FUNC command and
choose the design responses and their reference values (set RefValue = 150
for each design response).
Fig. 163 Defining an eigenfrequency design response for the first eigenfrequency in Tosca Structure.gui
Defining an objective function for a band gap maximization in Tosca Extension for ANSYS/Workbench
www.3ds.com/tosca
For a band gap maximization with four eigenfrequencies there are four
Design Responses needed, one for every eigenfrequency. All Design
Responses have to be inserted in one Objective Function tab.
The Reference Value in the objective function tab should be set (to 150
e.g.) for each listed Design Response in the tab.
SIMULIA
Tosca Structure
Typical Optimization Tasks for Modal Analysis
5.7.4
Constraining an eigenfrequency
Constraints for eigenfrequencies are allowed in the topology optimization
tasks such as stiffness optimization or minimizing the mass. The conditions
that the first eigenfrequency is above 100 Hz and the second eigenfrequency
is above 250 Hz are used in the example. For each condition, a separate
eigenfrequency design response is to be defined as follows:
DRESP
ID_NAME = eigenfrequency_1
DEF_TYPE = SYSTEM
TYPE = DYN_FREQ
LC_SET = MODAL, ALL, 1
END_
DRESP
ID_NAME = eigenfrequency_2
DEF_TYPE = SYSTEM
TYPE = DYN_FREQ
LC_SET = MODAL, ALL, 2
END_
CONSTRAINT
ID_NAME = con_eigen_1
DRESP = eigenfrequency_1
MAGNITUDE = ABS
GE_VALUE = 100.0
END_
ID_NAME = con_eigen_2
DRESP = eigenfrequency_2
MAGNITUDE = ABS
GE_VALUE = 150.0
END_
OPTIMIZE
...
CONSTRAINT = con_eigen_1
CONSTRAINT = con_eigen_2
...
END_
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
CONSTRAINT
SIMULIA
Tosca Structure
Topology Optimization
Fig. 165 Defining the constraints on the first and the second eigenfrequencies in Tosca ANSA environment
In CONSTRAINT_ITEM dialog, choose MAGNITUDE = ABS, VALUE =
GE_VALUE, VALUE = 100. Choose the appropriate load case in LC_SET
field either directly or by pressing "?" key in the text field and using the window that appears.
Defining a design response for a specific eigenfrequency in Tosca Structure.gui
www.3ds.com/tosca
Create a new design response and then set DefType = System, Category =
Base and Type = DYN_FREQ. Choose the load cases by pressing Add LC
SIMULIA
Tosca Structure
Typical Optimization Tasks for Modal Analysis
button and setting Analysis Type to MODAL, entering the load case ID and
the numbers of eigenmodes (e.g., 1) in Eigenmode/Subcase field.
Fig. 166 Defining an eigenfrequency design response for the first eigenfrequency in Tosca Structure.gui
Defining a design response for a specific eigenfrequency in Tosca Extension for ANSYS/Workbench
Fig. 167 Defining an eigenfrequency design response for a specific eigenfrequency in Tosca Extension for ANSYS/Workbench
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Add a Design Response to your project. By selecting Def Type = System, Category
=
Eigenfrequency and Response
Type
=
DYN_FREQ, the Design Response is set up for an eigenfrequency task.
Set the Load Case selection to Manual and select the desired eigenfrequency in the Steps/Mode field in a new created tab.
SIMULIA
Tosca Structure
Topology Optimization
5.8
Settings
Different settings can be made to control speed and convergence behaviour
of the topology optimization algorithms. Default values are available which
have been tried and tested on many occasions.
Other algorithm settings for the various optimization algorithms can be
selected using the OPT_PARAM command.
5.8.1
= optimization_control
= id_of_optimize
= SLOW
www.3ds.com/tosca
END_
SIMULIA
Tosca Structure
Settings
Remark
1. Too many elements may be removed in the first iteration if the starting
value is too high. Tosca Structure.topology may not be able to identify the
original force flux if the distribution of forces changes significantly, and the
corresponding elements may consequently be deleted.
In topology optimization, the given mass is distributed within the design area.
During this iterative process, elements with the original mass co-exist with the
original stiffness. But elements also exist that have no mass and no stiffness
as well as elements with an intermediate mass and an unknown stiffness. For
these elements, the relation between density and stiffness must be determined. Several methods can be found in publications determining this relation. One of the most common is the SIMP approach (Simple Isotropic
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Topology Optimization
www.3ds.com/tosca
p
0
E ijkl = f ( ) in this case with f ( ) = E ijkl -----
0
with E0 ijkl as material stiffness tensor of the original material of density 0
and E ijkl as material stiffness tensor of the unknown material with the corresponding density .
This relation was very controversial but it has proven to be successful in practice. In 1999, BENDSE and SIGMUND have presented the physical theoretical proof for the penalty exponents p 3 and for materials with a lateral
contraction coefficient = 1 3 .
For the integrated algorithms, the penalty factor can be modified using the
OPT_PARAM command. Tosca Structure uses values between 2 and 3 as the
default values depending on the algorithms.
OPT_PARAM
ID_NAME
OPTIMIZE
...
MAT_PENALTY
...
= optimization_control
= id_of_optimize
= 2.5
END_
SIMULIA
Tosca Structure
Settings
5.8.2
where the initial modes are equal to the modes of the first iteration. The
modes in the first optimization iteration are used for identifying the eigenfrequencies through the optimization iterations. The MAC matrix is equal to the
unity matrix if the initial modes are equal to the modes in a given optimization
iteration. However, this is only the case in the first optimization iteration due to
the optimization changes. The largest components of the MAC matrix are
determined in each optimization iteration for determining if any mode switching should be present. If significant off-diagonal terms exist in the MAC matrix,
it indicates that the mode switching is present. The MAC matrix is printed in
the TOSCA.OUT file. Then the user can see how close to 1 the components
of the MAC matrix are and whether mode switching is present. If all the values in the MAC matrix are significantly below 1, it indicates that the applied
mode set does not contain enough modes for mode tracking.
According to the above equation, mode tracking can lead to a significant
increase in CPU-time. First, all modes of the eigenfrequencies have to be
cross-checked with each other. Sometimes a high number of cross-checks is
required. Second, more eigenfrequencies have to be calculated by the finite
element solver.
Mode tracking is defined in OPT_PARAM command as in the example below:
OPT_PARAM
ID_NAME
OPTIMIZE
MODETRACKING
MODENUMBERS
=
=
=
=
opt_params
id_of_optimize
ON
15
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
MAC i ,j
( { } i [ Mass ] { reference } j )
= ----------------------------------------------------------------------------------------------------------------------------------( { } i [ Mass ] { } i ) ( { reference } j [ Mass ] { reference } j )
SIMULIA
Tosca Structure
Topology Optimization
END_
Setting the command MODETRACKING equal to ON activates the mode tracking. Default for MODETRACKING is OFF. Consequently, mode tracking will
only be applied if the user requests mode tracking. The value of MODENUMBERS specifies how many eigenfrequencies should be used in the mode
tracking. The default value of mode tracking is 5. In the above example,
MODENUMBERS is set to 15 meaning that 15 eigenfrequencies will be used
for the mode tracking. If, e.g., one maximizes the first eigenfrequency, this
eigenfrequency will be compared to the 15 specified eigenfrequencies in the
MODETRACKING command. It is important that the modal analysis file specified by the user also leads to an analysis having the same or more eigenfrequencies than specified in the MODENUMBERS command. For this example,
the user should specify at least 15 eigenfrequencies in the finite element file.
Sometimes it happens that many local modes having a low eigenfrequency
appear during the optimization iterations. Normally, this will lead to high number for MODENUMBERS which is not desirable because of high CPU-time.
However, this can be partly circumvented by setting a number in the input
finite element file avoiding the lower eigenfrequencies to be calculated. E.g.,
if it is known that the initial eigenfrequency is around 200 Hz, then it should be
specified in the finite element input file that the eigenfrequencies over 50 Hz
only are to be calculated.
To improve the performance, it is additionally possible to restrict mode tracking to a certain group of nodes in the model (e.g., every fifth node on the surface of the model) or nodes where lumped and rigid masses are attached. In
this case, the node group is referenced in the MODETRACKING parameter
as follows:
OPT_PARAM
ID_NAME
OPTIMIZE
MODETRACKING
MODENUMBERS
=
=
=
=
opt_params
id_of_optimize
ON, node_group
15
www.3ds.com/tosca
END_
When a node group is applied in the mode tracking, then the modal assurance criterion (MAC) yields
MAC i ,j
( { } i { reference } j )
= --------------------------------------------------------------------------------------------( { } i { } i ) ( { reference } j { reference } j )
SIMULIA
Tosca Structure
Settings
where the modes are not scaled with the mass. Therefore, the nodes of the
applied group are often chosen to be the nodes of frozen elements, lumped
or rigid masses.
Remarks
1. The finite element input file specified by the user should contain a modal
analysis containing at least as many eigenfrequencies as the value of
MODENUMBERS parameter.
2. A general rule for keeping the MODENUMBERS low and thereby saving
CPU-time is to specify a lower bound for the calculated eigenfrequencies in
the finite element file. Choosing 25% of the expected eigenfrequency as
the lower bound usually suffices. E.g., if the initial eigenfrequency of
interest in the first optimization iteration is around 100 Hz, then it can be
specified that only the eigenfrequencies over 25 Hz are to be calculated.
3. The mode tracking feature can not be guaranteed to work for all examples.
4. Mode tracking is not recommended for the Kreisselmaier-Steinhauser
formulation.
5. Mode tracking can increase the CPU-time significantly both for finite
element solver and Tosca Structure. Restrict mode tracking to a smaller
representative group of nodes to gain performance.
The relative density of each element is the design variable in topology optimization.
In the initial optimization iteration the design space has a homogenous material distribution, meaning that each element contains the same relative material volume.
Initially, all the elements get the density causing the material volume constraint to be exactly fulfilled if a material volume constraint is defined for the
optimization problem.
When no volume constraint is present in the optimization problem but the relative material volume is used in the objective function, each element has an
initial relative density of 50%. However, if the constraints (e.g., displacement
constraints) require a significantly higher relative material volume than 50%
for being fulfilled and this is known before the optimization, then the initial relative material volume in the design space can be set to a larger value (e.g., to
90%) using the command DENSITY_INITIAL:
OPT_PARAM
ID_NAME
= opt_params
OPTIMIZE
= id_of_optimize
DENSITY_INITIAL= 0.9
END_
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Topology Optimization
Similarly, if it is known before the optimization that the relative material volume of significantly less than 50% is required in order to fulfill the constraints,
the initial relative material volume can be set to a lower value (e.g., to 10%):
OPT_PARAM
ID_NAME
= opt_params
OPTIMIZE
= id_of_optimize
DENSITY_INITIAL= 0.1
END_
www.3ds.com/tosca
SIMULIA
Tosca Structure
Settings
from the calculation model. The deleted elements are reactivated if needed,
in case that the force flow changes during the optimization.
Fig. 169 Mesh of a bending beam with hard (red) and soft (blue) elements
(The elements in the holes have been deleted by soft_delete
algorithm)
Remarks:
1. SOFT_DELETE is turned on after the 5th iteration, and only if the relative
change of the objective is less than a certain limit. This is done in order to
prevent unstable configurations that might occur in the first iterations from
remaining unchanged.
2. SOFT_DELETEcan be used to stabilize geometrically non-linear models
where solver instabiities can occur due to degenerated or fully collapsed
void elements.
SOFT_DELETE based on neighouring elements
In Tosca Structure, this SOFT_DELETE option offers the possibility of removing the soft elements which only have soft neighboring elements. To use this
feature, an element group must be specified. The average element edge
length (radius) can be specified by the user as an optional parameter. This is
only necessary if the sizes of mesh elements vary strongly.
ID_NAME
= optimization_control
OPTIMIZE
= id_of_optimize
...
SOFT_DELETE = ALL_ELEMENTS, <radius>
SOFT_DELETE_METHOD = STANDARD ( AGGRESSIVE ),
<threshold>
...
END_
Remarks
1. If the average element edge length is not specified, the system will determine this value automatically. If the edge length varies considerably within
the mesh, this can influence the function of this feature.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
OPT_PARAM
SIMULIA
Tosca Structure
Topology Optimization
www.3ds.com/tosca
SIMULIA
Tosca Structure
Settings
OPT_PARAM
.....
SOFT_DELETE_METHOD = MIN_PRINCIPAL_STRAIN, <t_min_prin>
SOFT_DELETE
= <element_group>
.....
END_
.....
SOFT_DELETE_METHOD = PLASTICITY, <t_plastic>
SOFT_DELETE
= <element_group>
.....
END_
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
OPT_PARAM
SIMULIA
Tosca Structure
Topology Optimization
V deform V org
V rel = ----------------------------------V org
www.3ds.com/tosca
Remarks:
1. Often the elemental strains cannot be written as results for shell and
membrane elements. Thus, the only option is to use VOLUME_CHANGE for
SOFT_DELETE.
2. For examples with very large deformation soft delete seems to be more
stable using VOLUME_CHANGE instead of MAX_SHEAR_STRAIN and
MIN_PRINCIPAL_STRAIN.
3. Normally, the strain measure used for the element removal depends upon
the element type.
4. Additionally, strain measure used for the element removal can depend
upon the constitutive material modeling.
SIMULIA
Tosca Structure
Settings
5. Typically, finding a useful strain measure used for the element removal
requires several optimization executions.
6. Note, the strains used in the strain meaures for the elemental removal are
from the previous optimization iteration.
Thus, it is recommended to have a slow optimization iteration update of the
design variables for having consistency in the removel of the elements
which can be obtained using the following settings:
OPT_PARAM
.....
DENSITY_UPDATE = CONSERVATIVE
DENSITY_MOVE
= 0.10
.....
END_
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
7. The file TOSCA.OUT will for each optimization iteration contain information
for the progress regarding the SOFT_DELETE.
This information can be rather useful for choosing a correct value for the
SOFT_DELETE with respect to strain measure.
E.g. for SOFT_DELETE_METHOD = MAX_SHEAR_STRAIN the following
useful information can be found in TOSCA.OUT:
SIMULIA
Tosca Structure
Topology Optimization
www.3ds.com/tosca
=
=
=
=
opt_params
id_of_optimize
0.01
1.00
END_
SIMULIA
Tosca Structure
Settings
DENSITY_LOWER DENSITY_MOVE
+ DENSITY_MOVE DENSITY_UPPER
The reason for the change limit is that the sensitivity based optimization algorithm approximates the design responses around the actual design response
values using the sensitivities. These approximations are only valid in a small
range of design variables, thus the variation of the relative material values
should be limited.
Numerical experiments indicate that a value of 0.25 for the change limit is
usually acceptable. However, one can set the limit to, e.g., 0.4 using the
parameter DENSITY_MOVE:
OPT_PARAM
ID_NAME
OPTIMIZE
DENSITY_MOVE
= opt_params
= id_of_optimize
= 0.4
= opt_params
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
END_
SIMULIA
Tosca Structure
Topology Optimization
OPTIMIZE
= id_of_optimize
DENSITY_UPDATE = CONSERVATIVE
END_
www.3ds.com/tosca
The result of the optimization of a bending beam in Fig. 172 shows a numerical instability effect. The structure contains checkerboard-like areas with soft
(void) and hard elements. In a structure like this, many hard elements have
only the point contact to other hard elements. The result in Fig. 172 is not a
valid design because the checkerboard effect is a numerical instability. This
effect has been analyzed by BENDSE and SIGMUND (M. P. Bendse, O.
Sigmund, Topology Optimization Theory, Methods and Applications SpringerVerlag 2003) and references therein.
SIMULIA
Tosca Structure
Settings
This checkerboard effect depends on the mesh and the discretization. This is
obvious in Fig. 173. The mesh is refined in parts of the model.
5.8.2.7 FILTER_TYPE
The filter technique for the objective function can be changed using the
parameter FILTER_TYPE in the optimization settings (OPT_PARAM command). Changing the filter technique for the objective function is mainly interesting for stiffness optimization problems.
The FILTER_TYPE can be set to STANDARD and LOW, respectively. The filter for FILTER_TYPE = LOW is a relaxation of the STANDARD filter. It is use2 - 288 User Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
OPT_PARAM
SIMULIA
Tosca Structure
Topology Optimization
ful for coarse meshes yielding a clearer solid-void design and a lower number
of optimization iterations.For reasonable and fine meshes FILTER_TYPE
equal to LOW would often cause checkerboard.
FILTER_TYPE equal to LOW might also be useful for stabilizing dynamic
problems like modal eigenfrequency optimization and frequency response
optimization.
Remarks:
1. Changing the filter option has no effect when the objective is to minimize
the mass.
2. Changing the filter option has no effect when manufacturing constraints are
present.
e = 1
or
e 0
meaning that each element should be filled up with material (hard elements
with the relative material volume equal to 1) or contain no material (void elements with the relative material volume close to 0 but always positive). Thus,
the relative material volume of each element is defined as a design variable.
Numerically, the above optimization problem is an integer problem and therefore difficult to solve for a large number of design variables. Therefore, the
above optimization problem is relaxed so the relative densities can have values in between 0 and 1,
www.3ds.com/tosca
e = ]0, 1 ]
The material interpolation schemes penalizing the Youngs modulus E for the
intermediate densities are introduced for obtaining the solution of the relaxed
problem resulting in all elements being either hard or void elements. Tosca
Structure contains two material interpolation schemes described in the following. Both material interpolation schemes contain a penalization factor p that
defines to what extent the solution is forced toward a solution having with
hard or void elements only.
The SIMP (solid isotropic material with penalization) material interpolation
scheme is defined by
E = E0
and is very popular in the literature, e.g., see Mlejnek (1992), Bendse and
Sigmund (1999) and Bendse and Sigmund (2003) and references therein.
SIMULIA
Tosca Structure
Settings
The Youngs modulus E 0 is the Youngs modulus when the element is filled
up with material, thus being the Youngs modulus defined by the user. The
penalty factor p should be greater than 1. Numerical experiments indicate
that p=3 is a good value.
The RAMP (rational approximation of material properties) material interpolation scheme is defined by
E = E 0 ----------------------------1 + p(1 )
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Topology Optimization
www.3ds.com/tosca
Fig. 174 The SIMP and RAMP material interpolation scheme showing how
the Young modulus is penalized for the intermediate relative densities.
By default, the optimization algorithm chooses the SIMP interpolation scheme
with p=3 if all load cases are static. However, if at least one dynamic load
case is used, the RAMP interpolation scheme with p=3 is chosen by default.
The user has the possibility to choose the interpolation scheme and the value
of the penalty factor using the commands MAT_INTERPOLATION and
MAT_PENALTY, respectively. The valid values for MAT_INTERPOLATION
parameter are SIMP and RAMP.
E.g., the SIMP material interpolation scheme and a penalty of 3.5 are used in
the following example:
OPT_PARAM
ID_NAME
= opt_params
OPTIMIZE
= id_of_optimize
MAT_INTERPOLATION = SIMP
MAT_PENALTY
= 3.5
END_
The SIMP material interpolation scheme and a penalty of 2.5 are used in the
defined in OPT_PARAM command as follows:
SIMULIA
Tosca Structure
Stop Condition
OPT_PARAM
ID_NAME
= opt_params
OPTIMIZE
= id_of_optimize
MAT_INTERPOLATION = RAMP
MAT_PENALTY
= 2.5
END_
5.9
Stop Condition
Stop conditions are necessary to ensure that the optimization terminates.
These stop criteria can either simply allow a certain number of loops or
depend on the convergence behaviour of the optimization.
5.9.1
Convergence Criteria
For checking if the sensitivity based topology optimization has converged two
stop criteria are implemented.
The user can specify if both stop criteria should be fulfilled or just one of the
stop criteria has to be fulfilled for the optimization algorithm to stop. Default is
that both criteria should be fulfilled before the optimization algorithm stops. To
specify that just one of the criteria has to be fulfilled set
STOP_CRITERION_LEVEL equal to SINGLE. The default value for
STOP_CRITERION_LEVEL is BOTH.
E.g. the optimization algorithm should stop when just one of the criteria is fulfilled
ID_NAME
= opt_params
OPTIMIZE
= id_of_optimize
STOP_CRITERION_LEVEL = SINGLE
END_
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
OPT_PARAM
SIMULIA
Tosca Structure
Topology Optimization
n n 1
---------------------------- STOP_CRITERION_OBJ
n
where the index n is representing the present optimization iteration and is n-1
is the previous iteration. When the criterion is lower than
STOP_CRITERION_OBJ the stop criterion is fulfilled. The default for
STOP_CRITERION_OBJ is 0.001. The value can be changed by the user,
e.g.
OPT_PARAM
ID_NAME
= opt_params
OPTIMIZE
= id_of_optimize
STOP_CRITERION_OBJ = 0.01
END_
www.3ds.com/tosca
n n 1
----------------------------------------------------------------------- STOP_CRITERION_DENSITY
Number of elements
where the index n is representing the present optimization iteration and is n-1
is the previous iteration. When the criterion is lower than
STOP_CRITERION_DENSITY the stop criterion is fulfilled. The default for
STOP_CRITERION_DENSITY is 0.005. The value can be changed by the
user, e.g.
OPT_PARAM
ID_NAME
= opt_params
OPTIMIZE
= id_of_optimize
STOP_CRITERION_DENSITY = 0.0001
END_
SIMULIA
Tosca Structure
Stop Condition
5.9.2
= global_stop
= 55
END_
1. Please note that the global stop criterion is defined using a STOP
command whereas the convergence criteria are defined in the optimization
settings (OPT_PARAM command).
2. The global stop criterion leads to a hard stop of the optimization - independend of a complete convergence of the result (in particular with a small
number of iterations this cannot be achieved).
3. For the controller based algorithm the number of iterations required for full
convergence is set using the SPEED= ITER,<nr> parameter in the
OPT_PARAM command.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Remark:
SIMULIA
Tosca Structure
Topology Optimization
5.10 References
Kabus, S. and Pedersen, C.B.W. (2012). Optimal bearing housing designing
using topology optimization. Journal of Tribology. 134(2).
Sndergaard, M.B. and Pedersen, C.B.W. (2013). Applied topology optimization of vibro-acoustic hearing instrument models. Submitted to Journal of
Sound and Vibration.
Bendse, M.P. and Sigmund, O. (2003). Topology optimization: Theory,
methods and applications. Springer-Verlag, Berlin Heidelberg
New York.
Bendse, M.P. and Sigmund, O. (1999). Material interpolations in topology
optimization, Archive of Applied Mechanics. 69:635-654.
Hansen, L.V. (2005). Topology optimization of free vibrations of fiber laser
packages. Structural and Multidisciplinary Optimization.
29(5):341-348.
Mlejnek, H.P. (1992). Some aspects of the genesis of structures. Structural Optimization. 5:64-69.
www.3ds.com/tosca
SIMULIA
Tosca Structure
References
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Shape Optimization
Shape Optimization
Shape optimization allows specific detail improvements of existing designs.
Through shape optimization the surface geometry of a given model is modified automatically to avoid material failure and increase durability or comfort.
www.3ds.com/tosca
Fig. 175 Example of nonparametric shape optimization. Pictures by courtesy of Audi AG.
6.1
General Information
Shape optimization is mostly used at the end of the design process when the
general layout of a component is more or less fixed and only minor changes
and improvements are allowed. Typically, the objective function is to minimize
stress concentrations. Based on the results of a stress analysis modifications
of the surface geometry of a component are performed until the required
stress level is reached. This process is usually carried out manually by trialand-error.
Tosca Structure.shape allows an automatization of this improvement process.
The surface geometry of a given FE model is modified iteratively based on
the FE results, such that the required optimization target is reached. The start
model is taken from an existing design, which should be improved, or from a
previous topology optimization.
SIMULIA
Tosca Structure
The Optimization Task
6.1.1
Theoretical background
6.2
6.2.1
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Shape Optimization
www.3ds.com/tosca
SIMULIA
Tosca Structure
The Optimization Task
Objective function
5. Question: Which terms describe the values to be optimized? Should these
values be minimized or maximized or otherwise combined?
Procedure: Choose terms for optimization (design responses) and target.
TAE: OBJ_FUNC_ITEM_1, select New | <term for optimization>
command; apply Edit on OBJ_FUNC_ITEM_1 to choose whether the
objective function is to be minimized or maximized.
GUI: Define the design response (volume 3: DRESP) and assign it to the
objective function (volume 3: OBJ_FUNC).
Constraint
6. Question: Which design response describes the constraint? Which value
should the constraint have?
Procedure: Choose term for constraint and set target value or upper/lower
boundary.
TAE: CONSTRAINT, select New | <term for constraint> command.
GUI: Define the design response (volume 3: DRESP) and assign it to the
constraint (volume 3: CONSTRAINT).
Optimization task
7. Question: Are all of the command definitions listed above complete and
ready for the optimization job?
Procedure: If necessary complete any additional required definitions and
prepare the optimization job.
TAE: Automatically prepared by task manager.
GUI: Reference all definitions above in OPTIMIZE.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Stop Condition
SIMULIA
Tosca Structure
Shape Optimization
Completion
10.Question: Has all the required data been specified?
Procedure: If yes, finish the definition of the optimization problem and
save your definition.
TAE: Click twice on OUTPUT and change the jobname (or proceed with the
default jobname); Update writes the parameter file.
GUI: Save as <jobname>.par.
The essential commands required for the optimization model in shape optimization are described in the following. The order of their appearance corresponds to the order of the above listed procedures.
The definitions for the optimization job are assembled in a parameter file. The
exact syntax of the commands can be looked up in vol.3 Commands Manual.
Fig. 176 gives an overview of a standard optimization task and the relation
between the several commands. Only commands which are referenced in the
OPTIMIZE command will be included in the optimization.
www.3ds.com/tosca
6.3
Design Area
In shape optimization the form of the component is changed. The change in
form is achieved by moving the surface or a part of the component surface.
The surface area of the component that can be changed is called the design
area. The design area is defined using a node group consisting of design
nodes.
The current position of a design node in a design cycle is derived by superimposing the position of the node in the start model with an optimization displacement vector. These displacements may be restricted by design variable
constraints to ensure certain geometric properties of the component. Further,
nodes in an area surrounding the design nodes may be moved to ensure
mesh quality for the FE calculation (Mesh smooth area).
SIMULIA
Tosca Structure
Design Area
6.3.1
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Remarks
SIMULIA
Tosca Structure
Shape Optimization
www.3ds.com/tosca
SIMULIA
Tosca Structure
Design Area
displacement vectors are therefore not constant; they are subject to certain
changes in each cycle.
2. With the VECTOR parameter in the optimization settings (OPT_PARAM
command) it is possible to control when the optimization displacement
vectors are calculated (see volume 3: OPT_PARAM).
Definition in Tosca ANSA environment
In Tosca ANSA environment, design variables are defined in the DESIGN
AREA folder of the task manager. Edit opens the DV_SHAPE menu where the
node group of design nodes can be chosen. (For a detailed description see
vol.1 Start Manual.)
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Shape Optimization
= dv_design_nodes
= design_nodes
END_
www.3ds.com/tosca
6.3.2
SIMULIA
Tosca Structure
Design Area
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
1. The operation for mesh smoothing can require a great deal of computing
time depending on the selected options. It is therefore advisable to select
an area for the mesh smoothing that is sufficient but not too large. The size
of the area for mesh smoothing depends on the problem and must be
specified by the user.
SIMULIA
Tosca Structure
Shape Optimization
www.3ds.com/tosca
description
LAYER_<mesh_smooth_name>
<mesh_smooth_name>_ELEM
<mesh_smooth_name>_NODE
SIMULIA
Tosca Structure
Design Area
description
<mesh_smooth_name>_SF_ELEM
Table 25
Automatically generated element and node groups after preprocessing the MESH_SMOOTH command
description
<mesh_smooth_name>_SF_NODE
<mesh_smooth_name>_DV_ELEM
<mesh_smooth_name>_DL_NODE
<mesh_smooth_name>_DL_ELEM
<mesh_smooth_name>_SF
Automatically generated element and node groups after preprocessing the referencing OPTIMIZE command
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Table 26
SIMULIA
Tosca Structure
Shape Optimization
a)
b)
www.3ds.com/tosca
The MESH_SMOOTH area contains design nodes, surface nodes that are
not design nodes and inner nodes. In many cases it is desirable to adjust the
surface nodes (in proximity of the design nodes) in the mesh smoothing to
achieve a smooth transition between the design area and remaining area.
However, in other cases, it makes more sense to fix the surface nodes to
avoid an unwanted displacement of the nodes by the mesh smoothing. For
example, the front side of a component is the design area. The
MESH_SMOOTH area extends over the entire component. If the back side of
the component is to remain unchanged, the surface nodes on the back side
must be fixed. The FREE_SF=FIX setting enables free surface nodes to be
fixed automatically in all displacement directions during the mesh smoothing:
SIMULIA
Tosca Structure
Design Area
MESH_SMOOTH
...
FREE_SF = FIX, <number_of_node_layers>
END_
All surface nodes of the MESH_SMOOTH area that are neither design nodes
nor limited by restrictions (see vol.2 chapter 6.3.3) are interpreted as free surface nodes. FREE_SF=FIX,0 is set by default, i.e., the free surface nodes
cannot be moved during mesh smoothing.
The FREE_SF=FIX setting can also be modified by specifying a number of
node layers (layers field next to FREE_SF choice menu, default=0), e.g.
FREE_SF=FIX,5. This number of node layers specifies how many node layers, beginning with the design nodes along the surface, should remain free
and not be fixed. This enables the transition area in vicinity of the design area
to be kept free despite the fixed surface. Node layers consisting of mid-side
nodes are not taken into consideration, only node layers consisting of corner
nodes.
Remarks
1. All surface nodes of the MESH_SMOOTH area are interpreted as free
surface nodes if they are notdesign nodes and not restricted by a design
variable constraint. As a consequence surface nodes for which a
DVCON_SHAPE is defined will not be interptreted as free nodes.
3. Only corner nodes are fixed. Mid-side nodes are not taken into consideration.
4. In addition to the FREE_SF parameter, there is also the possibility to limit
the optimization displacements of the MESH_SMOOTH nodes using
design variable constraints (DVCON_SHAPE entries, see vol.2 chapter
6.3.3).
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
2. If FREE_SF = FIX, <number of layers> these nodes are identified and fixed
using a design variable constraint (DVCON_SHAPE command, see vol.2
chapter 6.3.3). A node group with the name <mesh_smooth_name>_SF is
automatically generated for this purpose. A DVCON_SHAPE command
with the name <mesh_smooth_name>_SFIX is then automatically generated for this node group defining the fixation of the nodes. The generated
DVCON_SHAPE command is then automatically taken into account in the
optimization.
SIMULIA
Tosca Structure
Shape Optimization
node group
<Mesh_smooth_id_name>_BOUN
with BOUNDARY = FIX
design_nodes
mesh-smooth area
www.3ds.com/tosca
SIMULIA
Tosca Structure
Design Area
Example
Starting at the design node group, a mesh smooth domain should be generated with 5 element layers:
MESH_SMOOTH
ID_NAME
MS_LAYER
FREE_SF
= new_mesh_smooth
= design_nodes, 5
= FIX, 3
END
Fig. 183 Definition of a mesh smooth area using layers in Tosca ANSA
environment (left) and Tosca Structure.gui (right)
The algorithms for mesh smoothing are iterative, i.e., the mesh smoothing is
performed in several successive steps. The decisive factor for the convergence of the smoothed mesh is the number of steps in combination with the
increments. The iterative process can be influenced using the convergence
parameter, LEVEL_CONV. The default setting is LEVEL_CONV=LOW, i.e.,
only a few iterations with large increments are performed. This is the most
efficient setting. The convergence behavior can be improved with the settings
LEVEL_CONV=MEDIUM and LEVEL_CONV=HIGH. These settings result in
increasingly more iterations with smaller increments to be performed which,
however, can result in a substantial increase in the computing time required.
The goal should always be to work with the lowest possible convergence
parameter to avoid unnecessarily long computing times!
MESH_SMOOTH
...
LEVEL_CONV
END_
= LOW
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Shape Optimization
Remarks
1. It is recommended to adjust the setting of the LEVEL_QUAL parameter
instead of increasing the convergence level.
2. The LOW convergence level is sufficient to create a good mesh. If a higher
convergence level (MEDIUM, HIGH) is desired, be prepared for a substantial increase in computing time.
= LOW
www.3ds.com/tosca
= LOW
Remarks
1. It is not recommended to deactivate the quality level
(LEVEL_QUAL=NOT).
SIMULIA
Tosca Structure
Design Area
2. The LOW level is sufficient for many applications. A higher level (MEDIUM,
HIGH) should only be selected if the results are unsatisfactory or the
quality of the mesh needs to be improved.
3. The more TETRA elements there are in a mesh, the higher the quality level
needed. The additional computing time should be endured in any case
because it is usually possible to achieve greater changes to the shape.
4. Further quality improvement may be achieved by reducing the amount of
optimization displacement (see vol.2 chapter 6.8.1). This option should be
tried if satisfying results have not been achieved despite having used the
HIGH level setting.
Quality parameters
The quality values of the sub-algorithm mentioned are determined for each
element and base on the angle quality and, for tetrahedral elements, the
quality of the aspect ratio. The quality value lies between 1 (best element
quality) and 0 (poorest element quality). The poorest quality value of an angle
or aspect ratio is always decisive for the element. The user can specify the
interval limit (*_LOW_*, *_HIGH_*) outside of which the elements are rated
as poor by the quality algorithm. The poorer an element is rated, the greater
the consideration it will be given in improving the element quality.
MESH_SMOOTH
...
QUAD_LOW_ANGLE
= <value>
QUAD_HIGH_ANGLE = <value>
TRIA_LOW_ANGLE
= <value>
TRIA_HIGH_ANGLE = <value>
TETRA_LOW_ASPECT = <value>
TETRA_HIGH_ASPECT = value>
The way the quality values are determined can be outlined as follows:
QUAD planes (QUAD elements, lateral planes of HEXA and PENTA elements):
- Optimum angle is 90-> quality=1.
- Angle smaller or equal to QUAD_LOW_ANGLE -> quality=0.
- Angle greater or equal to QUAD_HIGH_ANGLE -> quality=0.
TRIA surfaces (TRIA elements, lateral surfaces of TETRA and PENTA elements):
- Optimum angle is 60 -> quality=1.
- Angle smaller or equal to TRIA_LOW_ANGLE -> quality=0.
- Angle greater or equal to TRIA_HIGH_ANGLE -> quality=0.
2 - 314 User Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
END_
SIMULIA
Tosca Structure
Shape Optimization
TETRA elements:
- Optimum aspect ratio is 1.33 -> quality=1.
- Aspect ratio smaller or equal to TETRA_LOW_ASPECT -> quality=0.
- Aspect ratio greater or equal to TETRA_HIGH_ASPECT -> quality=0.
Remarks
1. With LEVEL_QUAL=NOT no element quality is calculated and the interval
limits are not required.
2. The default values are practical and usually do not need to be changed.
Changing the interval limits usually only leads to a slight change in the
mesh quality.
3. The value for QUAD_LOW_ANGLE must lie between 0 and 89. The
value for QUAD_HIGH_ANGLE must lie between 91 and 180. The value
for TRIA_LOW_ANGLE must lie between 0 and 59. The value for
TRIA_HIGH_ANGLE must lie between 61 and 180. The value for
TETRA_LOW_ASPECT must lie between 0.00177 and 1.30. The value for
TETRA_HIGH_ASPECT must lie between 1.36 and 999.
4. Determination of the local quality in the MESH_SMOOTH is decoupled
from the global quality determination that is activated for the entire model
with the READ_ELEM_QUALITY parameter of the OPTIONS command.
Output of the global quality values can be made through the Patran interface or the parameter LIST, ELEM, QUAL (see volume 3: LIST). The local
quality values of MESH_SMOOTH cannot be accessed by the user.
www.3ds.com/tosca
= NO
END_
Remark
5. The list of poor quality elements can only be printed for
LEVEL_QUAL=LOW, MEDIUM or HIGH. No element qualities are calculated with LEVEL_QUAL=NOT and poor elements cannot be identified.
SIMULIA
Tosca Structure
Design Area
...
SOLVER_CHECK
Q4TAPER
Q4SKEW
T3SKEW
TETRAAR
SOLVER_STOP
=
=
=
=
=
=
YES
<value>
<value>
<value>
<value>
YES
END_
Remarks
1. The allowed value limit for the element quality should be set identically in
Tosca Structure and the finite element solver.
2. The option SOLVER_STOP=YES is only active when
SOLVER_CHECK=YES is also set. This means that the regular program
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
MESH_SMOOTH
SIMULIA
Tosca Structure
Shape Optimization
stop due to poor mesh quality can only be carried out if the mesh quality is
checked.
3. The optimization in Tosca Structure stops when the SOLVER_STOP condition is fulfilled or stops when reaching the global condition STOP,
ITER_MAX (STOP) which set the maximum number of allowed iterations
(design cycles).
www.3ds.com/tosca
SIMULIA
Tosca Structure
Design Area
CE_CORRECTION_LOOPS=<int value>
CE_CORRECTION_FACTOR=<value> (0.5)
CE_FAIL_ACTION = RESET | CONTINUE
END_
Remarks
1. The element quality for tetrahedral elements with four nodes is determined
by calculating the aspect ratio. Use the TETRAAR setting to influence the
quality detection.
2. The element quality for quadratic tetrahedral elements and for hexahedral
elements is determined by calculating the Jacobian. If it is negativ the
element needs to get corrected.
3. To make sure that the solver will not fail due to bad element quality, the
TETRAAR quality criteria should be set a little bit lesser than in the solver.
4. This option is only working with tetrahedral, hexahedral and pyramid
elements (with or without midnotes).
5. The modified elements are saved to a group with name
CORRECTED_ELEMENTS_<iteration>.
6. When used during TEST_SHAPE with more than one increment only the
group of the last increment step is saved.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Shape Optimization
www.3ds.com/tosca
SIMULIA
Tosca Structure
Design Area
= mesh_smooth_name
= elem_group_name
END_
All other declarations are optional and are used for additional specifications in
the MESH_SMOOTH definition by the user.
Remarks
1. The recommended procedure is to define MESH_SMOOTH area immediately after defining the design area (see DV_SHAPE command) since the
two areas are assigned to one another.
2. The MESH_SMOOTH definition must be activated by reference in the
OPTIMIZE command. Non-activated definitions have no influence in the
optimization. The reference in the OPTIMIZE command assigns the design
area (see DV_SHAPE command) and the area for mesh smoothing (see
MESH_SMOOTH command) to one another.
3. It is recommended to define MESH_SMOOTH before the DVCON_SHAPE
entries (see vol.2 chapter 6.3.3) or a volume constraint (see vol.2 chapter
6.5.1). This enables the system-defined MESH_SMOOTH node group to
then be used for the DVCON_SHAPE definitions or the user/systemdefined MESH_SMOOTH element group to be used for the definition of the
volume constraint.
Restrictions (DVCON_SHAPE)
For shape optimization, restrictions are defined as boundary conditions that
limit the potential area of the node displacement. A design variable constraint
is a restriction that directly affects the individual design variables, i.e., the individual design nodes. Since the nodes in the mesh smoothing area (see volume 3: MESH_SMOOTH) can be interpreted as second order design nodes,
there is also the possibility to apply the restrictions (to a limited degree) to the
nodes of the mesh smoothing area. Compared to geometrical optimization
based on a few parameters, Tosca Structure.shape allows every design node
to be displaced independently from other design nodes.
To meet functional and manufacturing requirements, it is usually necessary to
limit the solution area and therefore the independence of the design nodes.
Unrestricted shape optimization can produce trivial results. For example, if
the shape of a shaft shoulder under axial tensile stress is optimized without
restricting the design nodes, a smooth beam will arise that will not be able to
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
6.3.3
SIMULIA
Tosca Structure
Shape Optimization
fulfill the original function. To achieve the best results the rule: As much flexibility as possible, as few restrictions as necessary! should be followed. The
possible restrictions are the specification of an allowed displacement area by
limiting the directional amount of optimization displacement and the specification of variation and frozen areas. It is also possible to influence the allowed
displacement direction by limiting the displacement to specific coordinate
directions. In addition, the optimization displacement of a node can be made
dependent on the optimization displacement of another node. The definition
of the design variable constraints for shape optimization is done with the
DVCON_SHAPE command.
The following restrictions are available for shape optimization:
Restriction of the amount of displacement (see vol.2 chapter 6.3.3.2)
Maximum and minimum member size (see vol.2 chapter 6.3.3.3)
Displacement check against solids (see vol.2 chapter 6.3.3.4)
Displacement check against elements of an element group (see vol.2
chapter 6.3.3.5)
Restriction of the displacement direction (see vol.2 chapter 6.3.3.6)
Restricting the displacement to a slide surface (see vol.2 chapter 6.3.3.7)
www.3ds.com/tosca
SIMULIA
Tosca Structure
Design Area
Remarks
1. Some of the design variable constraints for shape optimization can be
interpreted as side constraints or bounds (design variable boundaries) in
the same way these terms are used in standard optimization nomenclature.
2. Some of the design variable constraints for shape optimization relate not
only to the design variable itself but also to the corresponding optimization
displacement vectors (or the design coordinates). The term design variable constraint in this case should be interpreted in a more general sense.
3. In contrast to the DVCON_SHAPE parameter, which has a direct effect on
the individual design variables, the CONSTRAINT parameter defines a
constraint for the optimization job that affects the functional relationships of
several design variables (e.g. volume constraint).
4. The activated DVCON_SHAPE entries are executed in the order in which
they are referenced in the OPTIMIZE command or defined in Tosca ANSA
environment. The individual DVCON_SHAPE entries are checked independent of one another, i.e., a DVCON_SHAPE entry always overrides the
preceding DVCON_SHAPE entry. If mutually independent restrictions are
declared all restrictions are observed. If mutually dependent restrictions
are declared the user must select an order of execution that is logical and
specific for the problem.
This section only contained a general overview of the command forms without going into detail about the exact syntax and operations of the individual
restrictions. In the following sections the individual restrictions are described
in more detail.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
5. The restricted nodes are checked at the beginning and the execution stops
if the defined constraint is not fulfilled (CHECK_SLIDE, CHECK_LINK).
This behavior can be switched off with the parameter
FEASIBLE_START=NO. But for example if the surface described node
group is not stampable and this check is switched off the restriction
enforces the stampable surface.
SIMULIA
Tosca Structure
Shape Optimization
= <MAX_GROW_VALUE>
= <MAX_SHRINK_VALUE>
www.3ds.com/tosca
SIMULIA
Tosca Structure
Design Area
Remark
1. The CHECK_GROW and CHECK_SHRINK restrictions can only be
defined for surface nodes since only surface nodes exhibit a growth or
shrinkage direction. If inner nodes are contained in the node group
(ND_GROUP parameter), the DVCON_SHAPE definition will be rejected.
Fig. 189 Minimum member size with radius = 3.0 (thickness = 6.0 for TAE)
A typical parameter set for the member size restriction is of the following
form:
DVCON_SHAPE
ID_NAME
ND_GROUP
CHECK_MAX_MEM
CHECK_MIN_MEM
CHECK_NDGR
TOLERANCE
DVCON_SHAPE
=> ...
=> <MEMBER_SIZE_NODES>
=> <MEMBER_SIZE_RADIUS>
=> <MEMBER_SIZE_RADIUS>
=> <MEMBER_SIZE_CHECK_GROUP>
=> <TOLERANCE_FOR_INTERSECTION_TESTS>
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
For the definition of minimum member size a radius is specified, such that
normal to the surface of the model a minimum thickness of 2*radius must be
achieved. If optimization displacements break this restriction they will be
readapted according to the selected master criterion. If the structure is
smaller in certain regions from the very first, only growth is permitted in these
areas unless the areas fit the condition. CHECK_MAX_MEM works analogously. In Tosca ANSA environment, the settings are edited in
MEMBERSIZE_CONTROL dialog.
SIMULIA
Tosca Structure
Shape Optimization
ND_GROUP
CHECK_NDGR
www.3ds.com/tosca
SIMULIA
Tosca Structure
Design Area
3. For the same reason, the maximum member size tends to be conservative.
4. If your starting model does not fulfill your desired thickness, the member
size restriction is unable to fit the model to these values.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Shape Optimization
Remarks
www.3ds.com/tosca
SIMULIA
Tosca Structure
Design Area
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Shape Optimization
www.3ds.com/tosca
SIMULIA
Tosca Structure
Design Area
Loading the Node Fixations via the Interface from the FE Program
The full or partial fixation of nodes is the most common and most important
type of restriction; it is practically used in every optimization model. The most
efficient method for defining the displacement restrictions in the FE preprocessor is as an extra load case in the analysis model and then load it via the
FE interface in the optimization preprocessor. The interface must first be activated with the OPTIONS, BC = ... parameter. In this way all node fixations for
the optimization model can be defined in advance in the FE preprocessor.
The fixation is always based on the FE displacement coordinate system of
the node. The parameter
CHECK_BC
= YES
activates the node fixations of the node group (ND_GROUP parameter) that
are loaded in the FE model. Fixations that reference nodes not contained in
the node groups are not activated. To prevent loaded fixations from being
activated enter:
CHECK_BC
= NO
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Remarks
SIMULIA
Tosca Structure
Shape Optimization
ID_NAME
MASTER
CLIENT
CLIENT_DIR
TOL
CS
=
=
=
=
=
=
surface
NDGR, slide_master_ndgr
SURF_TURN
0, 0, 1
0.1, 0.1, 0.1
CS_0
www.3ds.com/tosca
LINK_SHAPE
SIMULIA
Tosca Structure
Design Area
END
END_
END_
=
=
=
=
=
surface
NDGR, slide_ndgr
FREE_FORM
0.1, 0.1, 0.1
CS_0
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
ID_NAME
CHECK_SLIDE
ND_GROUP
SIMULIA
Tosca Structure
Shape Optimization
Here, the node group "slide_ndgr" is used to generate the surface on which
the design nodes will be restricted. The CLIENT = FREE_FORM allows for
freeform surfaces.
Remarks
1. CHECK_SLIDE restrictions can be performed for surface nodes as well as
for inner nodes. To limit the exterior form of a component, it only makes
sense to restrict surface nodes. The restriction of inner nodes can be
undertaken. However, the node displacements in the MESH_SMOOTH
area should be limited.
2. To simplify the definition of the contact check it is useful to divide the
limiting surfaces by assigning various element property numbers (or materials). This greatly simplifies the selection and assembly of groups in the
optimization preprocessor.
3. If the elements being used in the check are loaded with the ADD_FILE
parameter of FEM_INPUT command, attention should be paid that node or
element IDs are not used twice since Tosca Structure cannot process duplicated IDs.
www.3ds.com/tosca
SIMULIA
Tosca Structure
Design Area
readers should skip this chapter at this time. This section can be read when
the need arises.
Remarks
1. An individual link condition can be assigned several times, i.e., an individual link condition can be activated in several DVCON_SHAPE entries for
several node groups.
2. Some manufacturing restrictions require the definition of numerous node
groups and restrictions. To make this easier, you can automatically
generate node groups using the GROUP_AUTO_DEF command and automatically assign link conditions as restrictions using the
DVCON_AUTO_SHAPE command.
3. A detailed description of the LINK_SHAPE command is available in vol.2
chapter 6.3.4.
4. In Tosca ANSA environment coupling conditions can be defined using the
modules buttons LINK_SHAPE and DVCON_SHAPE.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Shape Optimization
www.3ds.com/tosca
DVCON_SHAPE
ID_NAME
=name_of_dvcon_shape
ND_GROUP
=name_of_node_group
CHECK_GROW
=<max_grow_value>
CHECK_SHRINK =<max_shrink_value>
CHECK_MAX_MEM =<radius>
CHECK_MIN_MEM =<radius>
CHECK_SOLID
=name_of_solid
CHECK_ELGR
=name_of_element_group
CHECK_BC
=cs_name,[FREE|FIX],[FREE|FIX],[FREE|FIX]
CHECK_DOF
=[YES|NO]
CHECK_SLIDE
=name_of_link_shape
CHECK_LINK
=name_of_link_shape
FEASIBLE_START =[YES|NO]
END_
Remarks
1. It is possible to define several individual CHECK_* restrictions within a
DVCON_SHAPE command. The order of the execution of the individual
restrictions within a DVCON_SHAPE command appears as follows:
CHECK_GROW/ CHECK_SHRINK, CHECK_MAX_MEM,
CHECK_MIN_MEM, CHECK_SOLID, CHECK_ELGR, CHECK_BC,
CHECK_DOF, CHECK_SLIDE, CHECK_LINK. The individual restrictions
are checked independent of one another, i.e., an individual restriction
always overrides the preceding restriction.
SIMULIA
Tosca Structure
Design Area
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
6.3.4
SIMULIA
Tosca Structure
Shape Optimization
ture.gui.Using Tosca ANSA environment, link definitions are visualized graphically in the model view.
www.3ds.com/tosca
= name_of_link_shape
= ...
= ...
END_
SIMULIA
Tosca Structure
Design Area
LINK_SHAPE
...
CS
TOL
= name_of_coord_system
= <tol_1>, <tol_2>, <tol_3>
END_
master node
2. The definition of coupling conditions can require a great deal of time and
effort. In order to be able to estimate the best possible potential of an optimization, one optimizationshould be performed with as few restrictions as
possible and only a few coupling conditions at the beginning of a project.
3. Coupling conditions restrict the range of solutions for the system and
reduce the optimization potential.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Shape Optimization
This causes the master displacement to be determined from the same node
during the entire optimization.
Furthermore the master node may be determined from a master node group.
This allows the user to define a components edge to be the master edge for
optimization. The algorithm will determine the master node automatically from
the master node group. In this case the master node group must contain
exactly one node of each link group.
MASTER = NDGR, <NODEGROUP>
Another way is to have the system automatically determine the master node
according to two different criteria:
MASTER = MAX
or
MASTER = MIN
In this case, the master node is re-determined in every cycle. When the master node is automatically determined, the critical factor is identifying which
node displacement (determined by the stress) for the coupling group is relevant. Principally, there exist four different cases of how the largest and smallest node displacements relate to the reference value within the node group:
Case 1
The stress everywhere is greater than the reference value, i.e., a positive
displacement is determined for all design nodes of the coupling group. All
design nodes will grow out of the component.
www.3ds.com/tosca
Case 2
The stress everywhere is less than the reference value, i.e., for all design
nodes of the coupling group a negative displacement is determined. All
design nodes will shrink inwards.
Case 3
There are nodes with greater and less stress than the reference value and
the absolute shrinkage is greater than the absolute growth (abs(max_neg)
> abs(max_pos)).
Case 4
There are nodes with greater and less stress than the reference value and
the absolute shrinkage is less than the absolute growth (abs(max_neg) <
abs(max_pos)).
Case 1
Case 2
Case 3
Case 4
ALL_GROWTH
ALL_SHRINK
MORE_SHRINK
MORE_GROWT
H
SIMULIA
Tosca Structure
Design Area
max_growth
min_growth
OBJ_FUNC
max_growth
max_growth
OBJ_FUNC
min_shrink
OBJ_FUNC
max_shrink
max_shrink
OBJ_FUNC
max_shrink
lab1 =
MAX
max_growth
min_shrink
max_growth
max_growth
MIN
min_growth
max_shrink
max_shrink
max_shrink
The two criteria MAX and MIN, respectively, select different master nodes
corresponding to the selected displacement values:
MAX
The MAX-Criterion is the conservative option. Here, the maximum growth
(as in the cases 1, 3, 4) or the smallest shrinkage (as in case 2) is always
used to select the master node. This is the standard criterion for shape
optimization.
MIN
The MIN-Criterion moves the component surface inward as far as possible.
This criterion has to be used when linking conditions are required while
optimizing contact surfaces.
Remark
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Shape Optimization
www.3ds.com/tosca
SIMULIA
Tosca Structure
Design Area
=
=
=
=
PLANE_SYM
<X_1>, <X_2>, <X_3>
name_of_coord_system
<TOL_1>, <TOL_2>, <TOL_3>
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
2. Only the MASTER=MAX or MASTER=MIN criteria are allowed for determination of the master node.
SIMULIA
Tosca Structure
Shape Optimization
=
=
=
=
SURF_PLANE_SYM
<X_1>, <X_2>, <X_3>
name_of_coord_system
tolerance_value
www.3ds.com/tosca
MASTER
SIMULIA
Tosca Structure
Design Area
node,
reflected
by
symmetry
plane
displaced
model
surface
y
displaced
node
d1
d2
plane of
symmetry
original
position of
node
This link condition couples nodes in a not necessary symmetric mesh that
reoccur in a cyclic manner around a rotational axis.
To be able to build up the coupling, a symmetry axis and an angle must be
specified. The following six parameters are necessary for the definition of the
link condition:
CLIENT
CLIENT_DIR
CS
TOL
ANGLE
CYCLIC_SYM_START
=
=
=
=
=
=
SURF_CYCLIC_SYM
<X_1>, <X_2>, <X_3>
name_of_coord_system
tolerance_value
angle_in_degree
<X_1>, <X_2>, <X_3>
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Shape Optimization
absolute tolerance. The ANGLE divides the area around the axis
(CLIENT_DIR) in pieces of equal size that shall be made symmetric. Thus,
the angle must be a divisor of 360. The CYCLIC_SYM_START point defines
the starting point for the partitioning (see Fig. 200). Its coordinates are given
with reference to the global cartesian coordinate system. It must not lie on the
rotational axis.
Again, like for the SURF_PLANE_SYM link condition (chapter 6.3.4.4 Plane
symmetry for non-symmetric meshes (SURF_PLANE_SYM)) a master strategy might be selected:
MASTER
MAX | MIN}
axis
CYCLIC_SYM_START
www.3ds.com/tosca
Remarks
1. The coordinate system referenced by CS must be a Cartesian coordinate
system.
2. Only the MASTER=MAX or MASTER=MIN criteria are allowed for determination of the master node.
3. The coordinates of parameter CYCLIC_SYM_START are given with reference to the global cartesian coordinate system.
SIMULIA
Tosca Structure
Design Area
=
=
=
=
=
=
SURF_CYCLIC_PLANE_SYM
<X_1>, <X_2>, <X_3>
name_of_coord_system
tolerance_value
angle in degree
<X_1>, <X_2>, <X_3>
axis
planes of
symmetry
CYCLIC_SYM_START
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Shape Optimization
a)
b)
c)
www.3ds.com/tosca
CLIENT
CS
TOL
= POINT_SYM
= name_of_coord_system
= <TOL_1>, <TOL_2>, <TOL_3>
SIMULIA
Tosca Structure
Design Area
Remarks
1. The coordinate system referenced by CS must be a cartesian coordinate
system.
2. Only the MASTER=MAX or MASTER=MIN criteria are allowed for determination of the master node.
ROTATION_SYM
<X_1>,<X_2>,<X_3>
name_of_coord_system
<TOL_1>, <TOL_2>, <TOL_3>
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
CLIENT
CLIENT_DIR
CS
TOL
SIMULIA
Tosca Structure
Shape Optimization
the client nodes are calculated in such a way that they move rotational symmetric to the axis (see Fig. 204).
CLIENT
CS
= VECTOR
= name_of_coord_system
The procedure involves calculating the difference between the current coordinates and start coordinates of the master node in relation to the coordinate
systems referenced by CS.Then the start coordinates of the client nodes are
calculated in relation to the coordinate system, the difference of the master
www.3ds.com/tosca
The following two parameters are entered for coupling displacement coordinates:
SIMULIA
Tosca Structure
Design Area
node is applied and the current coordinates of the client nodes are determined (see Fig. 205).
Each of the three coordinates can be set to either ON or OFF. Only those displacement coordinates set to ON are coupled. Displacement coordinates set
to OFF are not taken into consideration for the coupling. The default setting is
VECTOR=ON, ON, ON.
Remarks
1. The coordinate system referenced by CS can be a Cartesian coordinate
system or a cylindrical or spherical coordinate system.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
2. If the coordinate system is Cartesian, all nodes have the same displacement vector (given the name CLIENT=VECTOR), i.e., all nodes are moved
translational like a rigid body. All nodes have the same displacement
direction and the same amount of displacement.
SIMULIA
Tosca Structure
Shape Optimization
CLIENT
CS
= DIRECTION
= name_of_coord_system
The procedure is the same as that for CLIENT=VECTOR, but with the difference that the retained displacement vector is rescaled to the original displacement amount of the client nodes (see Fig. 206).
Fig. 206 Coupling of the displacement direction (with reference to a Cartesian coordinate system)
Remark
1. See note for CLIENT=VECTOR (see vol.2 chapter 6: Remarks).
= LENGTH
www.3ds.com/tosca
SIMULIA
Tosca Structure
Design Area
= DISP_CS
Each of the three coordinates can be set to either ON or OFF. Only those displacement coordinates set to ON are coupled. Displacement coordinates set
to OFF are not taken into consideration for the coupling. The default setting is
DISP_CS=ON, ON, ON.
Remarks
1. The FE displacement coordinate system of the coupled nodes must be of
the same type, i.e. either Cartesian, cylindrical or spherical.
2. Each node can have its own FE displacement coordinate system. Alternatively, if all nodes have the same FE displacement coordinate system, an
identical link condition with CLIENT=VECTOR can be defined.
CLIENT
CLIENT_DIR
CS
= SURF_STAMP
= <x_1>,<x_2>,<x_3>
= name_of_coord_system
The master nodes are found using the standard master criterion. The stamping surface is defined using the given stamping direction and the cutting edge
automatically generated by Tosca Structure. All nodes of the node group are
linked to this surface.
An additional demolding direction can be included:
DEMOLD_DIR
= <x_1>,<x_2>,<x_3>
The demolding direction has to be orthogonal to the client direction. Therefore Tosca Structure projects the demold vector onto a plane normal to the client direction.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Shape Optimization
Remarks
1. This link condition allows the definition of stamping restrictions to arbitrary
meshes. No special meshing conditions have to be taken into consideration.
2. It is possible to define stamping restrictions for initial components which are
not stampable in the beginning of the optimization procedure. However,
this is not recommended because the conditions for stamping are met in
the first design cycle. This may lead to large node displacements and a
distorted finite element mesh.
= SURF_TURN
= <X_1>,<X_2>,<X_3>
= name_of_coord_system
The direction defined by the CLIENT_DIR and the origin of the coordinate
system specify the exact position and direction of the rotation axis.
The master nodes are found using the standard master criteria. The turning
surface is defined using the given rotation axis and the cutting edge automatically generated by Tosca Structure. All nodes of the node group are linked to
this surface.
www.3ds.com/tosca
Remarks
1. This link condition allows the definition of turning restrictions to arbitrary
meshes. No special meshing conditions have to be taken into consideration.
2. The referenced coordinate system must lie exactly on the rotation axis as
the algorithm always orientates the surface towards the coordinate system.
If non-symmetrical effects occur during optimization, the correct position of
the coordinate system has to be checked.
3. It is possible to define turning restrictions for initial components that are not
turnable in the beginning of the optimization procedure. However, this is
not recommended because the conditions for turning are met in the first
design cycle. This may lead to large node displacements and a distorted
finite element mesh.
SIMULIA
Tosca Structure
Design Area
=
=
=
=
SURF_DRILL
<X_1>,<X_2>,<X_3>
name_of_coord_system
<real> (0 < angle < 45)
The direction defined by the CLIENT_DIR and the origin of the coordinate
system specify the exact position and direction of the drill axis, the angle
specifies a minimum surface angle.
The shape of the drilling surface can be specified with an additional undercut
tolerance. The term drilling surface in this case should be interpreted in a
more general sense.
UNDERCUT_TOL
= <real> (>0)
drill
direction
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
undercut
tolerance
SIMULIA
Tosca Structure
Shape Optimization
CLIENT
DEMOLD_DIR
CS
CHECK_GROUP
TOL
=
=
=
=
=
SURF_DEMOLD
<X_1>,<X_2>,<X_3>
name_of_coord_system
name_of_node_group
<TOL_1>, <TOL_2>, <TOL_3>
www.3ds.com/tosca
UNDERCUT_TOL
= <real>
Remarks
1. It is possible to define demolding restrictions for initial components which
are not demoldable at the beginning of the optimization procedure.
However, this is not recommended as the conditions for demolding are met
in the first design cycle. This may lead to large node displacements and a
distorted finite element mesh.
2. No single master nodes need to be determined for demolding restrictions.
The master criterion in this case is used to determine a priority rule
between nodes in the undercut and overlapping nodes.
3. All SURF_xxx link commands have a parameter called: SURF_PARAM =
<master_areas>, <net_points> which are used to create a spline that
SIMULIA
Tosca Structure
Design Area
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Shape Optimization
=
=
=
=
link_rigid
NODE, 46
VECTOR
CS_0
END_
DVCON_SHAPE
ID_NAME
ND_GROUP
CHECK_LINK
= dvcon_rigid
= node_rigid
= link_rigid
END_
www.3ds.com/tosca
=
=
=
=
link_left_or_right
MAX
VECTOR
CS_0
END_
SIMULIA
Tosca Structure
Objective Function
DVCON_SHAPE
ID_NAME
ND_GROUP
CHECK_LINK
= dvcon_left
= ndgr_left
= link_left_or_right
END
DVCON_SHAPE
ID_NAME
ND_GROUP
CHECK_LINK
= dvcon_right
= ndgr_right
= link_left_or_right
END_
In each design cycle the system identifies which nodes in each of the node
groups, ndgr_left and ndgr_right, has the greatest positive displacement (in
the growth direction). Usually, these are the nodes with the largest stress difference between the effective value and the targeted value. These displacements are then applied to all nodes of the node groups ndgr_left and
ndgr_right, respectively. The following command can be used instead of the
two individual DVCON_SHAPE commands:
DVCON_AUTO_SHAPE
ID_NAME
= dvcon_*
ND_GROUP_FAMILY = ndgr_*
CHECK_LINK
= link_left_or_right
END_
6.4
Objective Function
The objective function describes the optimization target. In general, one scalar value (sometimes combined from other scalars) is to be maximized or
minimized.
6.4.1
Overview
The OBJECTIVE FUNCTION is the function, which value can be maximized
or minimized during the optimization. This function depends on the results of
the FE analysis combined into design responses (DRESP).
Tosca Structure.shape works with a CONTROLLER-based algorithm which
homogenizes the stresses with respect to a reference value (see also chapter
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
The naming left and right is determined automatically from the complete
name of the node groups and added to the root name of the automatically
generated DVCON_SHAPE entries. However, this requires that only these
two node groups begin with the name ndgr_ otherwise other node groups
will be taken into consideration.
SIMULIA
Tosca Structure
Shape Optimization
6.4.2
Reference stress
You may want to define a reference value yourself. In this case you need to
understand how Tosca Structure.shape works. The CONTROLLER-based
algorithm is driven by following redesign rule:
Design nodes with stress above the reference value are moved outwards
(growth).
Design nodes with stress below the reference value are moved inwards
(shrinkage).
This produces components with homogenized stress in the design area.
So, if you choose a high reference value most design nodes will shrink in
order to achieve this value. A low reference value will have the opposite
effect. With some practice, a good choice of reference value can be estimated giving the designer an optimal control over the shape optimization.
You may also choose the reference value to variable e.g. dependent on a
design response. This has a special use by design of relief notches where the
reference value is chosen outside the design nodes area. This causes the
design nodes to shrink until they have the same stress value as the reference
value. This trick can only be done if the design area is relatively close to the
area where the reference value is. Otherwise, you will not get the stress
dampening effect of a relief notch.
www.3ds.com/tosca
Remarks:
1. A reference value is NOT the same as a CONSTRAINT! For most real
structures, the maximum stress of a converged shape optimization will be
some percent larger than the given or the automatically calculated reference stress.
2. Some structures and/or loading situations are not well suited for the
CONTROLLER-based algorithm. You must have the correlation between
growth in design nodes also minimizes the stresses.
- One example is a cantilever beam with a prescribed displacement at its
free end. Due to the high stresses at the supports, the beam will become
thicker. Because of the prescribed displacement the stresses will be
higher in the next iteration. The homogenization works but the stresses
will increase because the beam stiffness increases as well.
SIMULIA
Tosca Structure
Objective Function
6.4.3
SIG_1
SIG_2
SIG_3
SIG_11
SIG_22
SIG_33
SIG_12
SIG_23
SIG_13
SIG_ABS_123
SIG_ABS_3
* The marked design responses are only supported by the Abaqus and
ANSYS interface, see vol.2 chapter 11.1, Abaqus and vol.2 chapter 11.2,
ANSYS.
** Note that ABQ_ND_PEEQ is the scalar value that Abaqus calculates as
PEEQ, which is NOT the same as STRAIN_PLASTIC. ABQ_ND_PEEQ is
only available in Abaqus.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Stress hypotheses
SIMULIA
Tosca Structure
Shape Optimization
SIG_MISES
SIG_TRESCA
SIG_BELTRAMI
SIG_GALILEI
SIG_KUHN
SIG_MARIOTTE
SIG_SANDEL
SIG_SAUTER
SIG_DRUCKER_PRAGER
SIG_CONTACT_PRESSURE *
SIG_CONTACT_SHEAR *
SIG_CONTACT_SHEAR_X *
SIG_CONTACT_SHEAR_Y *
SIG_CONTACT_TOTAL *
Strain formulations
STRAIN_ELASTIC*
STRAIN_PLASTIC*
STRAIN_TOTAL *
STRAIN_ENERGY
STRAIN_ENERGY_DENS
Solver specific results
ABQ_ND_PEEQ **
Damage results
www.3ds.com/tosca
DAMAGE
DAMAGE_LC
Description
Elastic Strain
Plastic Strain
Total Strain (elastic + plastic)
Strain energy
Strain energy density
Description
Abaqus PEEQ nodal value
Description
Damage value from durability analysis
Damage value from durability analysis
with loadcase information (mustuse
ONF 601)
* The marked design responses are only supported by the Abaqus and
ANSYS interface, see vol.2 chapter 11.1, Abaqus and vol.2 chapter 11.2,
ANSYS.
** Note that ABQ_ND_PEEQ is the scalar value that Abaqus calculates as
PEEQ, which is NOT the same as STRAIN_PLASTIC. ABQ_ND_PEEQ is
only available in Abaqus.
Remark:
ref
SIMULIA
Tosca Structure
Constraints
ref
2. Also, for controller based shape optimization the user must either set all
REFERENCE-values or none at all (automatic reference value calculation).
6.5
Constraints
The only allowed constraints for controller based shape optimization are volume and weight constraints.
6.5.1
Volume constraint
In order to select volume as the design response, the volume must be
requested with TYPE=VOLUME. The individual element volumes of the element group (EL_GROUP parameter) are then added together by the summation parameter (GROUP_OPER=SUM parameter) to achieve the total
volume. The volume is a variable independent of the load cases. The design
response is labeled with a unique name (ID_NAME parameter) so it can be
referenced as a constraint. A typical definition of a design response appears
as follows:
DRESP
=
=
=
=
=
=
dresp_volume
SYSTEM
all_elements
VOLUME
SUM
EVER
END_
Once the volume of an element area has been defined as the design
response, the design response must be defined as a constraint using the
CONSTRAINT parameter. The value of the equality constraint (EQ_VALUE
parameter) is also declared. In addition, the parameter EQ_VALUE is declared
as absolute value (MAGNITUDE=ABS) or relative value (MAGNITUDE=REL)
in relation to the initial volume. The constraint is labeled with a unique name
(ID_NAME parameter) so it can be referenced in an optimization job (see
OPTIMIZE command). A typical definition of a constraint appears as follows:
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
ID_NAME
DEF_TYPE
EL_GROUP
TYPE
GROUP_OPER
UPDATE
SIMULIA
Tosca Structure
Shape Optimization
CONSTRAINT
ID_NAME
DRESP
MAGNITUDE
EQ_VALUE
=
=
=
=
volume_constraint
dresp_volume
REL
1
END_
Example:
The total volume of a element group in the start model is 2000. For the optimized model a total volume of 1800 is requested for the element group. Using
absolute values, MAGNITUDE=ABS, EQ_VALUE=1800 must be declared.
Using relative values, MAGNITUDE=REL, EQ_VALUE=0.9 must be
declared.
Remarks
1. The CONSTRAINT definition must be activated by a reference in the OPTIMIZE command.
2. It is highly recommended to choose a volume constraint near the orignal
volume, say +/- 5% depending on the mesh quality and size of design area.
3. Tosca Structure.shape will enforce the volume constraint in first design
cycle. This may destroy the mesh, esspecially if the volume constraint is far
away from the initial volume. If you want to turn off this mechanism and let
Tosca Structure.shape iterate for more iteration to achieve volume
constraint use OPTIONS. This setting is not recommended as it will
simply cause more design cycles before the mesh is corrupted.
www.3ds.com/tosca
OPTIONS
SHAPE_FORCE_VOLUME = OFF
END_
SIMULIA
Tosca Structure
Typical Optimization Tasks for Static Analysis
6.5.2
Weight constraint
Weight constraints are defined in exactly the same way as volume constraints
(see chapter 6.5.1 Volume constraint). Using this design response a physical
target weight can be set explicitly. This is in particular useful when different
materials are present in the model. The corresponding design response is
defined as follows:
DRESP
ID_NAME
DEF_TYPE
EL_GROUP
TYPE
GROUP_OPER
UPDATE
=
=
=
=
=
=
dresp_volume
SYSTEM
all_elements
WEIGHT
SUM
EVER
END_
Once the volume of an element area has been defined, the design response
must be referenced in the CONSTRAINT definition.
6.6
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
6.6.1
SIMULIA
Tosca Structure
Shape Optimization
www.3ds.com/tosca
SIMULIA
Tosca Structure
Typical Optimization Tasks for Static Analysis
Commands
DRESP
ID_NAME
DEF_TYPE
TYPE
ND_GROUP
LC_SET
LC_SET
GROUP_OPER
=
=
=
=
=
=
=
DRESP_VON_MISES
SYSTEM
SIG_MISES
design_nodes
ALL,1,All
ALL,2,All
Max
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Tosca Structure.gui
SIMULIA
Tosca Structure
Shape Optimization
END_
OBJ_FUNC
ID_NAME
TARGET
DRESP
= MY_OBJ_FUNC
= MINMAX
= DRESP_VON_MISES, ,
END_
6.6.2
www.3ds.com/tosca
Fig. 210 The hole plate example with a reference value of 70 N/mm and
120 N/mm
SIMULIA
Tosca Structure
Typical Optimization Tasks for Static Analysis
Command
OBJ_FUNC
ID_NAME
TARGET
DRESP
END_
= MY_OBJ_FUNC
= MINMAX
= DRESP_VON_MISES, , 120.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Tosca Structure.gui
SIMULIA
Tosca Structure
Shape Optimization
6.6.3
Fig. 211 Design area and reference nodes for determining the reference
stress
www.3ds.com/tosca
In Fig. 211 is a simple notch shown with a relief notch. The primary notch is
not allowed to be changed only the relief notch. The result is shown in Fig.
212 where the stresses at the reference nodes are drastically minimized
through the optimized relief notch.
SIMULIA
Tosca Structure
Typical Optimization Tasks for Static Analysis
Tosca Structure.gui
1. Define a VARIABLE for the reference stress of the reference nodes.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Shape Optimization
Commands
VARIABLE
ID_NAME
DEF_TYPE
TYPE
ND_GROUP
LC_SET
LC_SET
GROUP_OPER
=
=
=
=
=
=
=
REF_NODE_STRESS
SYSTEM
SIG_MISES
refence_nodes
ALL,1,All
ALL,2,All
Max
=
=
=
=
=
=
=
DRESP_VON_MISES
SYSTEM
SIG_MISES
design_nodes
ALL,1,All
ALL,2,All
Max
END_
DRESP
ID_NAME
DEF_TYPE
TYPE
ND_GROUP
LC_SET
LC_SET
GROUP_OPER
END_
OBJ_FUNC
ID_NAME
TARGET
DRESP
= MY_OBJ_FUNC
= MINMAX
= DRESP_VON_MISES, , REF_NODE_STRESS
END_
www.3ds.com/tosca
6.7
6.7.1
SIMULIA
Tosca Structure
Advanced Tosca Structure.shape Optimizations
have a large constant stress over the plastic area. For this reason most analysts use a strain measure to inspect these areas.
Tosca Structure.shape optimization supports different strain measures for this
purpose, currently only supported by Abaqus, see vol.2 chapter 11.1,
Abaqus, and ANSYS, see chapter 11.2 ANSYS.
Example:
Choose TOTAL_STRAIN_ENERGY as design response measure:
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Shape Optimization
Tosca Structure.gui
Command
DRESP
www.3ds.com/tosca
ID_NAME
DEF_TYPE
TYPE
ND_GROUP
LC_SET
GROUP_OPER
=
=
=
=
=
=
MY_DRESP
SYSTEM
STRAIN_TOTAL
design_nodes
ALL,1,All
Max
END_
6.7.2
SIMULIA
Tosca Structure
Advanced Tosca Structure.shape Optimizations
big influence on the contact pressure. This is the reason for a small SCALE
value.
The CONTACT_PRESSURE design responses are currently only supported by
Abaqus, see vol.2 chapter 11.1, Abaqus.
Tosca ANSA environment
1. Choose TYPE = SIG_CONTACT_PRESSURE
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Shape Optimization
www.3ds.com/tosca
Tosca Structure.gui
Commands
DRESP
ID_NAME
DEF_TYPE
TYPE
ND_GROUP
LC_SET
GROUP_OPER
=
=
=
=
=
=
MY_DRESP
SYSTEM
SIG_CONTACT_PRESSURE
DESIGN_NODES
ALL,1,All
Max
END_
SIMULIA
Tosca Structure
Settings
OPT_PARAM
ID_NAME
OPTIMIZE
SCALE
= MY_PARAMETERS
= MY_OPTIMIZATION_TASK
= -0.001
END_
6.8
Settings
= param_for_shape_optimization
= shape_optimization
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Shape Optimization
6.8.1
www.3ds.com/tosca
...
SCALE
...
= <REAL_VALUE>
= <GROW_VALUE>, <SHRINK_VALUE>
SIMULIA
Tosca Structure
Settings
Remarks
1. It is highly recommended to perform the first optimization run with the
default increment size (SCALE=1.0). From evaluating the obtained results,
it can be decided if the optimization should be accelerated or slowed down.
2. Increasing the increment size can be useful when several optimization
steps in the same direction are performed in the beginning of the optimization and hardly any change in the increment size is observed. Especially,
for tight FE meshes with small element edge lengths, the increment size is
relatively small which leads to numerous design cycles with relatively small
changes in the model in each design cycle. If the selected increment size is
too large, the possibility that the optimum will be bypassed exists and the
optimization will not converge. In addition, the mesh quality decreases with
increasing increment size. In extreme cases individual elements may
collapse.
3. Decreasing the increment size is recommended when the start model is
close to optimum at the start. A decrease of the increment size can also be
helpful when numerous restrictions with link conditions (DVCON_SHAPE
with CHECK_ LINK) are contained in the optimization task. A decrease of
the increment size can also be of advantage when the mesh quality is poor.
6.8.2
= [ LINEAR | INTERPOLATE ]
With the default option LINEAR the midside node positions are linearly interpolated from the optimized position of the connected corner nodes. With the
option INTERPOLATE the midside node optimization displacements are inter2 - 378 User Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Shape Optimization
6.8.3
www.3ds.com/tosca
...
CURV_SMOOTH
...
SIMULIA
Tosca Structure
Settings
6.8.4
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Shape Optimization
i = 1 i Bij
j = ---------------------------N
i = 1 Bij
B ij = ( r j d ji )
r j = r max e
0 ,5 ( max )
max = max ( n j n R )
is the filter value for node j. The main filter function (B) decreases with the
distance (d) between node i and j. The maximal radius ( rmax ) defines the maximum distance for the nodes i to influence the filter value. The curvature
dependency ( r j ) defines a weight function to reduce the radius at higher local
surface curvature ( max ) approximated by the vector product of the node normal ( n j ) to the neighboring nodes ( n k ).
SIGMA ( ) and EXPONENT (p) are optional with the default values (0.2 and
1., respectively). The smaller the SIGMA, the larger is the influence of the
surface curvature. To avoid this effect, use a large SIGMA value (e.g.,
10000).
The exponent value defines the weight function which controls the influence
depending on the distance from the node.
To smooth local peaks of the nodal reference stresses, use the DRESP
OPER=FILTER which gives the user the possibility to define filters that correspond to single design responses. Example:
www.3ds.com/tosca
DRESP
ID_NAME
DEF_TYPE
VAR_OPER
VAR_A
RADIUS
EXPONENT
SIGMA
=
=
=
=
=
=
=
DRESP_MISES_FILTERED
OPER
FILTER
DRESP_MAX_MISES
30.0
1.0
1.0
END_
The parameters RADIUS, EXPONENT and SIGMA have the same meaning
as in the filtering of nodal displacements.
Remark
Large values of RADIUS may increase CPU-time.
SIMULIA
Tosca Structure
Settings
6.8.5
= [ EVER | FIRST ]
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
The default setting is VECTOR=EVER. The optimization displacement vectors are re-determined in every design cycle by the optimization algorithm
and consequently adjusted to changed conditions (for example shape of the
structure, effective restrictions, mesh quality, etc.). With the setting VECTOR=FIRST, the optimization displacement vectors are calculated only once
in the first design cycle and then kept constant in all other cycles. The optimization displacement vectors are not adjusted to changes in conditions during
the remaining part of the optimization. Fig. 215 provides an illustration of the
two settings. Generally, VECTOR=EVER provides better results since the
mesh smoothing algorithm is less restricted and a better mesh can be
achieved. However, in certain cases the setting VECTOR=FIRST can be of
advantage.
SIMULIA
Tosca Structure
Shape Optimization
6.8.6
= [ MINIMUM | AVERAGE ]
www.3ds.com/tosca
6.9
6.9.1
General
Before beginning an optimization, it is advisable to check the output file
(TOSCA.OUT) of the optimization preprocessors for any possible warnings or
errors. If the optimization preprocessing (for more detailed information see
vol.2 chapter 12) has been performed without error, the user has the option of
carrying out a test run for the shape optimization without a prior FE analysis.
This is done by applying pseudo optimization displacements. This option
enables the user to quickly and easily check if the mesh smoothing (see vol.2
SIMULIA
Tosca Structure
Check run (TEST_SHAPE)
chapter 6.3.2) and the restrictions (see vol.2 chapter 6.3.3) are fully defined
and will deliver the desired results. The above procedure is especially recommended for link conditions (see vol.2 chapter 6.3.4). The following are typical
questions that such a test run can answer:
Is the design area, i.e., the design nodes, selected correctly?
Is the MESH_SMOOTH area too small or too large?
Is the selected transition area between the design area and the border of
the MESH_SMOOTH area in order?
Will all of the restrictions be fulfilled (displacement directions, amount of
displacement, contact against solids or elements, link conditions)?
Will any nodes be moved by MESH_SMOOTH although they should not be
modified, so that additional restriction of these nodes is needed?
The results of the test run are sent to user-defined files that can be subsequently loaded into a suitable postprocessor for evaluation. This allows the
test results to be easily displayed and checked. If the results of the test run
are not satisfying, the optimization model may need to be modified. The effort
required to perform a test run in the optimization preprocessor is much less
than the effort required for a complete optimization. Unwanted side effects
can make a costly and time-consuming optimization useless although the
side effects might have been recognized without much effort in a test run.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
6.9.2
SIMULIA
Tosca Structure
Shape Optimization
6.9.3
www.3ds.com/tosca
Fig. 217 Start of a test run for shape optimization in Tosca Structure.gui
6.9.4
Command syntax
The test run in the shape optimization is controlled by the TEST_SHAPE
command. A test run is always based on a previously defined optimization job
that is referenced in the OPTIMIZE command. The format information for the
postprocessing is specified with the FORMAT parameter. The name of the file
into which the postprocessing data is written is specified with the FILE_NAME
parameter. The test displacement in a specified direction (DIRECTION) is
applied in a specified number of increments (INCREMENT parameter) until
reaching a maximum displacement (DISPLACEMENT parameter). A typical
TEST_SHAPE command appears as follows:
TEST_SHAPE
SIMULIA
Tosca Structure
Check run (TEST_SHAPE)
OPTIMIZE
FORMAT
DIRECTION
DISPLACEMENT
INCREMENT
= <name_of_optimize>
= ONF FILE_NAME=<name_of_output_file>
= [ GROW | SHRINK | RANDOM ]
= <value_of_max_displacement>
= <number_of_increments>
END_
Remarks
1. If all the information entered by the user is correct, the TEST_SHAPE
command is executed immediately after it is entered. The command does
not have its own name with which it can be referenced and all command
data are only temporarily active during the execution of the command.
2. The referencing of a previously defined optimization task (OPTIMIZE
command) is mandatory. The test displacements are applied to the design
nodes of the optimization job.
3. Specification of a file name (FILE_NAME parameter) is optional. By default
the file name TEST_SHAPE is used. An increment number is always
attached to the file names (for example, 000, 001, 002 etc.) to enable identification of the results from the various increments. Caution: The automatic
creation of the vtfx report requires the use of the default file name
"TEST_SHAPE".
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Shape Optimization
=
=
=
=
=
shape_optimization
test_grow
GROW
1.5
5
END_
www.3ds.com/tosca
6.10 Morphing
With TOSCA Structure.morph it is possible to apply changes to certain areas,
so called morph areas, by moving the nodes of these morph areas. This can
be used, e.g., to automatically generate several model variants and submit
analysis runs for these models. Further it allows to study the simultaneous
influence of changes in the morph areas on certain design responses defining
the quality of the design. These design responses are normally used to formulate optimization targets and constraints. Based on these quality criteria an
optimum start design for a subsequent local shape optimization can be
derived.
Please note: morphing is a new feature within Tosca Structure implemented
to access more optimization potential. At this point not all practical requirements may be considered yet. We appreciate your feedback to continuously
improve our user interfaces and workflow.
SIMULIA
Tosca Structure
Morphing
6.10.1 General
Performing a local shape optimization sometimes does not exploit the complete potential for design improvement. In particular for complex models,
when e.g. thermomechanical fatigue is involved, global interactions can be
observed. A change in the model geometry, in particular a large wall thickness modification in "less critical" areas, will influence the stiffness and transient temperature distribution in critical areas, but will have no significant
influence on the less critical areas.
Shape optimization results can thus be improved through start with a design
where these global effects are already considered..
Using TOSCA Structure.morph several design variants can be created automatically. With these variants global interactions and influences can be
assessed and evaluated prior to a local shape optimization. Thereby a specific design of experiments is performed which modifies the predefined morph
areas according to an user defined experiment plan.
Morphing is offered as add-on to shape optimization, where "morphed models" are created based on the experiment plan. In each step of the morphing
process (each experiment) a constant displacement is applied independently
to the nodes of each morph area. The modified (morphed) model is analysed
and the requested design responses (i.e. all values required for the optimization task) are evaluated.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Shape Optimization
The base of the parameter file is a shape optimization task where all nodes in
any MORPH_AREA must be part of the design area. MESH_SMOOTH and
DVCON_SHAPE commands defined in OPTIMIZE are referenced by
MORPH-command and thus used. Objective function and eventually constraint define relevant values for postprocessing and evaluation of the quality
of the design. These values will be available e.g. as fringe plots on the several morphing variants.
www.3ds.com/tosca
Remarks
1. For one optimization several independent (non-intersecting) morphing
areas can be defined.
2. All nodes in any MORPH_AREA must be part of the design area.
SIMULIA
Tosca Structure
Morphing
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Shape Optimization
www.3ds.com/tosca
SIMULIA
Tosca Structure
Morphing
[integer]
END_
The first line in the morphing parameter file contains the morphing areas
involved in the morphing process (referenced MORPH_AREA commands).
The order of appearance does not matter, but the commands must have been
defined in the parameter file prior to the MORPH command.
Each further line describes an experiment. Each morph_disp in a line tells
how much the corresponding MORPH_AREA area should be moved.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Shape Optimization
www.3ds.com/tosca
This file describes six morphing steps for four morphing areas Morph2,
Morph3, Morph4, Morph1. The first four lines move the nodes of each
MORPH_AREA by 1.0 each, starting with Morph2. Line 5 moves the nodes of
all areas together by 1.0 outwards, and line 6 moves all nodes inwards.
.
=
=
=
=
=
<morph_name>
[string]
<optimization_name> [string]
<MORPH_AREA_name_1>
[string]
<MORPH_AREA_name_2>
[string]
SIMULIA
Tosca Structure
Morphing
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Add a new MORPH command via right-click on MORPHING folder and adding New -> MORPH.
Link your MORPHING with a valid shape optimization task: click in OPTIMIZE and select via typing ? your previously defined shape optimization,
here OPTIMIZE_1_SHAPE_OPTIMIZATION_CONTROLLER.
Select your MORPH_PARAM_FILE csv file describing your morphing task
and the combinations of morphing displacements to be executed. Then select
the morphing areas.
PARALLEL_JOBS and SMOOTHING can be defined optionally.
SIMULIA
Tosca Structure
Shape Optimization
ton Add and activating the corrsponding areas. Enter a morph parameter file
and the number of processors..
www.3ds.com/tosca
SIMULIA
Tosca Structure
Morphing
After these settings you can run the morph task. Add a RUN_MORPH command via right-click on MORPHING folder.
Fig. 233 Start of a morphing run for shape optimization in Tosca Structure.gui
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
In Tosca Structure.gui your morphing will be defined using the MORPH command mask. To start the morphing run, start Tosca Structure with your parameter file including the morphing commands. Create your visualization
sequence using Tosca Structure.report. For an example please refer to vol.4
chapter 7, Morphing.
SIMULIA
Tosca Structure
Shape Optimization
ID_NAME
FILE
= OPTIMIZATION_MODEL
= model.ext
END_
DV_SHAPE
ID_NAME
ND_GROUP
areas)
= design_variables
= design_nodes (must contain all MORPH_DEF
END_
MORPH_AREA
ID_NAME
ND_GROUP
TYPE
= Morph1
= LEFT_NODES
= NORMAL
END_
MORPH_AREA
ID_NAME
ND_GROUP
TYPE
= Morph2
= UPPER_ROUND
= NORMAL
END_
MORPH_AREA
ID_NAME
ND_GROUP
TYPE
= Morph3
= LOWER_ROUND
= NORMAL
www.3ds.com/tosca
END_
MORPH_AREA
ID_NAME
ND_GROUP
TYPE
= Morph4
= LOWER
= NORMAL
END_
DRESP
ID_NAME
DEF_TYPE
= DRESP_MAX_MISES
= SYSTEM
SIMULIA
Tosca Structure
Morphing
TYPE
UPDATE
ND_GROUP
GROUP_OPER
= SIG_MISES
= EVER
= design_nodes
= MAX
END_
OBJ_FUNC
ID_NAME
DRESP
TARGET
= minimize_max_mises
= DRESP_MAX_MISES
= MIN
END_
OPTIMIZE
ID_NAME
DV
OBJ_FUNC
STRATEGY
=
=
=
=
shape_optimization
design_variables
minimize_max_mises
SHAPE_CONTROLLER
END_
STOP
ID_NAME
ITER_MAX
= global_stop
= 5
END_
ID_NAME = tosca_morph
OPTIMIZE = shape_optimization
MORPH_DEF = Morph1
MORPH_DEF = Morph2
MORPH_DEF = Morph3
MORPH_DEF = Morph4
MORPH_PARAM_FILE = test_morph.csv
NUM_PROCS = 1
SMOOTHING = NO
END_
6.10.5 Postprocessing
Postprocessing shows fringe plots of the typical results shown for the associated optimization task (in shape optimization; controller input for the objective
function, as well as optimization displacement) and a table of the requested
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
MORPH
SIMULIA
Tosca Structure
Shape Optimization
www.3ds.com/tosca
6.10.6 Evaluation
The morphing process can be used for a global indirect optimization to get an
improved start model for a subsequent local shape optimization. To this end,
the results of the different morphing steps are evaluated. Design responses
characterizing the objective and constraint are monitored and the best model
is considered. Eventually some more experiments with combined morphing
steps are required to get the best improvement in objective and constraint
values. The best morphing model can then be optimized by Tosca Structure.shape.
SIMULIA
Tosca Structure
Stop Condition
= global_stop
= 5
END_
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
2. The global stop criterion leads to a hard stop of the optimization - independend of a complete convergence of the result. For shape optimization tasks
this is no drawback as the optimization task can be continued for some
more steps using the input file of the last iteration as start file.
SIMULIA
Tosca Structure
Shape Optimization
objective function falls below a tolerance limit in one design cycle, the optimization can be considered as completed.
If the norm of the optimization displacements is smaller than a certain tolerance value within one design cycle, the modifications of the model will only
be small and the optimization is stopped. This condition has the advantage
that it is suitable for optimization jobs with and without constraints. The
condition can be equally used without any changes for a variety of objective functions (stress or frequency).
Stop conditions can be formulated and combined by linking the VARIABLE
definitions with LOGICAL variables. However, experiments have shown that it
is usually not worthwhile to define complicated stop conditions for shape optimization. It is often sufficient to limit the maximum number of allowable
design cycles as a global stop condition.
Also, a compact form of a stop condition is available which enables to compare the actual value of a variable with a value from the first or previous step
(parameters MOD_TYPE for the definition of the variable, MOD_OPER for the
comparison operator and MOD_REF for the reference value definition).
Remark:
1. Please note that the global stop criterion is defined using a STOP
command whereas convergence criteria are defined in the optimization
settings (OPT_PARAM command).
Per default, a global stop condition limiting the number of design cycles to 5 is
defined (visible in the task manager tree). If necessary, the number of design
cycles
can
be
changed
(Edit
command
applied
on
GLOBAL_STOP_CONDITION_1 item).
Several local stop conditions can be entered in the task manager (New |
STOP_CONDITION
command
applied
on
SHAPE_OPTIMIZATION_CONTROLLER item). In the pop up window the
parameters described above or in detail in vol.3 Commands Manual can be
defined. As this compact form of stop conditions is usually sufficient for opti-
www.3ds.com/tosca
SIMULIA
Tosca Structure
Stop Condition
Fig. 234 Local stop condition for shape optimization in Tosca ANSA environment
Fig. 235 Local stop condition for shape optimization in Tosca Structure.gui
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
In Tosca Structure.gui, the definition of stop conditions is available in the commands menu. For details about the several parameters refer tovol.3 Commands Manual. More complicated stop conditions like in vol.2 chapter 6:
Example 3: can be defined using variables, combining them to logical expressions and referring them in the stop condition.
SIMULIA
Tosca Structure
Shape Optimization
6.11.5 Examples
Example 1:
The number of design cycles should be limited to 5 as a global stop condition:
STOP
ID_NAME
ITER_MAX
OPTIMIZE
= stop_condition
= 5
= <name_of_optimize>
END_
Example 2:
The stop condition is fulfilled, if the maximum equivalence stress in the node
group ALL_NODES is less than 1% of the maximum equivalence stress of the
first iteration.
STOP
ID_NAME
MOD_NDGR
MOD_TYPE
MOD_OPER
MOD_REF
OPTIMIZE
=
=
=
=
=
=
stop_command
all_nodes
MAX, CTRL_INP_SHAPE
LE
0.01, MULT, FIRST
run
END_
Example 3:
If the sum of the optimization displacements of the design node group in a
given design cycle is smaller than 1% of the sum of the optimization displacements in the initial design cycle, the optimization should be stopped:
www.3ds.com/tosca
VARIABLE
ID_NAME
DEF_TYPE
TYPE
ND_GROUP
GROUP_OPER
UPDATE
=
=
=
=
=
=
sum_disp
SYSTEM
SHAPE_MOVE
design_nodes
SUM
EVER
=
=
=
=
=
=
sum_disp_first
SYSTEM
SHAPE_MOVE
design_nodes
SUM
FIRST
END_
VARIABLE
ID_NAME
DEF_TYPE
TYPE
ND_GROUP
GROUP_OPER
UPDATE
SIMULIA
Tosca Structure
References
END_
VARIABLE
ID_NAME
DEF_TYPE
VALUE
= one_percent
= FIX
= 0.01
END_
VARIABLE
ID_NAME
DEF_TYPE
VAR_OPER
VAR_A
VAR_B
=
=
=
=
=
sum_disp_first_001
OPER
MULT
one_percent
sum_disp_first
=
=
=
=
=
logical_for_stop
SYSTEM
LT
sum_disp
sum_disp_first_001
END_
LOGICAL
ID_NAME
DEF_TYPE
OPER
VAR_A
VAR_B
END_
STOP
ID_NAME
LOGI_NAME
OPTIMIZE
= stop_optimization
= logical_for_stop
= <name_of_optimize>
END_
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
6.12 References
SIMULIA
Tosca Structure
Bead Optimization
Bead Optimization
Bead optimization is a way to enhance shell structures without adding more
mass to the structure. The beads can easily be added in the stamping process which makes beads a low weight and cost neutral alternative to
enhance a sheet-metal structures.
7.1
General Information
The easiest way to understand bead optimization is a simple example every
mechanical engineer will intuitively understand.
a)
b)
www.3ds.com/tosca
Fig. 236 Simple plate in bending with loading and supports (a) and an
optimalbead (b). The maximal displacement of (a) is 6.6 mm and
(b) is 0.25 mm
In Fig. 236 is a simple flat plate in bending shown. It is evident that the solution in Fig. 236 (b) has a much greater stiffness than the original flat plate in
Fig. 236 (a).
Regarding the simple example in Fig. 236 a couple of comments must be
made:
Bead height
Bead width
Fig. 237 Bead height and bead width
The bead height (see Fig. 237) has the most significant effect on the stiffness
of the plate structure. Usually, the greater the bead height the greater the stiff-
SIMULIA
Tosca Structure
The Optimization Task
Increasing stiffness
Fig. 238 Bead layouts for simple geometries with a uniform pressure load.
From Oehler and Weber: "Steife Blech- und Kunststoffkonstruktionen", Springer-Verlag GmbH (1972)
7.2
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Bead Optimization
7.2.1
Fig. 239 Distribution of bending stress and scalar fields for bead direction
This method has the following advantages:
Solver-independent and sensitivity-independent
mesh-independent
clear results
www.3ds.com/tosca
SIMULIA
Tosca Structure
The Optimization Task
7.2.2
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
7.2.3
SIMULIA
Tosca Structure
Bead Optimization
the one algorithm. If the chapter is not marked (like this chapter or e.g. vol.2
chapter 7.3, Design Area) the content applies to both algorithms
a)
b)
www.3ds.com/tosca
Fig. 240 Bead pattern of maximization of first eigenfrequency using controller (a) vs. sensitivity (b) based algorithm
SIMULIA
Tosca Structure
The Optimization Task
a)
Fig. 241 Iteration history for controller (a) and sensitivity (b) based optimization from Fig. 240.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
b)
SIMULIA
Tosca Structure
Bead Optimization
In Fig. 240 and Fig. 241 is the same optimization task, maximizing first eigenvalue, done by the sensitivity based optimization algorithm and controller
based algorithm. Some of the main differences between the two algorithms
are listed here:
1. Bead pattern. The controller based algorithm creates nice bead structures
because of its bead-filter. Such bead generation is not implemented in the
sensitivity based solution, why the results do not show a distinct bead
pattern (see Fig. 240).
2. Number of optimization iterations. The controller based algorithm
always uses 3 optimization iterations. Whereas for the sensitivity based
optimization algorithm usually needs 20 or more iterations to converge (see
Fig. 241).
3. Analysis types. The controller based supports all analysis types which
produces a stress tensor as output, although it is recommended to only use
the algorithm for static analysis.
The sensitivity based algorithm supports the responses of:
- linear static
- linear eigenfrequency
- frequency response
Note the better results by sensitivity based optimization for dynamic problems, e.g. Fig. 241.
www.3ds.com/tosca
4. Objective and constraint types. The sensitivity based algorithm can have
one objective function and several constraints where the constraints are all
inequality constraints. The objective and the constraints can be based
upon the compliance, displacements, eigenfrequencies or frequency
dependent displacements. Whereas the controller based algorithm has the
compliance as objective and the BEAD_HEIGHT as an equality constraint.
5. Supported element types. The sensitivity based algorithm supports only
the elements given in Table 27. The controller algorithm supports all plate
and shell elements.
6. BEAD_HEIGHT. For sensitivity based algorithm all DRESP which can be
used in the object function (OBJ_FUNC) can also be used in the
CONSTRAINT definitions. The maximal nodal displacement is in this
context not considered a design response but instead a design variable
constraint (DVCON_BEAD). DRESP of the type BEAD_HEIGHT is not
allowed in sensitivity based algorithm (see volume 3: DRESP).
To get a similar optimization displacement in sensitivity based algorithm in
a benchmark example against the controller algorithm use:
DVCON_BEAD
SIMULIA
Tosca Structure
The Optimization Task
ID_NAME
ND_GROUP
CHECK_GROW
CHECK_SHRINK
=
=
=
=
name_of_dvcon_bead
design_nodes
<BEAD_HEIGHT>
0.0
END_
where the <BEAD_HEIGHT> is equal to the bead height defined by the controller input deck. Also note that the sensitivity based algorithm can move the
nodes in positive and in negative direction, thus the optimization parameter
SCALE has no effect by sensitivity based algorithm.
As already stated the following chapters will differ with respect to the two
bead optimization algorithms. To make it easier to distinguish which chapter
concerns what method we introduce two key words:
BEAD_CONTROLLER
BEAD_SENSITIVITY
These two words reappear in the OPTIMIZE commands item STRATEGY.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Fig. 242 Select the appropriate Tosca Structure Task in Tosca ANSA environment to choose between BEAD_CONTROLLER or
BEAD_SENSITIVITY strategies.
SIMULIA
Tosca Structure
Bead Optimization
7.2.4
www.3ds.com/tosca
SIMULIA
Tosca Structure
The Optimization Task
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
7. Question: Are all of the command definitions listed above complete and
ready for the optimization job?
Procedure: If necessary complete any additional required definitions and
prepare the optimization job.
TAE: Automatically prepared by task manager.
GUI: Reference all definitions above in OPTIMIZE.
SIMULIA
Tosca Structure
Bead Optimization
www.3ds.com/tosca
The essential commands required for the optimization model in bead optimization are described in the following.
The definitions for the optimization job are assembled in a parameter file. The
exact syntax of the commands can be looked up in vol.3 Commands Manual.
Fig. 244 gives an overview of a standard optimization task and the relation
between the several commands. Only commands which are referenced in the
OPTIMIZE command will be included in the optimization.
SIMULIA
Tosca Structure
Design Area
7.3
Design Area
During an optimization, only part of the model may be changed. This part is
defined as design area.
7.3.1
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Bead Optimization
Abaqus
element
type
Shell elements
SHELL_TRIANG_3
S3
S3R
STRI3
SHELL_QUAD_4
S4
S4R
SHELL143
SHELL181
SHELL41
SHELL43
SHELL63
SHELL_QUAD_8
S8R
SHELL93
www.3ds.com/tosca
SHELL_TRIANG_6
SIMULIA
Tosca Structure
Design Area
MSC
Nastran
element
type
Marc
element
type
PERMAS
element
type
Shell elements
SHELL_TRIANG_3
CTRIA3
CTRIAR
SHELL_TRIANG_6
CTRIA6
CTRIAX6
SHELL_QUAD_4
SHELL_QUAD_8
Table 27
7.3.2
138
TRIA3
TRIA3K
CQUAD4
CQUADR
CSHEAR
18
139
140
QUAD4
CQUAD8
30
72
Restrictions (DVCON_BEAD)
Restrictions in bead optimization can either be defined as boundary conditions that limit the node displacement or as a LINK-condition. The latter is
only allowed for controller based bead optimization. A design variable constraint is a restriction that directly affects the individual design variables or the
individual design nodes.
Possible restrictions are: the specification of an allowable displacement area
by limiting the signed absolute displacement and the specification of variation
and frozen areas. It is also possible to influence the allowable displacement
direction by limiting the displacement to specific coordinate directions. At last
it is possible to link the design variables and thereby force them to be optimized in a symmetric way (only controller).
The definition of the design variable constraints for bead optimization is done
using the DVCON_BEAD command.
Remarks
1. Possible restrictions for bead optimization are very similar to the restrictions of shape optimization (see vol.2 chapter 6.3.3, Restrictions
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
7.3.2.1 General
SIMULIA
Tosca Structure
Bead Optimization
www.3ds.com/tosca
DVCON_BEAD
ID_NAME
ND_GROUP
CHECK_SOLID
CHECK_ELGR
CHECK_GROW
CHECK_SHRINK
CHECK_BC
CHECK_DOF
CHECK_LINK
=
=
=
=
=
=
=
=
=
name_of_dvcon_bead
name_of_node_group
name_of_solid
name_of_element_group
<max_grow_value>
<max_SHRINK_value>
cs_name, FREE/FIX, FREE/FIX, FREE/FIX
YES/NO
<link_name>
END_
Remarks
1. Using CHECK_GROW and CHECK_SHRINK is the easiest way to constrain
design nodes for sensitivity based optimization. See also chapter 7.3.2.2
Restricting the absolute displacement.
SIMULIA
Tosca Structure
Design Area
= <MAX_GROW_VALUE>
CHECK_SHRINK
= <MAX_SHRINK_VALUE>
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Bead Optimization
=
=
=
=
MY_DVCON_BEAD
DESIGN_NODES
10.0
0.0
END_
The command above is equivalent to define the following BEAD_HEIGHT constraint in the controller based algorithm.
CONSTRAINT
ID_NAME
DRESP
EQ_VALUE
MAGNITUDE
=
=
=
=
MY_BEAD_HEIGHT_CONSTRAINT
BEAD_HEIGHT_DRESP
10.0
ABS
END_
www.3ds.com/tosca
SIMULIA
Tosca Structure
Design Area
Here is the example just described constraint all design nodes to a maximum
growth of 10.0 and no shrink using GROW/SHRINK_CONTROL.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Bead Optimization
ation area or restriction area, see vol.2 chapter 3.9, Solids (Geometric
Primitives)).
The parameter:
CHECK_SOLID
= solid_name
specifies a solid whose borders may not be penetrated. The solid must be
defined with a SOLID command before being referenced.
Remarks
1. Up to six different CHECK_SOLID parameters can be defined in every
DVCON_BEAD command. They are executed in the order of their declaration within the DVCON_BEAD command.
2. If the solid is a variation solid, all nodes of the node group in the start model
(see ND_GROUP parameter) must be located inside the variation solid. If
nodes are located outside the variation solid, the DVCON_BEAD definition
will be rejected. If the solid is a restriction solid, all nodes of the node group
in the start model must be located outside the restriction solid. If nodes are
located inside the restriction solid, the DVCON_BEAD definition will be
rejected.
www.3ds.com/tosca
CHECK_ELGR
= elgr_name
SIMULIA
Tosca Structure
Design Area
2. Some areas in the design domain should not be modified during optimization, e.g. the boundary of the design domain. These areas may be
restricted using the CHECK_DOF or CHECK_BC parameters.
The displacement boundary condition must be unique. In contrast to FE
boundary conditions of several load cases, the total of all supports for all load
cases are considered as supports in the optimization. A prescribed node displacement as an optimization boundary condition is also not permitted.
Loading Node Fixations via the Interface from the FE Program
The full or partial fixation of nodes is the most common and most important
type of restriction; it is practically used in every optimization model. The most
efficient method for defining the displacement restrictions in the FE preprocessing as an extra load case in the transition model and then to load it via
the FE interface in the optimization preprocessor. In order to do this, the interface must first be activated with OPTIONS, READ_BC=.... In this way all
node fixations for the optimization model can be defined in advance in the FE
2 - 424 User Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Bead Optimization
preprocessor. The fixation is always based on the FE displacement coordinate system of the node. The special features of the FE interfaces are
described in vol.2 chapter 11. The parameter
CHECK_BC
= ALL
activates the node fixations of the node group (ND_GROUP parameter) which
are loaded through the FE interface. Fixations that reference nodes not contained in the node groups are not activated. To prevent loaded fixations from
being activated enter:
CHECK_BC
= NO
= cs_name,[FIX|FREE],[FIX|FREE],[FIX|FREE]
all the displacements of all nodes in the node group selected with ND_GROUP
are fixed (FIX) or free (FREE) relative to the specified coordinate directions of
the coordinate system, cs_name. Either FREE or FIX is allowed for each
coordinate direction.
Remark
www.3ds.com/tosca
CS
= <link_name>
= POINT_SYM
PLANE_SYM, AXIS_*
ROTATIONAL_SYM, AXIS_*
= <cs_name>
SIMULIA
Tosca Structure
Design Area
END_
symmetry
Loads
Loads
Fig. 248 An asymmetric load case without (left) and with (right) symmetry
condition.
Remarks
1. AXIS_* can be AXIS_1, AXIS_2 or AXIS_3 of the chosen coordinate
system.
= MY_LINK_BEAD
= CS_0
= PLANE_SYM, AXIS_2
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Bead Optimization
END_
DVCON_BEAD
ID_NAME
CHECK_BC
ND_GROUP
CHECK_LINK
=
=
=
=
MY_DVCON_BEAD_SYM
NO
DESIGN_NODES
MY_LINK_BEAD
www.3ds.com/tosca
END_
SIMULIA
Tosca Structure
Objective Function
7.4
Objective Function
The objective function describes the optimization target. In general, one scalar value (sometimes combined from other scalars) is to be maximized or
minimized.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Bead Optimization
7.4.1
Overview
Bead optimization is mostly used to maximize stiffness of a structure or
improve the dynamical properties of a shell structure. As already noted (chapter 7.2.3 Differences between bead optimization algorithms) Tosca Structure.bead has two different optimization approaches. The differences have
already been discussed in general. The possible design responses in the
objective function is one of the major differences which becomes obvious
looking at the following Table 28.
Static analysis
Gravity / Inertia
Frequency
response
DISP_ABS
CENTER_GRAVITY_X
FS_ACCEL_X
DISP_X
CENTER_GRAVITY_Y
FS_ACCEL_Y
DISP_X_ABS
CENTER_GRAVITY_Z
FS_ACCEL_Z
DISP_Y
INERTIA_XX
FS_DISP_ABS
DISP_Y_ABS
INERTIA_XY
FS_DISP_X_ABS
DISP_Z
INERTIA_XZ
FS_DISP_Y_ABS
DISP_Z_ABS
INERTIA_YY
FS_DISP_Z_ABS
ROT_X
INERTIA_YZ
FS_VELOCITY_X
ROT_Y
INERTIA_ZZ
FS_VELOCITY_Y
ROT_Z
FS_VELOCITY_Z
www.3ds.com/tosca
STRAIN_ENERGY*
Modal analysis
DYN_FREQ*
DYN_FREQ_KREISS
EL
Table 28
SIMULIA
Tosca Structure
Typical Optimization Tasks for Linear Static Analysis
Remarks:
1. Only design responses marked with * are allowed in controller based algorithm (BEAD_CONTROLLER).
2. BEAD_HEIGHT is not allowed in sensitivity algorithm. Use DVCON_BEAD
instead.
3. The Gravity / Inertia design response types are only usable if at least one
design response of the other types is used in the objective function or
constraints.
In the following chapters typical optimization tasks are described which can
be solved with Tosca Structure.bead.
7.5
7.5.1
=
=
=
=
=
=
=
dresp_compliance
STRAIN_ENERGY
SYSTEM
EVER
ALL_ELEMENTS
SUM
Static,1,All
END_
Remarks
1. Compliance is defined as the sum of the energy of all the elements in the
FE-model regardless how large your design domain may be.
2. The algorithm is based on element stress tensors. Therefore these must be
requested in the FE-analysis, but Tosca Structure for most solvers adds
these result request (see Vol.I Chapter 13).
2 - 430 User Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
DRESP
SIMULIA
Tosca Structure
Bead Optimization
= minimize_compliance
= dresp_compliance
= MIN
END_
=
=
=
=
minimize_compliance
dresp_compliance_1, 0.90
dresp_compliance_2, 1.10
MIN
END_
Here, the first design response is weighted 10% less than the norm, and the
second 10% more than the norm. The norm (1.0) is default.
Remarks
1. It is highly recommended only to combine linear static load cases!
2. It is recommended to look up the definition of load cases in (DRESP).
www.3ds.com/tosca
=
=
=
=
=
=
dresp_min_compliance
SYSTEM
ALL_ELEMENTS
STRAIN_ENERGY
SUM
All,All,All
END_
Tosca Structure.bead will try to combine All load cases in the finite element
calculation with the weighting of 1.0. Once again, this method is NOT recom-
SIMULIA
Tosca Structure
Typical Optimization Tasks for Linear Static Analysis
mended and the former mentioned method of defining the load cases separately and then combining them in the objective function is emphasized.
7.5.2
=
=
=
=
=
=
dresp_compliance
SYSTEM
ALL_ELEMENTS
STRAIN_ENERGY
SUM
Static,1,All
END_
ID_NAME
DRESP
TARGET
= min_compliance
= dresp_compliance
= MIN
END_
Explanation:
A design response with name "dresp_compliance" is defined for the first
static load case. Note that the design response is defined using
GROUP_OPER = SUM over ALL_ELEMENTS which is also the correct
definition because compliance must be equal to the outer work (force x displacement). The compliance design response is minimized (TARGET=MIN) in the object function.
Note that no constraint is necessary, but remember to add a DVCON_BEAD
which constrains the nodes in positive and negative normal direction.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
OBJ_FUNC
SIMULIA
Tosca Structure
Bead Optimization
7.6
7.6.1
=
=
=
=
dresp_max_eigenfrequency
SYSTEM
DYN_FREQ
Modal,All,1
END_
www.3ds.com/tosca
OBJ_FUNC
ID_NAME
DRESP
TARGET
= maximize_eigenfrequency
= dresp_max_eigenfrequency
= MAX
END_
Explanation:
The type of the design response is DYN_FREQ (eigenfrequency). To
choose the first eigenfrequency the third argument in the item LC_SET is
set to 1. This design responses ID_NAME is referenced in the OBJ_FUNC
where it is set to be maximized.
SIMULIA
Tosca Structure
Typical Optimization Tasks for Modal Analysis
Remarks
1. To consider for example the second eigenfrequency, the LC_SET parameter has to be set as follows: LC_SET = Modal, All, 2. More information can
be found in Commands manual (see volume 3: DRESP).
2. Warning: Do NOT define the third argument in the LC_SET command as
All (e.g. LC_SET=Modal,1,all). The algorithm will then try to combine All
modes from the modal analysis, which normally will NOT lead to good
results for the controller based algorithm.
7.6.2
BEAD_SENSITIVITY
The definition of a maximization of an eigenvalue problem could be done similar to the controller based bead algorithm. But this is not recommended.
In the sensitivity based algorithm we have more control over the modes. A
problem you usually want to avoid when optimizing eigenmodes is modeswitching because it destabilizes the optimization algorithm. The typical problem is by maximizing the first eigenmode it may "overtake" the second mode hence, the modes switch place (previous second mode becomes the first
mode) and sensitivity algorithm must suddenly take a new mode into consideration.
Mode tracking can of course be used (chapter 7.8.2.3 Optimization parameters for mode tracking), but the computationally cheapest way to push the first
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Bead Optimization
= --- ln
k
j = 1 e
kf j
In the formulation f j is the eigenfrequency, e the base of the natural logarithm and and k are constants.
In the following the formulation will enforce the 5 first modes to keep their
sequence. This is usually sufficient to avoid mode switching among the first
couple of modes. See also Fig. 241 at iteration 13-14 where modes almost
switch, but do not because of this formulation.
DRESP
ID_NAME
DEF_TYPE
TYPE
LC_SET
=
=
=
=
dresp_eig_kreissel
SYSTEM
DYN_FREQ_KREISSEL
Modal,All,1-5
END_
OBJ_FUNC
ID_NAME
DRESP
TARGET
= max_dresp_eig_kreissel
= dresp_eig_kreissel
= MAX
END_
www.3ds.com/tosca
Explanation
The definition above will enforce the 5 first modes to keep their sequence.
This is usually sufficient to avoid mode switching among the first couple of
modes. The first mode is maximized (TARGET=MAX) until it comes near
the higher modes in which case they are being considered as well.
=
=
=
=
dresp_eigs_1-5
SYSTEM
DYN_FREQ
Modal,All,1-5
END_
OBJ_FUNC
SIMULIA
Tosca Structure
Typical Optimization Tasks for Modal Analysis
ID_NAME
DRESP
TARGET
= max_dresp_eigs_1-5
= dresp_eigs _1-5
= MAX
END_
Explanation
Here, the 5 first modes are summed in one design response (dresp_eigs_15). This sum is being maximized (TARGET=MAX).This solution often has the
pitfall that the higher modes usually are weighted higher than the lower ones.
One way to circumvent this is to define a design response for each eigenmode:
DRESP
ID_NAME
DEF_TYPE
TYPE
LC_SET
=
=
=
=
dresp_eig1
SYSTEM
DYN_FREQ
Modal,All,1
=
=
=
=
dresp_eig2
SYSTEM
DYN_FREQ
Modal,All,2
END_
DRESP
ID_NAME
DEF_TYPE
TYPE
LC_SET
END_
DRESP
ID_NAME
= dresp_eig...
OBJ_FUNC
ID_NAME
DRESP
DRESP
DRESP
DRESP
DRESP
TARGET
=
=
=
=
=
=
=
max_dresp_eigs_1-5
dresp_eig1, 0.10, 100.
dresp_eig2, 0.05, 200.
dresp_eig3, 0.04, 250.
dresp_eig4, 0.0025,400.
dresp_eig5, 0.002, 500.
MAX
Hz
Hz
Hz
Hz
Hz
END_
Explanation
Here, each of the 5 first modes are multiplied by a weight (reciprocal value
of the initial eigenvalue) and then summed and maximized.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
...
SIMULIA
Tosca Structure
Bead Optimization
=
=
=
=
dresp_eig2
SYSTEM
DYN_FREQ
Modal,All,2
END_
OBJ_FUNC
ID_NAME
DRESP
TARGET
= max_ dresp_eig2
= dresp_eig2
= MAX
END_
OPTIMIZE
ID_NAME
DV
STRATEGY
OBJ_FUNC
=
=
=
=
opt
my_design_nodes
BEAD_SENSITIVITY
max_ dresp_eig2
=
=
=
=
my_parameters
opt
ON
10
END_
OPT_PARAM
ID_NAME
OPTIMIZE
MODETRACKING
MODENUMBERS
Explanation:
The second mode is chosen to be maximized. The important difference is
that mode tracking is activated the optimization parameters (MODETRACKING= ON). Default by mode tracking in Tosca Structure is to take 5
modes into account, but this can be changed by the item MODENUMBERS.
This should not be set too high because of computational effort.
www.3ds.com/tosca
END_
SIMULIA
Tosca Structure
Typical Optimization Tasks for Modal Analysis
=
=
=
=
dresp_eig_2
SYSTEM
DYN_FREQ
Modal,All,2
END_
OBJ_FUNC
ID_NAME
DRESP
TARGET
END_
CONSTRAINT
= max_dresp_eig_2
= dresp_eig_2
= MAX
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
DRESP
SIMULIA
Tosca Structure
Bead Optimization
ID_NAME
DRESP
MAGNITUDE
LE_VALUE
=
=
=
=
con_dresp_eig_2_le_15Hz
dresp_eig_2
ABS
15.
=
=
=
=
=
opt
my_design_nodes
BEAD_SENSITIVITY
max_ dresp_eig2
con_dresp_eig_2_le_15Hz
END_
OPTIMIZE
ID_NAME
DV
STRATEGY
OBJ_FUNC
CONSTRAINT
END_
Explanation:
The second eigenmode will be maximized, but because of the constraint it
may not become higher than 15. Hz.
1
-----------------
fk fk
www.3ds.com/tosca
=
=
=
=
dresp_eig_2
SYSTEM
DYN_FREQ
Modal,All,2
END_
OBJ_FUNC
ID_NAME
DRESP
TARGET
= move_dresp_eig_2_from_15Hz
= dresp_eig_2, 1.0, 15.
= MINMAX
SIMULIA
Tosca Structure
Constraints
END_
Constraints
The number of constraints allowed for BEAD_SENSITIVITY is almost as vast
as the possibilities for object function definition. For BEAD_CONTROLLER
the only allowed and necessary constraint is the BEAD_HEIGHT which is not
allowed in BEAD_SENSITIVTITY.
Static analysis
Gravity / Inertia
Frequency response
DISP_ABS
CENTER_GRAVITY_X
FS_ACCEL_X
DISP_X
CENTER_GRAVITY_Y
FS_ACCEL_Y
DISP_X_ABS
CENTER_GRAVITY_Z
FS_ACCEL_Z
DISP_Y
INERTIA_XX
FS_DISP_ABS
DISP_Y_ABS
INERTIA_XY
FS_DISP_X_ABS
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
7.7
SIMULIA
Tosca Structure
Bead Optimization
DISP_Z
INERTIA_XZ
FS_DISP_Y_ABS
DISP_Z_ABS
INERTIA_YY
FS_DISP_Z_ABS
ROT_X
INERTIA_YZ
FS_VELOCITY_X
ROT_Y
INERTIA_ZZ
FS_VELOCITY_Y
ROT_Z
FS_VELOCITY_Z
STRAIN_ENERGY
Independent of
analysis type:
BEAD_HEIGHT*
Table 29
Modal analysis
DYN_FREQ
Remark:
1. The Gravity / Inertia design response types are only usable if at least one
design response of the other types is used in the objective function or
constraints.
www.3ds.com/tosca
7.8
Settings
Each OPT_PARAMcommand has a unique name (ID_NAME parameter) and
references a previously defined optimization job (OPTIMIZE parameter). The
specified parameters only relate to the given optimization task. A typical
OPT_PARAM command appears as follows:
OPT_PARAM
ID_NAME
OPTIMIZE
...
= param_for_bead_optimization
= bead_optimization
END_
SIMULIA
Tosca Structure
Settings
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
2. The OPT_PARAM command is also used in shape and topology optimization. However, the optimization parameters that can be set, depend upon
the given type of optimization. The only parameters that can be set here
are those allowable for bead optimization. Topology and shape optimization parameters cannot be set.
SIMULIA
Tosca Structure
Bead Optimization
Tosca
Structure
Task
|
PRE-PROCESSING
BEAD_OPTIMIZATION_<type> | [New] | [SETTINGS]
www.3ds.com/tosca
BEAD_SENSITIVITY
Example of setting the FILTER_RADIUS parameter for sensitivity based
bead optimization:
Tosca
Structure
Task
|
PRE-PROCESSING
|
BEAD_OPTIMIZATION_<type> | [New] | [SETTINGS]
SIMULIA
Tosca Structure
Settings
Example of setting the SCALE parameter for controller based bead optimization:
7.8.1
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
BEAD_SENSITIVITY
Example of setting the FILTER_RADIUS parameter for sensitivity based
bead optimization:
SIMULIA
Tosca Structure
Bead Optimization
= -1
END_
www.3ds.com/tosca
...
VECTOR
...
= FIRST
END_
7.8.1.3
SIMULIA
Tosca Structure
Settings
BEAD_WIDTH=2*max(2*height_of_bead, 3.2*mean_edge_length) of the elements attached to design nodes. The user can define own values for the
bead width by the OPT_PARAM command.
Remarks
1. The value for the bead width is used for internal filtering. The generated
beads will not have the exact width specified by the user.
2. Because bead optimization is a very ill-posed optimization problem (many
"optimal" solutions), it is recommended that a couple of optimizations is
done with different BEAD_WIDTHs.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
The functions make sure that the areas that either have very low stresses or
a low bending/membrane stress ratio are disregarded by the optimization.
SIMULIA
Tosca Structure
Bead Optimization
Load
Load
Fig. 251 The penalized elements are dark blue. Left is the
BEAD_MIN_STRESS criteria used, and right is the
BEAD_MAX_MEMBRANE used.
www.3ds.com/tosca
Load
Load
Fig. 252 Left with no penalization criteria used and right with both.
SIMULIA
Tosca Structure
Settings
Remarks
1. The default settings are:
BEAD_MIN_STRESS
= 0.001
BEAD_MAX_MEMBRANE = 1.0
This means that if an element has less than 0.1% of the Von Mises stress or
the membrane stress is higher than the bending stress, it will not be optimized.
2. Both penalty conditions can be shut of by setting the parameters to zero:
BEAD_MIN_STRESS
= 0.0
BEAD_MAX_MEMBRANE = 0.0
3. After optimization or after a run of the type TEST2 (vol.2 chapter 12.2.8),
the penalized areas can be visualized by generating a bead_ctrl vtfx-file
(vol.2 chapter 10.2). The penalized areas for BEAD_MAX_MEMBRANE and
BEAD_MIN_STRESS have the "Bead-values" -3 and -4, respectively in the
resulting bead_ctrl-plot.
a)
b)
c)
Fig. 253 CURV_SMOOTH for values 1.0 (a), 5.0 (b) and 10.0 (c).
The node smoothing (BEAD_NODE_SMOOTH) ensures that the optimization
displacement of neighbouring nodes does not become too great. This is
especially an issue near boundaries or active design variable constraints.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
These two parameters control the filter radius of two mesh enhancing features in Tosca Structure.bead. It is recommended not to change these
parameters.
Curvature smoothing (CURV_SMOOTH) filters the optimization direction, so
that normals in areas with high curvature do not cross, which results in poor
or useless mesh. Default is 5.0, which means the filter size is 5 times the middle element edge length. In case of mesh problems try setting this value
higher, eg. CURV_SMOOTH = 10.0.
SIMULIA
Tosca Structure
Bead Optimization
a)
b)
c)
7.8.2
www.3ds.com/tosca
OPT_PARAM
...
FILTER_RADIUS = <filter_radius> , <unit_type>
END_
Default value is 4.0, REL. First item is the filter radius. Second option is
whether the radius is relative to the medium edge length of elements in the
design area (REL). Radius may also be set to an absolute value (ABS), fx. :
FILTER_RADIUS = 5.0, ABS
SIMULIA
Tosca Structure
Settings
Default value is NODAL_MOVE = 0.1. The value must be between 0.0 and
1.0. The absolute move limit is the maximum possible optimization displacement times NODAL_MOVE.
MMA asymptote update (NODAL_UPDATE)
BEAD_SENSITIVITY
The optimization parameter NODAL_UPDATE can be used to control the
update of asymptotes in MMA. The value of nodal update may be conservative (NODAL_UPDATE =CONS) which is default or normal
(NODAL_UPDATE =NORM).
Only advanced users should change this parameter.
Sensitivity calculation (ONLY_DES_NODES)
BEAD_SENSITIVITY
Tosca Structure.bead calculates sensitivities only for design nodes:
ONLY_DES_NODES = YES
MODETRACKING=<ON/OFF>, <NODE_GROUP>
MODENUMBERS =<NUMBER_MODES>
Mode tracking is activated by setting the optimization parameter MODETRACKING= ON. The second item on MODETRACKING can be used to with a
(small) node group which is used for the mode tracking which can improve
performance. Default by Tosca Structures mode tracking is to take 5 modes
into account, but this can be changed by the item MODENUMBERS =
<number_modes>. This should not be set too high because of computational
effort.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
BEAD_SENSITIVITY
Mode tracking is controlled by two optimization parameters
SIMULIA
Tosca Structure
Bead Optimization
! Structural mass
! damping
! Viscous mass
! damping
DAMP_VISCOUS_STIFF = <real>
! Viscous stiffness
! damping
SUM_Q_FACTOR = <real>
! Exponent to emphasize
! high values Q
7.9
www.3ds.com/tosca
TEST_BEAD
OPTIMIZE
FORMAT
FILE_NAME
DIRECTION
DISPLACEMENT
INCREMENT
=
=
=
=
=
=
<name_of_optimize>
ONF
<name_of_output_file>
GROW
<value_of_max_displacement>
<number_of_increments>
END_
Remarks
1. If all information entered by the user is correct, the TEST_BEAD command
is executed immediately after it is entered. The command does not have its
own name with which it can be referenced, i.e. all command data is only
temporarily active during the execution of the command.
SIMULIA
Tosca Structure
Check run (TEST_BEAD)
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Bead Optimization
OPTIMIZE
FORMAT
FILE_NAME
DIRECTION
DISPLACEMENT
INCREMENT
=
=
=
=
=
=
bead_optimization
MSC/PATRAN
test_grow
GROW
1.5
5
END_
www.3ds.com/tosca
SIMULIA
Tosca Structure
Check run (TEST_BEAD)
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Bead Optimization
= MY_STOP
= 30
www.3ds.com/tosca
END_
SIMULIA
Tosca Structure
Special Remarks Using Sensitivity Based Algorithm
PRE-PROCESSING
-----Kjk
K = K +
x
where
K0 + p K0
K = -------------------------x
Where K is the stiffness matrix, K 0 is the original matrix and K 0 + p is the perturbed matrix when one of the nodes is moved. The first term in the above
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Bead Optimization
www.3ds.com/tosca
SIMULIA
Tosca Structure
References
7.12 References
Barthelemy, B. and Haftka, R.T. (1988). Accuracy analysis of the semi-analytical method for shape sensitivity analysis. AIAA Paper 88-2284: Proc.
AIAA/ASME/-ASCE/ASC 29th Structures, Structural Dynamics
and Materials Conference. 1: 562-581. Also Mechanics of Structures and Machines.18:407-432 (1990).
Bletzinger, K.-U., Firl, M. and Daoud, F. (2006). Approximation of derivatives
in semi-analytical structural optimization. III ECCM Lisbon, Portugal.
June 5-8.
Clausen, P. and Pedersen, C.B.W. (2006): Non-parametric large scale structural optimization for industrial applications. III ECCM Lisbon, Portugal. June 5-8.
Emmrich, D. (2004): Entwicklung einer FEM-basierten Methode zur Gesaltung von Sicken fr biegebeanspruchte Leitsttzstrukturen im Konstruktionsprozess. Forschungsberichte
des
Instituts
fr
Produktentwicklung. 13. Karlsruhe
Svanberg, K. (1987). The Method of Moving Asymptotes -A New Method For
Structural Optimization. International Journal for Numerical
Methods in Engineering.24:359-373.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Sizing Optimization
Sizing Optimization
At the beginning of the conventional design process, the design engineer
often defines new components using the experience and the results gained
from existing designs. This results in an evolution process that might require
several manual design iterations and a long process development time.
Optimization tools provide the engineer with an automatic procedure to
develop fundamentally new designs and shorten the development process.
For sheet metal structures ideal sheet thicknesses according to the existing
load and boundary conditions have to be derived.
With Tosca Structure, it is possible to carry out sizing optimization in the existing CAE environment. Within this process shell thicknesses are calculated
automatically to obtain optimal sheet metal structures.
www.3ds.com/tosca
8.1
General Information
Sizing is a tool to optimize sheet metal components through modification of
sheet thicknesses. It is mostly applied at a later stage of the development
process when the general layout of a component (i.e. the topology) is more or
less fixed.
Starting with the design area (which represents the sheet structures to be
modified) and with the boundary conditions, such as loads, fixtures and manufacturing conditions, the optimization system will determine a new thickness
distribution by modification of the shell thicknesses in the design area. This
design proposal should fulfill all mechanical requirements and often represents a weight-optimal design proposal. Sizing with Tosca Structure allows
changes for each single shell element in the model as well as clustering of
thicknesses, i.e. simultaneous modification of shell thicknesses for specific
areas.
SIMULIA
Tosca Structure
The Optimization Task
For the optimization, the following constraints and objectives can be applied:
stiffness (compliance and displacements);
eigenfrequencies;
internal and reaction forces;
weight, volume;
center of gravity;
moment of inertia.
Different constraints can be defined, like member size constraints, freezing of
parts, symmetry and different coupling constraints.
As result, the optimization creates a design proposal with new shell thicknesses. This design proposal can then be transferred back to your CAD system.
8.2
Tosca Structure.sizing supports the responses of linear static (non-conservative forces) and linear eigenfrequency (not allowed to be prestressed) finite
element analysis. Temperature loading is allowed for Abaqus and ANSYS.
Non-linearities
Tosca Structure.sizing supports contact for Abaqus and ANSYS.Furthermore,
prescribed displacements are allowed in the CAE model for static sizing optimization. However, prescribed displacements are not allowed for modal and
frequency response analysis.
Model
Tosca Structure.sizing supports only single layered shells (admitted for sensitivity based opimization). For specific aspects regarding supported element
types please refer to chapter 11 Solver Specific Features. Contact for Abaqus
and ANSYS is supported in and outside the design area.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Analysis types
SIMULIA
Tosca Structure
Sizing Optimization
8.2.1
www.3ds.com/tosca
SIMULIA
Tosca Structure
The Optimization Task
3. Question: Are there elements in the design space which have to have
certain restrictions (e.g. symmetry and manufacturing restrictions)? How
can these restrictions be described?
Procedure: Define design variable constraints for element group.
GUI: Choose or define element groups with restrictions (GROUP_DEF).
Define the restrictions using DVCON_SIZING command.
4. Question: Are there certain symmetry conditions that should be fulfilled?
Procedure: Create a symmetry coupling condition.
GUI: Create a LINK_SIZING condition and reference it in the restriction
command (LINK_SIZING).
Objective Function
5. Question: Which terms describe the values to be optimized? Should these
values be minimized or maximized or otherwise combined using the
minmax formulation? Are any special weighting factors or target values
required?
Procedure: Choose the terms for optimization (design responses) and the
target type.
GUI: Define the design response (DRESP) and assign it to the objective
function (OBJ_FUNC).
Constraint
Optimization Task
7. Question: Are all of the command definitions listed above complete and
ready for the optimization job?
Procedure: If necessary, make the additional definitions and prepare the
optimization job.
GUI: Reference all definitions above in OPTIMIZE.
Stop Condition
8. Question: Should the stop condition be modified?
Procedure: Modify stop condition
GUI: STOP.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
6. Question: Which terms describe the constraint? What value should the
constraint have?
Procedure: Choose the term for the constraint and set the target value or
upper/lower boundary.
GUI: Define the design response (volume 3: DRESP) and assign it to the
constraint (CONSTRAINT).
SIMULIA
Tosca Structure
Sizing Optimization
Completion
9. Question: Is all required data specified?
Procedure: If yes, finish the definition of the optimization problem and
save your definition.
GUI: Save as <jobname>.par
The essential commands required for the optimization model for sizing are
described in the following.
The definitions for the optimization job are assembled in a parameter file. The
exact syntax of the commands can be looked up in vol.3 Commands Manual.
Fig. 257 gives an overview of a standard optimization task and the relation
between the several commands. Only commands which are referenced in the
OPTIMIZE command will be included in the optimization.
www.3ds.com/tosca
8.3
Design Area
During an optimization, only part of the model may be changed. This part is
defined as design area.
8.3.1
Design variables
For each optimization problem, the design variables represent the values to
be changed during the optimization. The elemental thicknesses of shell elemenents are the design variables for the sizing optimization in Tosca Structure.
SIMULIA
Tosca Structure
Design Area
The thicknesses change during the optimization in order to fulfill the optimization goals.
Valid design elements are the most typical shell elements. The list of valid
element types for sizing is given in vol.2 chapter 11, Solver Specific Features
for the different FE solvers.
Design variable definition in Tosca ANSA environment
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
In order to choose the design element group, the command Edit should be
applied on the item DESIGN_AREA. Then, pressing "?" key in GROUP_DEF
field (after the field EL_GROUP is set to GROUP_DEF) opens the window SET
HELP where all existing groups are listed; if needed, a new element group
can be created by using New command of this window.
SIMULIA
Tosca Structure
Sizing Optimization
= dv_design_elem
= design_elem
END_
8.3.2
www.3ds.com/tosca
Frozen area
Element fixing by exclusion from the optimization group.
Element fixing by freezing elements (CHECK_TYPE = FROZEN).
Shell thickness control
Upper and lower bounds for shell thicknesses (CHECK_TYPE =
THICKNESS_BOUNDS).
Clustering of element areas with the same shell thickness
(CHECK_TYPE = CLUSTER)
Symmetry control
Area linking (LINK_SIZING)
Symmetry restriction(LINK_SIZING)
SIMULIA
Tosca Structure
Design Area
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Sizing Optimization
= frozen_area
= frozen_grp
= FROZEN
END_
www.3ds.com/tosca
SIMULIA
Tosca Structure
Design Area
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Sizing Optimization
=
=
=
=
=
=
dvcon_thickness_bounds
my_group
THICKNESS_BOUNDS
REL/ABS
END_
www.3ds.com/tosca
SIMULIA
Tosca Structure
Design Area
set of it. For the definition of the frozen area, only an element group is necessary. No further properties have to be set.
Fig. 266 Definition of a design variable constraint to "cluster" shell thicknesses of an existing element group
The resulting command looks like:
DVCON_SIZING
ID_NAME
EL_GROUP
EL_GROUP
EL_GROUP
=
=
=
=
cluster_area
cluster_grp_1
cluster_grp_2
cluster_grp_3
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Sizing Optimization
...
CHECK_TYPE
= CLUSTER_GROUPS
END_
www.3ds.com/tosca
Fig. 267 Example with free sizing optimization and clustering (below) for
certain (approx. 200) areas.
SIMULIA
Tosca Structure
Design Area
for avoiding high oscillations in the thickness distribution and that the structure has subcomponents with a minimum width.
Additionally, the minimum cluster width for the width control can partly circumvent the two following problems:
1. First, checkerboards might appear if one is applying a minimal value of the
lower bound of the thickness and applying lower order shell elements as 3
node triangular shell elements. When using higher order shell elements or
the lower bound of the thickness is not minimal then checkerboards are not
frequent.
2. Secondly, a minimum cluster width ensures uniqueness of the optimization
solution independent upon the mesh size and discretization. A coarse
mesh and a fine mesh lead to the same optimized structure if the minimum
cluster widths for both cases are set to the same absolute size. Please
note that the size in both cases should be larger than the average element
edge length.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
For the definition of the minimum cluster width, the element group and the
desired minimum width should be entered in CLUSTER_WIDTH dialog.
SIMULIA
Tosca Structure
Sizing Optimization
=
=
=
=
END_
www.3ds.com/tosca
point symmetry
rotational symmetry
cyclic translational symmetry (replication of an area with a given distance)
link condition (coupling of arbitrary areas of the model)
Fig. 271 Beam without symmetry (left) and with reflection symmetry (right)
SIMULIA
Tosca Structure
Design Area
defined
using
DV_CONSTRAINTS
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
A symmetry condition
SYMMETRY_CONTROL.
SIMULIA
Tosca Structure
Sizing Optimization
www.3ds.com/tosca
SIMULIA
Tosca Structure
Design Area
The frozen elements of one area are also considered as frozen for the linked
areas if Frozen checkbox is checked.
LINK_SIZING
ID_NAME
CS
TYPE
TRANSLATION
ANGLE
END_
DVCON_SIZING
ID_NAME
EL_GROUP
CHECK_TYPE
CHECK_LINK
=
=
=
=
END_
More than one symmetry condition can be defined for an element group.
Geometrically, different combinations have to be feasible.
Remark
1. The FE meshes do not have to be symmetric. The restriction can also be
applied to unstructured meshes or to tetrahedron meshes. The elements
should have nearly the same size because the result is the resolution of the
coarsest part of the mesh. It is possible that the linked elements are not
determined correctly if the size of the elements differs too much.
1. The element group for a certain restriction should be a subset of the design
element group. If this is not the case, Tosca Structure will stop the optimization.
2. The DVCON_TOPO ID_NAME has to be referenced in the OPTIMIZE
command in order to activate the restriction. In Tosca ANSA environment
all commands which are not disabled in the task manager are added automatically to the optimization task. In Tosca Structure.gui the DVCON_TOPO
entry has to be activated in the OPTIMIZE mask.
OPTIMIZE
...
DVCON
...
= name_of_dvcon_entry
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Sizing Optimization
END_
8.4
Objective Function
The objective function describes the optimization target. In general, one scalar value (sometimes combined from other scalars) is to be maximized or
minimized.
www.3ds.com/tosca
8.4.1
Overview
The OBJECTIVE FUNCTION is the function, which value can be maximized
or minimized during the optimization. This function depends on the results of
the FE analysis. Therefore, the values of interest must be derived from the FE
results in order to define an objective function and functional constraints. The
results of the FE analysis (total displacement, energy, etc.) for determining
the objective function and functional constraints are called design
responses. A single value from the design response must be specified for the
definition of the objective function using the command DRESP (DESIGN
RESPONSE). For details about design responses refer to chapter 4.4 Design
Responses. General comments about the definition of objective functions can
be found in chapter 4.2 Objective Function.
8.4.2
SIMULIA
Tosca Structure
Objective Function
Eigenfrequency terms
for objective
+C k
+ ( V V )
+f k
--- ln
k
j = 1 e
+R i
+F i
+ i
+M i
+M i
+ R i
2
+u i
+ u i
kf j
+ F i
2
+ u x + u y + u z
+ R x + R y + R z
+ F x + F y + F z
+ ( u i ,1 u i ,2 )
+ ( R i ,1 R i ,2 )
+ ( F i ,1 F i ,2 )
+ ( u i ,1 u i ,2 )
+ ( R i ,1 R i ,2 )
+ ( F i ,1 F i ,2 )
Center of gravity
terms for objective
Moment of inertia
terms for objective
+i i
+I ij
In this table, the indices i and j indicate a direction of an axis (x, y or z) of the
global or a local coordinate system. The compliance, eigenfrequencies, displacements and forces can be based upon results from different load cases.
The reference values marked with "*" are defined in DRESP parameter of
OBJ_FUNC command. By default, the reference values are zero. The reference values can be set individually for each term in the objective function.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Sizing Optimization
END_
Remarks
1. A minimization optimization task can be converted into a maximization optimization task (or vice versa) by changing the sign of the weighting factors
in the definition of the objective function.
8.4.3
Eigenfrequency terms
in Min-Max
( C k C k )
( V V )
1
-----------------
fk fk
www.3ds.com/tosca
Compliance terms in
Min-Max
SIMULIA
Tosca Structure
Objective Function
( u i u i )
( )
( R i R i )
(M M )
( u i u i )
( R i R i )
( u x + u y + u z u )
((u u ) u )
( R x + R y + R z R )
((R R ) R )
( ( u i , 1 u i , 2 ) u i )
2
( ( R i ,1 R i ,2 ) R i )
i ,1
i ,2
i ,1
i ,2
Center of gravity
terms in Min-Max
Moment of inertia
terms in Min-Max
i C i C
I ij I ij
where the index i and j are indicating one of the x-y-z-directions. The compliance, eigenfrequencies, displacements and reaction forces can be from different load cases.
The REFERENCE values marked with the star "*" are defined by the use in
the DRESP command in OBJ_FUNC. Normally, the reference values are zero.
Hence, by default all reference values are set to zero. The reference can be
set individually for each term in the objective function.
The WEIGHT factors are defined by the user in the DRESP command in
OBJ_FUNC. The weight factors can be different for each individual term in the
objective function. By default the weighting factors are all set to one. Hence,
by default all weighting factors are set to one.
The reference value and weight factor can be changed, e.g. to 2.5 and 14.0
for response id_dresp in the following way:
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Sizing Optimization
OBJ_FUNC
...
DRESP
...
END_
The main difference between the scheme in vol.2 chapter 8.4.2 and the present scheme is the way the frequency terms are defined in the objective.
8.5
Constraints
Constraints are fundamental parts of the definition for an optimization task,
see also chapter 4.3 Constraints. The purpose of having constraints is to
ensure that the optimized design is feasible. The following two tables
describe which design response types are valid as constraints. These design
responses can be constrained using lower equal constraint or greater equal
constraint as explained in chapter 4.3 Constraints. Moreover, new combinations using VAR_OPER or GROUP_OPER for the DRESP can also be
applied in the constraints as described in chapter 4.3 Constraints:
C k C k
V V
[ V V ]
[ C l C l ]
Eigenfrequency terms
for constraints
f k f k
f l f l
[ f k f l f ]
www.3ds.com/tosca
f k f l f
SIMULIA
Tosca Structure
Constraints
u i u i
R i R i
F i F i
u i u i
R i R i
F i F i
i i
M i M i
M i M i
i i
M i M i
M i M i
2
u i u i
R i R i
2
F i F i
2
[ u i u i ]
[ R i R i ]
[ F i F i ]
u x + u y + u z u
2
R x + R y + R z R
2
F x + F y + F z F
2
[ u x + u y + u z u ]
2
2
2
2
2
2
[ R x + R y + R z R ] [ F x + F y + F z F ]
u i ,1 u i ,2 u i
R i ,1 R i ,2 R i
F i ,1 F i ,2 F i
u i ,1 u i ,2 u i
R i ,1 R i ,2 R i
F i ,1 F i ,2 F i
( u i ,1 u i ,2 ) u i
2
[ ( u i ,1 u i ,2 ) u i ]
2
( R i ,1 R i ,2 ) R i
2
( F i ,1 F i ,2 ) F i
2
[ ( R i ,1 R i ,2 ) R i ] [ ( F i ,1 F i ,2 ) F i ]
2
i ,1 u i ,1 + i ,2 u i ,2 + u i
Center of gravity
terms for
constraints
Moment of inertia
terms for
constraints
i i i i
I ij I ij
i i i i
I ij I ij
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
i ,1 u i ,1 + i ,2 u i ,2 + u i
SIMULIA
Tosca Structure
Sizing Optimization
8.6
8.6.1
min Vol
i = 1, n
u j u restrict,j
j =1...m
where Vol is the relative material volume of an element in the design area, u j
is the nodal displacement and u restrict ,j is the restriction for the nodal displacement of the node j.
A model for the minimization of the relative material volume under the displacement of the loaded nodes is presented in the example below
Formulation of the optimization problem
www.3ds.com/tosca
The following figures show different load cases with its constraints and the
corresponding formular. The amplitude of the distortion is defined by two variables: u1 and u2 gives the displacement at the two pints where the load is
SIMULIA
Tosca Structure
Typical Tasks for Static Analysis
applied. The indices x and z are directions in local or global coordinate systems.
Bending stiffness
u z, 2 + u z, 1
arg et
------------------------- u tbending
2
u z, 2 u z, 1
arg et
------------------------- u ttorsional
2
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Torsional stiffness
SIMULIA
Tosca Structure
Sizing Optimization
Axial stiffness
u x, 2 + u x, 1
arg et
-------------------------- u taxial
2
Necessary definitions
Two design responses are needed:
2. The second design response is the displacement of the loaded node. The
absolute displacement is used in this case. Alternatively, the displacement
in the direction of the load (in the example it is Z- or X-direction of a local
coordinate system) can be used. The restriction to one direction reduces
the number of load cases generated by the optimization system because
using absolute displacement leads to the need of 3 additional load cases in
order to calculate the sensitivities while the displacement in Z-direction only
requires one additional pseudo-load case for the calculation of the sensitivities. The constraint is then defined as an inequality constraint with an
absolute value for the displacement value.
www.3ds.com/tosca
1. The first design response is the design response representing the relative
material volume of the design area. This design response is the objective
function that is to be minimized.
SIMULIA
Tosca Structure
Typical Optimization Tasks for Modal Analysis
Iterations
Fig. 275 Objective function: Minimize mass (mass normalized)
Bending
Axial
Torsional
Iterations
In Fig. 275 you can see the gradient of the normalized mass about 15 Iterations. In this example the reduction amounts about 15%. Illustrated in Fig.
276 are the gradients of the normalized three stiffness constraints for the
three loadcases (bending, axial and torsional). What you can see is, that they
are fullfilled.
8.7
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Sizing Optimization
quencies using optimization. Otherwise, the first and secondary mode might
switch during the optimization as shown in Fig. 277 (a).
For some optimization problems it can be desirable that a sudden eignefrequency is increased whereas the other eigenfrequencies are allowed to
decrease as shown in Fig. 277 (a).
In chapter 8.7.1 Maximization of the first eigenfrequencies is described how
several lowest eigenfrequencies are increased (Fig. 277 (b)) and chapter
8.7.2 Maximizing the torsional modal eigenfrequency addresses how a specific eigenfrequency in an eigenfrequency spectrum is optimized using mode
tracking (Fig. 277 (a)).
In chapter 5.7.4 Constraining an eigenfrequency is shown how an eigenfrequency can be applied in a constraint, e.g. when maximizing the stiffness
under the condition that the first eigenfrequency is above 100 Hz or when
minimizing the mass under the condition that the eigenfrequencies are be
below or above certain specified values.
www.3ds.com/tosca
Fig. 277 Optimizing all the lowest eigenfrequencies using the Kreisselmaier-Steinhauser formulation (b) and the single lowest eigenfrequency using mode tracking (a)
8.7.1
SIMULIA
Tosca Structure
Typical Optimization Tasks for Modal Analysis
The design response is defined using the Kreisselmaier-Steinhauser formulation as described in chapter 4.4.6 Eigenfrequency.
Any number of natural frequencies in the design response can be specified
using the DRESP command.
Formulation of the optimization problem
The optimization task is to maximize the lowest modal eigenfrequencies with
a volume constraint of 100%.
Model:
f=20.4Hz:
f=25.8Hz:
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
f=22.1Hz:
SIMULIA
Tosca Structure
Sizing Optimization
f=26.4Hz:
f=30.6Hz:
f=35.0Hz:
www.3ds.com/tosca
In Fig. 278 you can see the model and the first six modal eigenfrequencies.
SIMULIA
Tosca Structure
Typical Optimization Tasks for Modal Analysis
Higher Eigenfrequency
Iterations
Fig. 279 Objective function: Maximize eigenfrequencies
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Iterations
SIMULIA
Tosca Structure
Sizing Optimization
END_
OBJ_FUNC
ID_NAME = maximize_eigenfrequencies
DRESP = all_lowest_eigenfrequencies
TARGET = MAX
END_
8.7.2
www.3ds.com/tosca
Often it is needed to increase a specific eigenfrequency in the eigenfrequency spectrum belonging to a certain eigenmode as illustrated in Fig. 277
(a). In this case, a specific eigenfrequency is defined using TYPE =
DYN_FREQ, see also chapter 4.4.6 Eigenfrequency.
SIMULIA
Tosca Structure
Typical Optimization Tasks for Modal Analysis
f=21.6Hz:
f=25.8Hz(has to be maximized):
f=29.6Hz:
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
f=34.2Hz:
SIMULIA
Tosca Structure
Sizing Optimization
f=36.3Hz:
f=37.5Hz:
www.3ds.com/tosca
In Fig. 281 you can see the model and the first six modal eigenfrequencies.
SIMULIA
Tosca Structure
Typical Optimization Tasks for Modal Analysis
Results
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
DRESP
SIMULIA
Tosca Structure
Sizing Optimization
END_
8.8
Settings
Different settings can be made to control speed and convergence behaviour
of the sizing optimization algorithms. Default values are available which have
been tried and tested on many occasions.
Other algorithm settings for the various optimization algorithms can be
selected using the OPT_PARAM command.
8.8.1
Mode tracking
It is possible to apply a simple mode tracking function for the modal analysis
using the modal assurance criterion (MAC) including a mass weighting.
The modes of the different eigenfrequencies are compared in the modal
assurance criterion (MAC) for identifying if the eigenfrequencies from optimization iteration to optimization iteration have been switching yielding
2
www.3ds.com/tosca
MAC i ,j
( { } i [ Mass ] { initial } j )
= ---------------------------------------------------------------------------------------------------------------------( { } i [ Mass ] { } i ) ( { initial } j [ Mass ] { initial } j )
where the initial modes are equal to the modes of the first iteration. The
modes in the first optimization iteration are used for identifying the eigenfrequencies through the optimization iterations. The MAC matrix is equal to the
unity matrix if the initial modes are equal to the modes in a given optimization
iteration. However, this is only the case in the first optimization iteration due to
the optimization changes. The largest components of the MAC matrix are
determined in each optimization iteration for determining if any mode switching should be present. If significant off-diagonal terms exist in the MAC matrix,
it indicates that the mode switching is present. The MAC matrix is printed in
the TOSCA.OUT file. Then the user can see how close to 1 the components
of the MAC matrix are and whether mode switching is present. If all the values in the MAC matrix are significantly below 1, it indicates that the applied
mode set does not contain enough modes for mode tracking.
According to the above equation, mode tracking can lead to a significant
increase in CPU-time. First, all modes of the eigenfrequencies have to be
cross-checked with each other. Sometimes a high number of cross-checks is
SIMULIA
Tosca Structure
Settings
=
=
=
=
opt_params
id_of_optimize
ON
15
Setting the command MODETRACKING equal to ON activates the mode tracking. Default for MODETRACKING is OFF. Consequently, mode tracking will
only be applied if the user requests mode tracking. The value of MODENUMBERS specifies how many eigenfrequencies should be used in the mode
tracking. The default value of mode tracking is 5. In the above example,
MODENUMBERS is set to 15 meaning that 15 eigenfrequencies will be used
for the mode tracking. If, e.g., one maximizes the first eigenfrequency, this
eigenfrequency will be compared to the 15 specified eigenfrequencies in the
MODETRACKING command. It is important that the modal analysis file specified by the user also leads to an analysis having the same or more eigenfrequencies than specified in the MODENUMBERS parameter. For this example,
the user should specify at least 15 eigenfrequencies in the finite element file.
Sometimes it happens that many local modes having a low eigenfrequency
appear during the optimization iterations. Normally, this will lead to high number for MODENUMBERS which is not desirable because of high CPU-time.
However, this can be partly circumvented by setting a number in the input
finite element file avoiding the lower eigenfrequencies to be calculated. E.g.,
if it is known that the initial eigenfrequency is around 200 Hz, then it should be
specified in the finite element input file that the eigenfrequencies over 50 Hz
only are to be calculated.
To improve the performance, it is additionally possible to restrict mode tracking to a certain group of nodes in the model (e.g., every fifth node on the surface of the model) or nodes where lumped and rigid masses are attached. In
this case, the node group is referenced in the MODETRACKING parameter
as follows:
OPT_PARAM
ID_NAME
OPTIMIZE
MODETRACKING
MODENUMBERS
END_
=
=
=
=
opt_params
id_of_optimize
ON, node_group
15
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
END_
SIMULIA
Tosca Structure
Sizing Optimization
When a node group is applied in the mode tracking, then the modal assurance criterion (MAC) yields
2
MAC i ,j
( { } i { initial } j )
= -------------------------------------------------------------------------------( { } i { } i ) ( { initial } j { initial } j )
where the modes are not scaled with the mass. Therefore, the nodes of the
applied group are often chosen to be the nodes of frozen elements, lumped
or rigid masses.
Remarks
1. The finite element input file specified by the user should contain a modal
analysis containing at least as many eigenfrequencies as the value of
MODENUMBERS parameter.
2. A general rule for keeping the MODENUMBERS low and thereby saving
CPU-time is to specify a lower bound for the calculated eigenfrequencies in
the finite element file. Choosing 25% of the expected eigenfrequency as
the lower bound usually suffices. E.g., if the initial eigenfrequency of
interest in the first optimization iteration is around 100 Hz, then it can be
specified that only the eigenfrequencies over 25 Hz are to be calculated.
3. The mode tracking feature can not be guaranteed to work for all examples.
4. Mode tracking is not recommended for the Kreisselmaier-Steinhauser
formulation.
www.3ds.com/tosca
5. Mode tracking can increase the CPU-time significantly both for finite
element solver and Tosca Structure. Restrict mode tracking to a smaller
representative group of nodes to gain performance.
8.8.2
= opt_params
SIMULIA
Tosca Structure
Settings
OPTIMIZE
= id_of_optimize
THICKNESS_UPDATE=CONSERVATIVE
END_
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
8.8.3
SIMULIA
Tosca Structure
Sizing Optimization
8.8.4
FILTER_TYPE
The filter technique for the objective function can be changed using the
parameter FILTER_TYPE in the optimization settings (OPT_PARAM command). Changing the filter technique for the objective function is mainly interesting for stiffness optimization problems.
The FILTER_TYPE can be set to STANDARD and LOW, respectively. The filter for FILTER_TYPE = LOW is a relaxation of the STANDARD filter. It is useful for coarse meshes yielding a clearer design and a lower number of
optimization iterations.For reasonable and fine meshes FILTER_TYPE equal
to LOW would often cause checkerboard.
FILTER_TYPE equal to LOW might also be useful for stabilizing dynamic
problems like modal eigenfrequency optimization.
Remarks:
1. Changing the filter option has no effect when the objective is to minimize
the mass.
2. Changing the filter option has no effect when manufacturing constraints are
present.
8.9
Stop Condition
Stop conditions are necessary to ensure that the optimization terminates.
These stop criteria can either simply allow a certain number of loops or
depend on the convergence behaviour of the optimization.
www.3ds.com/tosca
8.9.1
Convergence Criteria
For checking if the sensitivity based sizing optimization has converged two
stop criteria are implemented.
The user can specify if both stop criteria should be fulfilled or just one of the
stop criteria has to be fulfilled for the optimization algorithm to stop. Default is
that both criteria should be fulfilled before the optimization algorithm stops. To
specify that just one of the criteria has to be fulfilled set
STOP_CRITERION_LEVEL equal to SINGLE. The default value for
STOP_CRITERION_LEVEL is BOTH.
E.g. the optimization algorithm should stop when just one of the criteria is fulfilled
OPT_PARAM
ID_NAME
= opt_params
SIMULIA
Tosca Structure
Stop Condition
OPTIMIZE
= id_of_optimize
STOP_CRITERION_LEVEL = SINGLE
END_
n n 1
---------------------------- STOP_CRITERION_OBJ
n
where the index n is representing the present optimization iteration and is n-1
is the previous iteration. When the criterion is lower than
STOP_CRITERION_OBJ the stop criterion is fulfilled. The default for
STOP_CRITERION_OBJ is 0.001. The value can be changed by the user,
e.g.
OPT_PARAM
ID_NAME
= opt_params
OPTIMIZE
= id_of_optimize
STOP_CRITERION_OBJ = 0.01
END_
The third stop criterion is based upon the change in the thicknesses (design
variables) in each element from one optimization iteration to the next optimization iteration and is defined by
Number of elements
n n 1
----------------------------------------------------------------------- STOP_CRITERION_THICKNESS
Number of elements
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Sizing Optimization
where the index n is representing the present optimization iteration and is n-1
is the previous iteration. When the criterion is lower than
STOP_CRITERION_THICKNESS the stop criterion is fulfilled. The default for
STOP_CRITERION_THICKNESS is 0.005. The value can be changed by the
user, e.g.
OPT_PARAM
ID_NAME
= opt_params
OPTIMIZE
= id_of_optimize
STOP_CRITERION_THICKNESS = 0.0001
END_
www.3ds.com/tosca
8.9.2
= global_stop
= 55
END_
SIMULIA
Tosca Structure
Stop Condition
Remark:
1. Please note that the global stop criterion is defined using a STOP
command whereas the convergence criteria are defined in the optimization
settings (OPT_PARAM command).
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
2. The global stop criterion leads to a hard stop of the optimization - independend of a complete convergence of the result (in particular with a small
number of iterations this cannot be achieved).
SIMULIA
Tosca Structure
www.3ds.com/tosca
Sizing Optimization
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Stop Condition
SIMULIA
Tosca Structure
Result Transfer and Validation Run
9.1
Tosca Structure.smooth
www.3ds.com/tosca
Tosca Structure.smooth takes the ONF files produced during the optimization
as input, generates the smooth isosurface or the model surface (depending
on settings and optimization type) and saves the surface in one or several
output formats so that it can be used for following reasons:
1. Validation run (only available with Tosca ANSA environment): surface for
remeshing and generation of validation model (Reconstruct).
2. Transfer to CAD: surface in STL or IGES format, slices in IGES or CLI
format.
3. Representation of the surface in solver formats (INP, BDF, CDB).
4. Visualization of the processed optimization results in VTFX format.
Also, when started from within Tosca ANSA environment, the surface is
saved in ONF format and loaded into Tosca ANSA environment so that it can
be viewed and processed further. Please note: Reconstruct (generation of
validation models) in Tosca ANSA environment only supports one material in
the design area.
SIMULIA
Tosca Structure
Tosca Structure.smooth
Tosca Structure.smooth reads the names of input files and other parameters
form a Tosca Structure parameter file. Although it is possible to set up the
parameter file manually and start Tosca Structure.smooth in command line, it
is recommended to use Tosca ANSA environment (or, to lesser extent, Tosca
Structure.gui) to generate the parameter file and to call the Tosca Structure.smooth executable.
9.1.1
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Result Transfer and Validation Run
9.1.2
www.3ds.com/tosca
In Tosca Structure.gui, there are two ways to define and run a Tosca Structure.smooth task. First, in Tosca Structure.pre editor, a SMOOTH block can be
inserted in Tosca Structure parameter file so that Tosca Structure.smooth is
called from Tosca Structure automatically once the optimization ends. To
define it, select Command | SMOOTH in Tosca Structure.pre screen (Fig.
285). Multiple SMOOTH blocks are allowed in a single Tosca Structure parameter file.
SIMULIA
Tosca Structure
Tosca Structure.smooth
again. The button View Result opens a dialog for the resulting VTFX file to
be opened in Tosca Structure.view.
Note that in this case, the names of input ONF files should be supplied using
relative or absolute paths, while Tosca ANSA environment and Tosca Structure.gui usually fill in the correct file names automatically.
9.1.3
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
END_
SIMULIA
Tosca Structure
Result Transfer and Validation Run
www.3ds.com/tosca
To solve the project and to start the smoothing run, click Solve having the
Smooth Result selected or use the right mouse button on Smooth
Result and choose Solve.
Fig. 289 Start the smoothing run either with the right mouse button or
using the Solve-button
SIMULIA
Tosca Structure
Tosca Structure.smooth
9.1.4
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Result Transfer and Validation Run
www.3ds.com/tosca
SIMULIA
Tosca Structure
Tosca Structure.smooth
Tosca Structure.gui
pre
smooth
ID_NAME
ID_NAME
ID Name
TASK
TASK
Task
Task
Description
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Parameter
name
SIMULIA
Tosca Structure
Result Transfer and Validation Run
www.3ds.com/tosca
Tosca ANSA
environment field
Tosca Structure.gui
Description
pre
smooth
MODEL
Inserted
automatically
FEM-File
RESULT
Result File
(if blank, set to a
file name found
in Jobname
Folder)
Inserted
automatically
Optimization Results
OUTPUT_
FILE
Automatically set
to
"TOSCA_POST/
<ID_NAME>"
Output
File
Output File
Name
ISO_VALUE
ISO_VALUE
Iso Value
ISO-Value
TARGET_
VOLUME
TARGET_
VOLUME
Target
Volume
Volume
SMOOTH_
CYCLES
SMOOTH_
CYCLES
Smooth
Cycles
Smooth
Cycles
Number of surface
smoothing cycles
REDUCTION_
RATE
REDUCTION_
RATE
Reduction Rate
Reduction
Rate (%)
REDUCTION_
ANGLE
REDUCTION_
ANGLE
Reduction Angle
Angle
Limiting angle
parameter used in
data reduction
SELF_
INTERSECTION_
CHECK
SELF_
INTERSECTION
_CHECK
Self Intersection
Self Intersection
Check
Defines whether
(and what kind of)
self-intersection
check is to be performed
SIMULIA
Tosca Structure
Tosca Structure.smooth
Tosca Structure.gui
pre
smooth
MIN_ANGLE
Min Angle
Minimal allowed
angle of surface triangles
MIXED_MESH
Mixed
Mesh
Mixed Mesh
Triangles or mixed
(triangles and quadrangles)
FORMAT
Output Format
(Format = ONF
is added automatically)
Output
Formats
Output Format
Output format;
multiple entries are
allowed
OUTPUT_
SURFACE
Output
Surface
Isotype
VTF_
ORIGINAL_
MODEL
VTF_
ORIGINAL_
MODEL
Show
Original
Model in
Vtf
Original
Model
IGES_UNIT
iges_unit
Iges Unit
SLICE_
NUMBER
SLICE_
NUMBER
Number
of Slices
#Slices
Number of section
planes for slices
SLICE_
NORMAL
SLICE_
NORMAL
Slice Normal
<x,y,z>
Sl_Normal
SLICE_
FORMAT
SLICE_
FORMAT
Slice Format
Format
BORDER
BORDER_
OUTPUT
Border
Selectable
in Slices
Description
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Parameter
name
SIMULIA
Tosca Structure
Result Transfer and Validation Run
www.3ds.com/tosca
Tosca ANSA
environment field
Tosca Structure.gui
Description
pre
smooth
GROUP_FILE
Inserted
automatically
Group File
GROUP_
EXCLUDE
Name in
drop down
list right
from Group
File when
delete is
chosen
GROUP_
INCLUDE
Element
Group
Name in
drop down
list right
from Group
File when
plot is
chosen
GROUP_
SURFACE
ISO_VALUE_
GROUP
TARGET_
VOLUME_
GROUP
ISO_
SEQUENCE
Incremental Iso
Sequence
EXCLUDE_
LOADED
EXCLUDE_LOA
DED (Default:
YES)
Exclude
Loaded
Elements
(Default
NO)
SIMULIA
Tosca Structure
Tosca Structure.smooth
Tosca ANSA
environment field
Tosca Structure.gui
pre
smooth
ORIGINAL_
SURFACE_
SMOOTHING
Orig. Surf.
Smoothing
Orig Surf
Smooth
RESULT_
FILTERING
Result Filtering
Result Filtering
KEEP_CONNE
CTION_NODES
KEEP_CONNEC
TION_NODES
Keep Conn.
Nodes
SHRINKAGE_C
ORRECTION
Shrinkage
Correction
Prevent shrinkage
effects caused by the
laplacian smoothing
COMPONENT_
LIMITING_SIZE
Component
Limit Size
Defines if small
unconnected parts
are to be removed
Table 30
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
9.1.5
Comp.
Limiting
Size
Description
SIMULIA
Tosca Structure
Result Transfer and Validation Run
border nodes only. In both cases, the smoothing can be turned off, though it is
not recommended.
Original model
(MODEL_fem.onf)
Topology optimization
result generated by Tosca
Structure.report (TP_015.onf)
Isosurface generated by
Tosca Structure.smooth
(no smoothing, no reduction)
www.3ds.com/tosca
SIMULIA
Tosca Structure
Tosca Structure.smooth
another ONF file is chosen in Result File field. For additional information
about RESULT parameter as well as parameters controlling the isocut and the
smoothing, see vol.2 chapter 9.1.7. The parameters for data reduction are
discussed in vol.2 chapter 9.1.8. Finally, vol.2 chapter 9.1.9 deals with parameters defining the output formats. All output files are created in the same
directory, and their names are constructed as some common part plus the
corresponding suffix (if needed) and extension. The parameter
OUTPUT_FILE defines both the directory and this common part.
Example: using
OUTPUT_FILE = c:\MyDirectory\MyOutput
with the output in VTFX and IGES format for slices using cubic splines results
in the files
c:\MyDirectory\MyOutput.vtfx
c:\MyDirectory\MyOutput_slices.igs.
In Tosca ANSA environment, OUTPUT_FILE is set automatically to
<jobname>/TOSCA_POST/<SMOOTH item name>, where <SMOOTH item
name> is the name of the item in Task Manager (SMOOTH_INSTANCE by
default). If this parameter is omitted in the parameter file, it is set to
<directory of ONF model>/<ID_NAME>.
There is also the possibility to visualize the optimization process by generating the isosurfaces for all optimization iterations and saving them in an animation sequence in a VTFX file. This feature is not supported in Tosca ANSA
environment. This is done if the parameter file contains following lines:
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
TASK = all_iterations
MODEL = <model file name>.onf or <model file name base>
RESULT = <optimization result file name base>
SIMULIA
Tosca Structure
Result Transfer and Validation Run
Note that these model and result file names should be entered manually in
the Tosca Structure.smooth screen of Tosca Structure.gui. In Tosca Structure.pre screen of Tosca Structure.gui, it suffices to set Task field to
all_iterations.
The isovalues (see vol.2 chapter 9.1.7) for the isosurfaces generated at each
iteration are either constant or linearly increasing. In the first case, the parameter ISO_SEQUENCE should be set to const (this is its default value); the isovalue then is specified by ISO_VALUE parameter. In the second case,
ISO_SEQUENCE = incr should hold, and the isovalue for iteration i is
iso_value * (i+1)/ (n+1), where iso_value is the value of ISO_VALUE
parameter and n is the number of the last iteration.
9.1.6
www.3ds.com/tosca
TASK = surface
MODEL = <model file name>.onf
RESULT = <optimization result file name>.onf
In Tosca ANSA environment, it suffices to choose TASK = SURFACE (note
that by default TASK = ISO) and the file names will be inserted automatically.
In Tosca Structure.gui (Tosca Structure.smooth screen), use "Create Surface
+ Optimization displacements (Shape and Bead optimization)" value of Task
field and choose appropriate model and optimization result files.
Additionally, there is the possibility to generate the surface of the input model,
without applying the optimization displacements. This works for the models
used in topology optimization as well. In this case, RESULT field should be
omitted in the parameter file; in Tosca ANSA environment as well as in Tosca
Structure.pre screen of Tosca Structure.gui, this is the case for the topology
optimization, while for shape and bead optimization the surface with optimization displacements is always generated. In Tosca Structure.smooth screen of
Tosca Structure.gui, choose "Create Surface Model from ONF File" as the
value of Task field.
After the surface is generated, the data reduction can be performed; it is
turned off by default. See vol.2 chapter 9.1.8 for the description of data reduction parameters. Both data reduction and the output in various formats (see
vol.2 chapter 9.1.9) are done in the same way as when processing the topology optimization results.
SIMULIA
Tosca Structure
Tosca Structure.smooth
9.1.7
Value
Description
Supported by
TS.pre
TS.smooth
TExt
ISO_
VALUE
SMOOTH_
CYCLES
Non-negative
integer number
Default: 5
ORIGINAL_
SURFACE_
SMOOTHING
off
(original surface is
not smoothed)
shrink
(limited original
surface smoothing)
full
(original surface is
smoothed)
default: off
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
TAE
GUI
SIMULIA
Tosca Structure
Result Transfer and Validation Run
Value
Description
Supported by
TAE
TS.pre
TS.smooth
TExt
GUI
SELF_
INTERSECTION_
CHECK
off
(no checks)
check
(check once)
runtime
(check always)
iterative
(first run without
check, rerun if
needed)
Default: iterative
MIN_ANGLE
www.3ds.com/tosca
Table 31
All parameters have default values that are useful in most cases. However,
these parameters affect the appearance of the isosurface as described
below.
The isovalue specified using the parameter ISO_VALUE defines the position
between the elements with zero and maximal material value where the isosurface is constructed. More precisely, the interpolated material values are
first found for each node, and then the new nodes are constructed on the
edges that have varying material values (i.e., material value for one end is
SIMULIA
Tosca Structure
Tosca Structure.smooth
less than and for the other one larger than the isovalue). The ratio in which
the edge is subdivided by the new node is defined by the iso-value in respect
to the material values of the ends of the edge, but is limited to a range from a
to 1-a with a constant value a (currently 0.3) in order to prevent edges of very
small lengths. As the result, increasing the isovalue leads to shifting the isosurface towards the inside of the model, thus the model volume decreases.
For the structures with thin components, it is not recommended to use large
isovalues (larger than 0.7), since the structure might become disconnected.
See Fig. 294 for an example of how the isovalue influences the result.
isovalue = 0.2
isovalue = 0.8
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Fig. 294 Isosurfaces and smoothing parameters in Tosca Structure.smooth. Isosurfaces for the isovalues 0.2 and 0.8.
SIMULIA
Tosca Structure
Result Transfer and Validation Run
set to off or check; the difference in these cases is that, in case this parameter is set to check, the self-intersection test is performed once for the entire
model after the smoothing and data reduction are made, and the user
receives the information about the number of intersecting faces as well as a
VRML
file
containing
these
faces.
In
case
that
SELF_INTERSECTION_CHECK parameter is set to iterative, the smoothing is first performed without the self-intersection checks, and then is redone
if the self-intersections appear after the smoothing. Note that in case of
SELF_INTERSECTION_CHECK parameter set to iterative or runtime,
similar self-intersection checks are done for isocut and data reduction as well;
however, in rare cases, self-intersections that occur during the isocut cannot
be prevented, and they are likely to remain after the smoothing and data
reduction are done.
In order to achieve smoother surfaces, higher value of SMOOTH_CYCLES
parameter should be used. However, this leads to the increase of the computation time that might be noticeable especially in the case that the self-intersection test is turned on. In practice, 5 to 10 smoothing cycles are usually
sufficient. Further smoothing might have a negative effect of contracting thin
components; in certain cases, the smoothing has to be turned off by setting
SMOOTH_CYCLES to 0. See Fig. 295 for an example of smoothing with various numbers of smoothing cycles.
0 smoothing
cycles
(smoothing turned
off)
www.3ds.com/tosca
3 smoothing
cycles
10 smoothing
cycles
Fig. 295 Isosurfaces and smoothing parameters in Tosca Structure.smooth: 0, 3 and 10 smoothing cycles
SIMULIA
Tosca Structure
Tosca Structure.smooth
ORIGINAL_
SURFACE_
SMOOTHING =
off
ORIGINAL_
SURFACE_
SMOOTHING =
shrink
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
The parameter ORIGINAL_SURFACE_SMOOTHING defines if the original surface (that is the part of the surface of original elements, in contrast to the new
surface produced by isocut) should be smoothed.
SIMULIA
Tosca Structure
Result Transfer and Validation Run
ORIGINAL_
SURFACE_
SMOOTHING =
full
Fig. 297 Isosurfaces and smoothing parameters in Tosca Structure.smooth: 0, 3 and 10 smoothing cycles
If it is set to off, the original surface remains unchanged. In most cases, this
is desired since the surface nodes might have some additional information
(e.g. forces or boundary conditions) associated with them. However, the
resulting surface will be smoother if the original surface gets modified as well.
To do this, set ORIGINAL_SURFACE_SMOOTHING to full. The third option
ORIGINAL_SURFACE_SMOOTHING = shrink allows modifying the original
surface, but in a way that the new surface does not occupy the region beyond
the initial design. This is achieved by prohibiting the nodes to be moved
towards the outside of the model.
Note that the surface of the frozen regions that are chosen using
GROUP_SURFACE commands is not modified even if the original surface
smoothing is turned on.
Reduction parameters
Using the data reduction, the number of surface triangles can be reduced, or
the triangles can be pairwise united in quadrilaterals. Data reduction is applicable to any surfaces generated by Tosca Structure.smooth; it also affects the
original surface, but does not modify loaded nodes. By default, data reduction
is turned off.
Following parameters guide the data reduction:
www.3ds.com/tosca
9.1.8
SIMULIA
Tosca Structure
Tosca Structure.smooth
Value
Description
Supported by
TS.pre
TS.smooth
TExt
REDUCTION_
RATE
REDUCTION_
ANGLE
MIXED_
MESH
yes
(unite triangles to
quadrilaterals)
no
(no change)
default: no
SELF_
INTERSECTION_
CHECK
off
(no checks)
check
(check once)
runtime
(check always)
iterative
(first run without check,
rerun if needed)
Default: iterative
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
TAE
GUI
SIMULIA
Tosca Structure
Result Transfer and Validation Run
Value
Description
Supported by
www.3ds.com/tosca
Table 32
TExt
TS.smooth
TS.pre
MIN_ANGLE
TAE
GUI
SIMULIA
Tosca Structure
Tosca Structure.smooth
the angles of triangles after the reduction are larger than the value of
MIN_ANGLE parameter;
no self-intersection occurs after the reduction (only checked if
SELF_INTERSECTION_CHECK parameter is set to iterative or runtime).
REDUCTION_RATE = 0 (default)
REDUCTION_ANGLE = 15 (default)
4842 faces (100%)
REDUCTION_RATE=100
REDUCTION_ANGLE =15 (default)
REDUCTION_RATE = 50
REDUCTION_ANGLE = 15 (default)
2420 faces (50.0%)
REDUCTION_RATE = 100
REDUCTION_ANGLE = 45
480 faces (9.9%)
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
As seen from the example shown in Fig. 298, in order to achieve maximal
data reduction, REDUCTION_RATE parameter should be set to 100 and
REDUCTION_ANGLE parameter to a large value (e.g. 45). However, the surface then becomes coarse. By changing the REDUCTION_ANGLE parameter,
the surface with sufficient smoothness and reasonably small number of triangles can be obtained.
The parameters MIN_ANGLE and SELF_INTERSECTION_CHECK usually do
not influence the number of triangles remaining after the data reduction,
unless MIN_ANGLE is set to a large value (30 or more; default value is 15).
Note that these parameters are also used in the surface smoothing.
SIMULIA
Tosca Structure
Result Transfer and Validation Run
presented in Fig. 299. Note that the output of a mixed surface is only available for certain output formats (namely VTFX, ONF, IGES and WRL). In case
of other formats, the triangular surface is always saved, thus the parameter
MIXED_MESH has no influence on the result. Also, the triangular surface is
always used for the generation of the slices and the border.
The generation of the mixed mesh can be combined with the data reduction
described above; it is performed after the data reduction is finished.
9.1.9
Output parameters
After the surface is generated and (if necessary) the smoothing and data
reduction are finished, it can be saved to the output file(s) in various formats.
The output is controlled by following parameters:
www.3ds.com/tosca
SIMULIA
Tosca Structure
Tosca Structure.smooth
Value
Description
Supported by
TS.pre
TS.smooth
TExt
FORMAT
See Table 34
OUTPUT_
FILE
<name>
default:
<model>_smooth,
where <model> is
the name of input
model file without
extension
OUTPUT_
SURFACE
original
new
both
default: both
VTF_
ORIGINAL
_MODEL
yes
no
default: no
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
TAE
GUI
SIMULIA
Tosca Structure
Result Transfer and Validation Run
Value
Description
Supported by
TExt
TS.smooth
in: inches
mm: millimeters
ft: feet
mi: miles
m: meters
km: kilometers
mil: mils
um: microns
cm: centimeters
uim: microinches
TS.pre
IGES_UNI
T
TAE
GUI
default: mm
Table 33
www.3ds.com/tosca
Using FORMAT parameter, the user requests the saving of the generated surface(s) to various output formats that are intended to be used with following
programs:
FORMAT
parameter
Abaqus/CAE
inp
iges1
<name>.inp
<name>.igs (IGES using block 114)
ANSYS
cdb
iges3
<name>.cdb
<name>_3.igs (IGES using block 128)
CATIA
stl
iges3
obj
SIMULIA
Tosca Structure
Tosca Structure.smooth
Program
FORMAT
parameter
GLView Inova
vtfx
<name>.vtfx
MEDINA
stl
<name>.stl
(using FEM formats is also possible)
MSC Nastran
bdf
<name>.bdf
Patran
out
Pro/E
iges1
stl
<name>.stl
Solid Works
iges2
Tosca Structure.view
vtfx
<name>.vtfx
NX
stl
<name>.stl
obj
Other pre/postprocessors
See
above
Tosca ANSA
environment
ONF
Table 34
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Result Transfer and Validation Run
www.3ds.com/tosca
SIMULIA
Tosca Structure
Tosca Structure.smooth
Parameter
Value
TAE
TS.pre
TS.smooth
TExt
Supported by
SLICE_
NUMBER
Nonnegative integer;
default: 0
SLICE_
NORMAL
<x>,<y>,<z>
with real
values x, y, z
SLICE_
FORMAT
default:
igs_polygon
igs_polygon
(file name:
<name>_slices.igs)
igs_polygon: polygons
saved using cubic parametric
splines for each segment
(IGES block 112)
igs_curves
(file name:
<name>_slices_spl.igs)
cli
(file name:
<name>_slices.cli)
all
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
GUI
SIMULIA
Tosca Structure
Result Transfer and Validation Run
Parameter
Value
TAE
TS.pre
TS.smooth
TExt
Supported by
BORDER
yes
no
default: no
IGES_
UNIT
in: inches
mm: millimeters
ft: feet
mi: miles
m: meters
km: kilometers
mil: mils
um: microns
cm: centimeters
uim: microinches
GUI
default: mm
Output parameters of Tosca Structure.smooth.
* TAE=Tosca ANSA environment, TS=Tosca Structure
TExt=Tosca Extension for ANSYS/WB
** x = supported, - = unsupported
www.3ds.com/tosca
Table 35
SIMULIA
Tosca Structure
Tosca Structure.smooth
Note: operations with groups are not supported in Tosca ANSA environment.
In order to restrict the isocut and/or the surface calculation to certain areas of
the model, the user may specify the groups of elements that should be used.
The groups are read from the ONF file specified by the parameter
GROUP_FILE. Then, the group names defined in the file, and, additionally,
the group ALL containing all elements, can be used as values of following
parameters:
GROUP_EXCLUDE: the elements of the group are ignored for all operations;
GROUP_INCLUDE: the elements of the group are marked as normal and
are used for the (iso)surface calculation;
GROUP_SURFACE: the surface of the elements will be calculated even if
they would be deleted or cut otherwise.
Any number of these commands can be specified. If an element belongs to
several groups mentioned in the commands, the last command applies. For
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Result Transfer and Validation Run
GROUP_EXCLUDE
= all
GROUP_INCLUDE
= DESIGN_ELEM2
(upper part only)
www.3ds.com/tosca
SIMULIA
Tosca Structure
Tosca Structure.smooth
IGROUP_EXCLUDE
= all
GROUP_INCLUDE
=DESIGN_ELEM1
GROUP_SURFACE
=DESIGN_ELEM2
(lower part and the
surface of the
upper part)
Fig. 302 Tosca Structure.smooth. Isosurfaces obtained by using various
group commands; the original model is shown in gray.
For solid models, the volume displayed in this message is the ratio of the volume of solid(s) defined by the isosurface to the original volume, which is the
sum of volumes of all solid elements used in the topology optimization, except
those excluded using the group commands. The original volume is also equal
to the volume of the solid(s) defined by the surface produced from the same
model file using surface task, provided that the data reduction is turned off.
For shell element models, the definition is the same except that "volume"
should be replaced with "area". If the model contains both solid and shell elements, only the solid elements are considered.
In order to achieve required relative volume, the user may change the isovalue and recalculate the isosurface, keeping in mind that larger isovalues
usually lead to smaller volumes, as illustrated in Fig. 294. The same result
can be achieved using the automatic approach implemented in Tosca Structure.smooth. In order turn it on, the parameter TARGET_VOLUME should be
set to a value between 0 and 1. Then, the isovalue specified by ISO_VALUE
parameter is ignored and an iterative equation solving method is used to
determine the isovalue that leads to specified target relative volume. If this
volume is larger than the volume for isovalue equal to zero or smaller than
the volume for isovalue equal to 1, an error message is produced; in this
2 - 538 User Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Result Transfer and Validation Run
case, it is unlikely that the required relative volume can be achieved for any
isovalue between 0 and 1. Otherwise, the convergence to a solution is guaranteed unless the dependence of target volume on isovalue is noncontinuous, that sometimes occurs for small models. The maximal number of
iterations is fixed (currently 20); if the iterations fail to converge before this
number is reached, an error message will be produced. In this case, it is recommended to run Tosca Structure.smooth again using the isovalue obtained
in the last iteration, although the resulting relative volume would probably differ from the value used initially. The iterations are treated as having converged if the difference between the calculated and the desired values is less
than 10% of the desired value, and, in the same time, less than 1%.
If the model contains several design areas, different target relative volumes
might be needed for one or more regions. For this reason, the possibility to
define isovalues and target volumes differently for each group is implemented
in Tosca Structure.smooth; however, it is not supported neither in Tosca
ANSA environment nor in Tosca Structure.gui. The command
TARGET_VOLUME_GROUP = <group
volume>
name>, <target
relative
with <group name> being a name of a group defined in an ONF group file
defines the relative volume for this group. Then, for each such command, the
isovalue for the group will be found first by using the iterative method applied
to this group alone, after excluding the elements marked as deleted. For other
groups, the isovalue can be specified directly using
www.3ds.com/tosca
SIMULIA
Tosca Structure
Tosca Structure.smooth
Value
Description
Supported by
TS.pre
TS.smooth
TExt
RESULT_
FILTERING
off:
no filtering
moderate:
one filtering cycle
full:
5 filtering cycles
default: off
COMPONENT_
LIMITING_
SIZE
Real value
between 0 and 0.5
Default: 0
Defines the minimal allowed relative size of a connected component (calculated using its number
of faces). All components with the
relative size below this value are
removed. Default: 0
Table 36
The result filtering averages the material values ("densities") in the places
where it affects the isosurface most, and therefore it may account for large
changes of the surface geometry. See Fig. 303 for the influence of the result
filtering on the geometry in various cases.
No result filtering
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
TAE
GUI
SIMULIA
Tosca Structure
Result Transfer and Validation Run
Small isolated
components are
removed
Narrow "bridges"
are removed
www.3ds.com/tosca
Narrow caverns
and small holes
(including the
holes inside the
model) are
removed
SIMULIA
Tosca Structure
Tosca Structure.smooth
9.1.14 Troubleshooting
Unfeasible target relative volume. If this value lies outside of the range of
relative volumes attained at isovalues equal to 0 and 1, an error message
is produced since it is unlikely that such relative volume will be attained at
any isovalue. The error message suggests what values may be used as
the target relative volume.
Models with "jumps" of relative volume. In some cases, the relative volume
depends non-continuously upon the isovalue, and therefore it may happen
that a certain target relative volume cannot be obtained. Typically, it happens when the target volume is larger than the total volume of all nonempty elements of the model, or otherwise in small models. The iterations
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Result Transfer and Validation Run
do not converge and stop when the maximal number of iterations (currently
20) is reached:
Preparations
-- Iteration
-- Iteration
-- Iteration
-- Iteration
-- Iteration
-- Iteration
...
-- Iteration
-- Iteration
rel.
rel.
rel.
rel.
rel.
rel.
volume
volume
volume
volume
volume
volume
=
=
=
=
=
=
1.000
0.040
0.105
0.218
0.260
0.326
www.3ds.com/tosca
In this example, the target volume has been equal to 0.4. Here, one can only
attain relative volumes either between 0.04 and 0.355 or equal to 1.0 (this
happens if the isovalue is below 0.001: the surface of the whole model is produced since all elements have material values above 0.001). Here, the solution might be to set the target volume to 0.355 or lower, or set a fixed isovalue
(e.g. to 0.135 in order to get relative volume equal to 0.326).
SIMULIA
Tosca Structure
Validation Run in Tosca ANSA environment
Structure.smooth is not able to complete the isocut. An error message typically looks like this:
Meshes with inner holes. If the model contains an empty domain that is
completely surrounded by material, the calculated volume will be incorrect
as the volume of this hole will be added to the total volume instead of being
subtracted. Otherwise, this has no effect on Tosca Structure.smooth. It
might be suspected that the inner holes exist if a message "Surface is disconnected; the number of connected components is.." is produced and the
number of connected components is too large. The parameters
RESULT_FILTERING and COMPONENT_LIMITING_SIZE are designed to
solve this problem.
If an error occurs during the generation of an output file, a warning instead of
an error is produced so that the remaining output files could be generated.
Such warnings might help understand why the files cannot be saved
9.2
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Self-intersecting surfaces. Although Tosca Structure.smooth is able to prevent new self-intersections, those that are present in the original model are
likely to remain. Coplanar faces with common inner points also count as
intersecting; thus, a warning of large number of self-intersections happens
e.g. if a wall inside of a solid structure exists and is remeshed differently
from both sides. This wall will also remain inside of the resulting surface. In
Tosca ANSA environment, the self-intersections of a surface might remain
after RECONSTRUCT (in rare cases, RECONSTRUCT creates new self-intersections), that in turn makes SOLID_MESH fail.
SIMULIA
Tosca Structure
Result Transfer and Validation Run
solver using File | Output | <solver name> menu command. However, this model will only contain the geometry information, namely the
smooth isosurface (or model surface) generated by Tosca Structure.smooth
plus the loaded elements copied from the original model. In order to construct
an optimized model suitable for the validation run, following actions are provided by Tosca ANSA environment:
1. BATCH_RECONSTRUCT or MANUAL_RECONSTRUCT: modification of the
surface
2. SOLID_MESH: remeshing of the volume defined by the modified surface
3. VALIDATION_OUTPUT or MODIFICATION_FILES: saving the remeshed
model and the information copied from the original model in solver format.
If needed, FE analysis of the produced model by the selected solver can be
started from within Tosca ANSA environment using VALIDATION_RUN. This
option is available only when the verification model was created using the
VALIDATION_OUTPUT command.
Due to specific aspects of ANSYS models not supported by ANSA, in this
case the generation of validation models using modification files is required.
The validation run can then be started manually in your familiar solver environment (ANSYS workbench). This is also an alternative if the standard way
using VALIDATION_OUTPUT does not work.
www.3ds.com/tosca
9.2.1
SIMULIA
Tosca Structure
Validation Run in Tosca ANSA environment
fied in a way that complies to the conditions. Additionally, the user can freeze
the SPC nodes manually.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Result Transfer and Validation Run
Freeze SPC Nodes: Freezes the nodes with applied single point constraints.
www.3ds.com/tosca
SIMULIA
Tosca Structure
Validation Run in Tosca ANSA environment
Information about other settings can be found in the tool tips of the corresponding fields.
Using Update command on BATCH_RECONSTRUCT item starts the reconstruction of the entire model surface.
If it is needed to modify only a part of the surface, MANUAL_RECONSTRUCT
item should be used. In this case, the command Edit opens Shell Mesh
Parameters dialog; after using Update command, the desired shell elements are to be selected first and then the selection confirmed by clicking the
middle mouse button; then, select or deselect the edges of the feature lines (if
needed) and click the middle mouse button again. Then, the selected region
will be reconstructed and a preview window shown; after confirming the modification, repeat the process with other regions or press Escape key (or click
the middle mouse button once more) if finished.
In order to undo the surface modifications made by BATCH_RECONSTRUCT or
MANUAL_RECONSTRUCT, and, if needed, to repeat it with different settings,
the most simple way is to repeat Tosca Structure.smooth run. To do it, apply
Change command on RUN_SMOOTH item in order to remove the results of
Tosca Structure.smooth and to reload the initial model. Then, run Tosca
Structure.smooth again using Update command.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Fig. 306 Tosca ANSA environment: Target length for edge size
SIMULIA
Tosca Structure
Result Transfer and Validation Run
9.2.2
SOLID_MESH
The remeshing of the solid model defined by its surface is done using the
item SOLID_MESH (Fig. 307).
www.3ds.com/tosca
9.2.3
SIMULIA
Tosca Structure
Validation Run in Tosca ANSA environment
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
the node-related information is only conserved for the nodes that are common to the original model and the surface generated by Tosca Structure.smooth. E.g., since the intermediate nodes of quadratic elements are not
taken into account by Tosca Structure.smooth, any loads assigned to them
are lost. The only exception to this rule is that the new nodes placed between
two SPC nodes by Tosca Structure.smooth get SPC status as well.
For 3D models, Tosca Structure.smooth replaces the solid elements with the
isosurface but leaves the loaded elements unchanged. Therefore, the only
element-related information that remains in the model for validation run is
restricted to the loaded elements. The loaded nodes (but not SPC nodes) are
automatically marked as remaining by Tosca Structure.smooth, so that they
are necessarily present in the isosurface, unless they belong to a small isolated
part
that
gets
removed
(see
the
description
of
COMPONENT_LIMITING_SIZE parameter of Tosca Structure.smooth).
The model for validation run is written in the same solver format as the original model using the item Tosca Structure
Task
|
SMOOTH
|
SMOOTH_INSTANCE | VALIDATE | VALIDATION_OUTPUT (Fig. 308).
Choosing New | VALIDATION_OUTPUT on VALIDATE item opens a file
saving dialog; after the file is chosen, its name is used as the name of the
VALIDATION_OUTPUT item. To change the file name, apply Edit command
on this item. Further solver specific settings may be available. Select Update
to generate the model. For the models with solid elements, it is recommended
to save the model after applying SOLID_MESH, since otherwise only the surface (plus the loaded elements) will be saved.
SIMULIA
Tosca Structure
Result Transfer and Validation Run
does not preserve the information about element properties. Initially, the
default properties have DEFINED = NO as can be seen when applying Edit
command to such property in the window opened via Windows | Properties main menu command. Because of that, these properties are not saved
in the model for validation run, and thus it contains elements with undefined
properties and the solver run fails. A solution to this problem is to set DEFINED = YES manually to the automatically defined property (usually called
PSHELL 1) using the dialog opened by Windows | Properties main
menu command.
Using File | Output command, it is possible to save the model in any
available solver format; however, this method is not recommended since only
the model geometry and the groups are expected to be saved, and, also, the
shell elements should be removed manually if the result of SOLID_MESH
alone is to be saved.
Remark:
For the automatic generation of validation models in Tosca ANSA environment only one material can be supported in the design area.
Modification files
www.3ds.com/tosca
The model for validation run is written in the same solver format as the original model using the item TOSCA Structure Task | SMOOTH |
SMOOTH_INSTANCE | VALIDATE | MODIFICATION_FILES (see Fig. 309).
In the appeared Save dialog, the user must specify the name of the verification model in the optimization neutral .onf format. However after choosing
MODIFICATION_FILES | Update the verification model will be created in the
solver format of the design space model.
SIMULIA
Tosca Structure
Validation Run in Tosca ANSA environment
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
9.2.4
SIMULIA
Tosca Structure
Result Transfer and Validation Run
VALIDATION_RUN item, the solver can be started from command line with
the same consequences.
www.3ds.com/tosca
9.3
SIMULIA
Tosca Structure
Validation Run in Tosca Extension for ANSYS/Workbench
reconstructed and can be loaded with the original forces and supported with
the original boundary conditions.
Mesh generation for validation model:
Optimization result.
Validation result.
The solid mesh is ready to be used and
can be loaded with loads and boundary
conditions again.
Remark:
After a smoothing run and an adjected validation run, there might be some
artifacts contained within the geometry. Once the validation model is opened
in the Mechanical application, it is possible to delete (suppress) any artifacts
easily by hand.
To delete such artifacts simply suppress all undesired parts of the geometry.
Attention: They might be small and not even noticable. They can only be sup2 - 554 User Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Solid model.
The smooth model
gets remeshed to
a tetraeder solid
mesh.
SIMULIA
Tosca Structure
Result Transfer and Validation Run
pressed because they are listed in the Geometry section in the Tree Outline window.
Starting the Validation Run:
As mentioned above, the solid model has to be reloaded within a Mechanical application for further use.
To apply the original loads and boundary conditions to the modified optimization result, there is an automatically copied Static Structural system to
reuse all defined loads and boundary conditions on the new model for a new
calculation. There are different steps and methods to set up the Validation.
1. Click Validation | Run to
start the optimization. The
process takes a few minutes
and is finished as soon as the
new Validation System is
opened.
Common Validation Procedure, reassigning Geometry:
www.3ds.com/tosca
The described procedure below works on condition that you dont want to
change the mesh of the Validation Model (e. g. not adding Mesh Controls
like Sizing, or using Virtual Topology to adjust the geometry) or if you
want to change the geometry or the mesh, and no errors occur during
remeshing. Otherwise, see "Remark 1 - Changing the Mesh is not possible".
SIMULIA
Tosca Structure
Validation Run in Tosca Extension for ANSYS/Workbench
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Result Transfer and Validation Run
www.3ds.com/tosca
SIMULIA
Tosca Structure
Validation Run in Tosca Extension for ANSYS/Workbench
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Result Transfer and Validation Run
If you want to split one face into several small faces or add an edge or vertex
at a specific location, you have to use Virtual Topology. The following
steps will give you a short introduction.
www.3ds.com/tosca
SIMULIA
Tosca Structure
Validation Run in Tosca Extension for ANSYS/Workbench
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Result Transfer and Validation Run
www.3ds.com/tosca
9.4
SIMULIA
Tosca Structure
Result Transfer
9.5
Result Transfer
If requested, Tosca Structure.smooth outputs the generated (iso)surface in a
format suitable for the result transfer. See vol.2 chapter 9.1.1 or vol.2 chapter
9.1.2 for details about how Tosca Structure.smooth can be started from Tosca
ANSA environment or Tosca Structure.gui.
Tosca Structure.smooth enables the output of the (iso)surface in IGES and
STL formats as well as the output of slices in IGES or CLI format. See vol.2
chapter 9.1.9 and, specifically, Table 34 for the detailed description.
9.5.2
Result transfer to NX
The results of the shape optimization can be transferred to the CAD model in
such a way that the results are used to deform/modify the geometry of the
CAD based component. All modifications added by the optimization system
will be applied. To obtain the modification file, a specific USERFILE definition
has to be activated in your parameter file. In your installation directory the
macro uf_shape_nx_deform.mac already contains the necessary output
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
9.5.1
SIMULIA
Tosca Structure
Result Transfer and Validation Run
www.3ds.com/tosca
request (see also chapter 10.5.4.2 Modification file for CATIA RSO module).
In NX the function "global deformation/Point from File" can be used for further
processing.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Result Transfer
SIMULIA
Tosca Structure
Postprocessing of Optimization Results
10 Postprocessing of Optimization
Results
Postprocessing of Tosca Structure optimization results consists mainly of
visualizing the model changes in the optimization process and regarding plots
and tables of optimization relevant values. These data can be combined and
provided using Tosca Structure.report. Visualization and processing is done
using Tosca Structure.view.
Certainly, the analysis results of the single optimization steps can be evaluated in your familiar FE-postprocessing system by reading the corresponding
solver result file from the SAVE.<ext> directory. Further, the results of your
validation run can also be processed in your postprocessing environment.
www.3ds.com/tosca
SIMULIA
Tosca Structure
Generation of Postprocessing Data
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Postprocessing of Optimization Results
CONTOUR_PLOT parameters
ALL | LAST
TYPE_PROP
ERTY
ELEMENT
FILL FILTER
NODAL CONTINUOUS
(SHAPE)
NODAL DISPLACEMENT(SHAPE
)
NODAL CONTINUOUS
(BEAD)
Bead optimization results (model with optimization displacements), plus the controller input values as fringe plot
NODAL DISPLACEMENT
(BEAD)
Bead optimization results (model with optimization displacements), plus the optimization displacements as fringe plot
MODEL
MODEL AND
SETS
<value>
www.3ds.com/tosca
ITERATION
FILTER
MIN (MAX)
SIMULIA
Tosca Structure
Generation of Postprocessing Data
CONTOUR_PLOT parameters
FRINGE
MIN (MAX)
Table 37
<value>
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
TOSCA_POST/GENERATE_REPORT_FILE.vtfx.
SIMULIA
Tosca Structure
Postprocessing of Optimization Results
In the field Jobname select the parameter file of the optimization job for which
the postprocessing report is to be generated. The Directory of the job is
shown for control reasons and is filled in automatically. The Output Name is
set automatically to <jobname>_report, but can be changed by the user.
Group selection allows to write the whole report restricted to one group chosen in the Select Group drop down dialogue. With this option you can
reduce the file size significantly and also focus the attention directly to special
preselected regions of interest.
The flag Original Model defines if the start model including groups is
added to the report. Additional parameters can be used to add command line
parameters manually and are mostly used for debug reasons.
When selecting your parameter file, all optimization results available for this
job appear in the result selection table. Per default, all results will be added to
the report and can be visualized as 3D animation sequences. To decrease
the report file size, several results can be excluded from the report generation.
www.3ds.com/tosca
SIMULIA
Tosca Structure
Generation of Postprocessing Data
Result Name
File
Controller
Input
TP
Material Distribution
(normalized)
TP
Optimization
Displacements
SHAPE
Controller
Input
SHAPE
Controller input values from shape optimization shown as fringe plot on corresponding case
Opt. Displacement
Values
SHAPE
Optimization
Displacements
BEAD
Controller
Input
BEAD
Controller input values from bead optimization shown as fringe plot on corresponding
case
Opt. Displacement
Values
BEAD
Table 38
Specific settings are available for some of the results to control colouring and
filtering.
Tosca Structure.report: Result Selection Parameters
ITER
ALL | LAST
|<nr>
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Postprocessing of Optimization Results
<value>
FRINGE
MIN (MAX)
<value>
ADD UNDEFORMED
MODEL
Table 39
Adds undeformed model (in blue) to all displacement views in the vtfx file.
www.3ds.com/tosca
SIMULIA
Tosca Structure
Generation of Postprocessing Data
All optimization and smooth results are provided within the Mechanical application.
Fig. 317 Use the Graph window to either create an iteration animation of
the optimization run or visualize single iteration steps
Tosca Structure.view can also be used since a vtfx-file is generated automatically during the optimization run. It is saved in the tosca-folder of the work
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Postprocessing of Optimization Results
directory. Find it using the right mouse button on solution and select Open
Solver Files Directory, then go to the folder tosca\TOSCA_POST.
Fig. 318 Use the right mouse button to find the files directory
Input
--input_file
Option
parfilename
www.3ds.com/tosca
--logstderr
Comment
parameter file name (with or without .par extension)
log to stderr instead of stdout
--loglevel
QUIET
CRITICAL
ERROR
WARNING
NOTICE
INFO
DEBUG
TRACE
DEVELOP
loglevel
--job
<string>
--add_user
_data
<string>
--version
SIMULIA
Tosca Structure
Generation of Postprocessing Data
Input
Option
--help
Comment
Displays usage information and exits.
REPORT
ID_NAME
= __JOBNAME___report
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
CONTOURPLOT
SIMULIA
Tosca Structure
Postprocessing of Optimization Results
RESULT
MODEL
OUTPUT_FILE
CONTOURPLOT
=
=
=
=
"SAVE.onf/TP"
"SAVE.onf/MODEL_fem.onf"
__JOBNAME___report
TOPO_MAT
END_
A smoothed model can be added to the report automatically. Isovalue or target volume can be set in the OPTIONS command in the parameter file.
CONTOURPLOT
ID_NAME
TYPE_PROPERTY
TITLE
DESCRIPTION
=
=
=
=
FRINGE_RESULT
DISP_RESULT
ITERATION
GROUP_FILE
=
=
=
=
SHAPE_CTRL
NODAL_CONTINUOUS
"Controller Input on deformed model"
"TOSCA Structure.shape
Optimization Result"
CTRL_INPUT(OPT.)eqv.
DISP_OPT
ALL
"SAVE.onf/GROUPS.onf"
www.3ds.com/tosca
END_
SIMULIA
Tosca Structure
Generation of Postprocessing Data
REPORT
ID_NAME
RESULT
MODEL
OUTPUT_FILE
CONTOURPLOT
CONTOURPLOT
=
=
=
=
=
=
__JOBNAME___report
"SAVE.onf/SHAPE"
"SAVE.onf/MODEL_fem.onf"
__JOBNAME___report
SHAPE_CTRL
SHAPE_DISP
END_
=
=
=
=
=
=
=
UF_SHAPE_NORM_DISP
ONF
ALL_ELEMENTS
SHAPE_NORM_DISP
SHAPE_NORMAL_DISP
EVER
VAR2
For generating the plots within a TEST_SHAPE run, the dispalcements of the
next iteration mus be requested and the test_shape FORMAT must be set to
user defined post processing output.
= UF_SHAPE_NORM_DISP
= SHAPE_NORM_DISP_N
TEST_SHAPE
OPTIMIZE = OPTIMIZE_SHAPE_CONTROLLER
DIRECTION = GROW
DISPLACEMENT = 10
INCREMENT = 5
USER_FILE
= UF_SHAPE_NORM_DISP
FORMAT
= USER_FILE
END_
Both commandos create a bunch of onf files in the SAVE.onf directory. Now,
TOSCA_GUI can be used to generate vtfx plots.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
USER_FILE
ID_NAME
! [...]
TYPE
END_
SIMULIA
Tosca Structure
Postprocessing of Optimization Results
=
=
=
=
=
__JOBNAME___report
"SAVE.onf/BEAD"
"SAVE.onf/MODEL_fem.onf"
__JOBNAME___report
BEAD_DISP
END_
www.3ds.com/tosca
=
=
=
=
=
=
=
GENERATE_REPORT_FILE
"SAVE.onf\MODEL_fem.onf"
"SAVE.onf\SIZING"
"TOSCA_POST\GENERATE_REPORT_FILE"
SIZING_THICKNESS
SIZING_DELTA_THICKNESS
MODEL
END_
SIMULIA
Tosca Structure
Generation of Postprocessing Data
CONTOURPLOT
ID_NAME
TYPE_PROPERTY
TITLE
DESCRIPTION
=
=
=
=
SIZING_THICKNESS
ELEMENT_THICKNESS
Thickness from Sizing Optimization
TOSCA Structure.sizing
Optimization Result
FRINGE_RESULT = THICKNESS
ITERATION
= ALL
GROUP_FILE
= "SAVE.onf\GROUPS.onf"
END_
CONTOURPLOT
ID_NAME
TYPE_PROPERTY
TITLE
DESCRIPTION
Result
FRINGE_RESULT
ITERATION
GROUP_FILE
=
=
=
=
SIZING_DELTA_THICKNESS
ELEMENT_DELTA_THICKNESS
Thickness Change from Sizing Optimization
TOSCA Structure.sizing Optimization
= DELTA_THICKNESS
= ALL
= "SAVE.onf/GROUPS.onf"
END_
CONTOURPLOT
ID_NAME
TYPE_PROPERTY
TITLE
DESCRIPTION
= SHAPE_CTRL_XXX
= NODAL_CONTINUOUS
= "Controller Input on deformed model"
= "TOSCA Structure.shape Morphing Result.
..."
FRINGE_RESULT = CTRL_INPUT(OPT.)eqv.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
CONTOURPLOT
ID_NAME
TYPE_PROPERTY
TITLE
DESCRIPTION
SIMULIA
Tosca Structure
Postprocessing of Optimization Results
DISP_RESULT
ITERATION
GROUP_FILE
GROUP
END_
REPORT
ID_NAME
RESULT
MODEL
CONTOURPLOT
CONTOURPLOT
END_
= DISP_OPT
= ALL
= "SAVE.onf/GROUPS.onf"
= __GROUP_NAME__
= JOBNAME_report_XXX
= "SAVE.onf/TOSCA_MORPH"
= "SAVE.onf/MODEL_fem.onf"
= SHAPE_CTRL_XXX
= SHAPE_DISP_XXX
Remark:
1. The USER_FILE command writing the sensitivity data to ONF format must
be in the original parameter file, because Tosca Structure.control must
know all OBJ_FUNCs and CONSTRAINTs.
For generating the ONF Data with the sensitivities inside the following statement has to be placed in the parameter file:
www.3ds.com/tosca
Bead optimization
The sensitivities are written to an ONF file with the following command:
USER_FILE
ID_NAME = UF_BEAD_ONF_SENS
FORMAT = ONF
EL_GROUP = ALL_ELEMENTS
TYPE = BEAD_DATA_SENS
FILE_NAME = BEAD_SENS
WRITE = EVER
FILE_OPTION = VAR2
END_
SIMULIA
Tosca Structure
Tosca Structure.view
INCLUDE, UF_BEAD_SENS_ONF.MAC
Topology optimization
The sensitivities can be written in original form:
USER_FILE
ID_NAME = UF_TOPO_ONF_SENS
FORMAT = ONF
EL_GROUP = ALL_ELEMENTS
TYPE = TOPO_WITH_SENS
FILE_NAME = TP_SENS
WRITE = EVER
FILE_OPTION = VAR2
END_
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Postprocessing of Optimization Results
clicked. In Tosca ANSA environment, the viewer opens with the item
VTF_VISUALIZATION | View (see Fig. 320).
www.3ds.com/tosca
SIMULIA
Tosca Structure
Tosca Structure.view
Vtfx files generated by Tosca Structure.report usually contain several optimization steps and result cases. Initially, the first step and case is displayed
(see Fig. 321).
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Postprocessing of Optimization Results
Model navigation
In the main window in the middle you see the model (or result graph) of your
active case. To rotate or move the model you have to press Ctrl and use your
mouse as follows:
To rotate the model in space, move the mouse
while holding Ctrl + right mouse button.
To translate the model, move the mouse while
holding Ctrl + middle mouse button.
To rotate the model in plane, move the mouse
while holding Ctrl + left mouse button.
Use the mouse wheel to zoom in or out. Pressing F key scales the model to fit
in the current view.
Case Panel
On the case panel you can select another case by double click on it or you
pull by pressing left mouse button the other case in the main window. You can
select for example the origin model or, if you are in shape optimization you
can watch the displacements. But you can also select different graphs, for
example the convergence of the constraint. If you want to superpose two
cases press additionally Alt-key when pulling second case in the main window. More information about the case are shown in the lower part of panel.
Toolbar functions
Several useful items of the menu are created as buttons, which are arranged
in the button panel:
www.3ds.com/tosca
Open file.
Capture active view, QuickCapture active view
(with previous settings) and Capture all view
cases to Tosca Structure Report Builder(see
chapter 10.4 Tosca Structure Report Builder).
Show or hide Info Box, Text and Legend. (See
also View menu).
Reset view: Restores the default view.
SIMULIA
Tosca Structure
Tosca Structure.view
You can add or remove the case panel, the selection panel, the settings panel and the result
panel.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Postprocessing of Optimization Results
Selection Panel
The selection button on the toolbar enables the selection of parts
(such as the original and the new
surface in VTFX files generated
by Tosca Structure.smooth), elements or nodes by clicking them
with the mouse. The selected
object is shown in details in
Selection Panel activated by
a toolbar button
Settings Panel
www.3ds.com/tosca
The button Settings Panel displays the panel containing the list of parts
and groups (denoted "Element Sets"; the node groups are also shown via
artificial element sets). It allows to set visibility and drawing modes of parts
and element sets (see also chapter 10.2.3 Model and group visualization).
SIMULIA
Tosca Structure
Tosca Structure.view
Result Panel
In order to change the settings of
the fringe plot, display Results
Panel using a button on the
toolbar or Panels | Results
Panel main menu command. In
this window, the coloring scheme
can be changed in Legend
Settings panel; the values corresponding to the colors can be
changed by deselecting Automatic range settings
check box and entering the values in Minimum and Maximum
text fields or using the arrows
below.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
The information about remaining toolbar buttons appears in the help window
shown by Help | Help Contents command or when F1 key is pressed.
SIMULIA
Tosca Structure
Postprocessing of Optimization Results
Viewport settings
Tosca Structure.view allows to save the actual viewport and to reload existing
user defined viewports.
Right click in the view window
and choose View From |
User Defined | Save. A file
dialogue opens which allows the
saving of the actual viewport in a
.vcx file. This feature can also be
accessed using the menu View
| View From | User Defined | Save.
An existing viewport is loaded in
the same manner (right click in
the view window and choose
View From | User Defined
| Open...). All viewports
(.vcx files) saved in the same
folder as the vtfx file are directly
available in the submenu.
www.3ds.com/tosca
SIMULIA
Tosca Structure
Tosca Structure.view
Preferences
With View | Preferences general settings for Tosca Structure.view can be
saved. These include setting the plot line width.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Postprocessing of Optimization Results
for example, Part 1 is visible, but the draw style can only be changed for Part
2, because Part 1 is not selected.
Fig. 324 Change the draw style of parts in Settings Panel of Tosca
Structure.view
www.3ds.com/tosca
The part named Node Part refers to all nodes of the model represented by
little squares; it is only visible if Draw as filled surface or Draw as
points radio buttons are chosen in Draw Style. If you miss the Draw
Style panel right click in the field Table of Parts and activate As context menu.
Using the tab Element Sets, it
is possible to restrict the displayed objects to some element
or node groups. Note that the
parts that are hidden in Parts
tab are not shown regardless of
chosen groups in Element
Sets tab; therefore, in order to
visualize a node group, you need
to turn on Node Part in Parts
tab as shown above (it is turned
off by default).
In order to visualize a certain group alone, first make sure that all parts are
turned on in Parts tab, then click Show visible radio button in Element
Sets tab and check the group you wish to show. Show invisible displays
SIMULIA
Tosca Structure
Tosca Structure.view
all groups except the chosen ones. In the example below, the design area of
shape optimization (a node group MY_DESIGN_GROUP) is shown:
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Postprocessing of Optimization Results
Parts tab is active for Part 1, the location of selected nodes is clearly
seen:
www.3ds.com/tosca
SIMULIA
Tosca Structure
Tosca Structure.view
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
ronment, it is the value of FILTER MIN field of CONTOUR_PLOT PARAMETERS dialog. See chapter 10.1 Generation of Postprocessing Data for details
about this parameter.
The following figure shows the first and the last iterations of a topology optimization:
SIMULIA
Tosca Structure
Postprocessing of Optimization Results
Fig. 328 Optimized geometry (colored) with original surface (blue) and the
fringe plot of controller input for shape optimization results
www.3ds.com/tosca
SIMULIA
Tosca Structure
Tosca Structure.view
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
The way to preset the minimal and maximal values for the fringe plot is to set
the values FRINGE MIN and FRINGE MAX in CONTOUR PLOT PARAMETERS
dialog of Tosca ANSA environment (see chapter 10.1 Generation of Postprocessing Data for the parameter names in Tosca Structure.gui). This way is
preferable in order not to need to modify the settings each time the VTFX file
is opened, e.g., when the file is imported in Microsoft PowerPoint presentation or a web page. Note that the viewer is not able to modify the files, so that
the settings are not saved in VTFX files.
SIMULIA
Tosca Structure
Postprocessing of Optimization Results
www.3ds.com/tosca
Fig. 329 Optimized geometry with the fringe plot of optimization displacements
See the previous section about the possibilities to control the appearance of
the fringe plot.
SIMULIA
Tosca Structure
Tosca Structure.view
See also chapter 10.1 Generation of Postprocessing Data for more details on
Tosca Structure.report, including the description of VTFX file generation from
Tosca Structure.gui.
The plug-in is not included in the Tosca Structure installation package and
must be installed separately on each computer. It is realized as an ActiveX
component that can be embedded in a Microsoft PowerPoint presentation,
Microsoft Word document or html file. The plug-in loads a VTFX file generated by Tosca Structure and provides means for user interaction with the
sequence of models saved in the file.
The plug-in is compatible with the following software:
Microsoft Windows XP / Vista / 7
Microsoft Office 2007 and above
(for Office 2010 only 32bit versions are supported!)
Internet Explorer, Firefox or Chrome
For the operation of the plug-in, a graphic card that supports OpenGL (including actual driver software) is required.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Postprocessing of Optimization Results
The plug-in can be downloaded directly from the home page of FE-DESIGN
GmbH (http://www.fe-design.de) or Ceetron (http://www.ceetron.com).
Fig. 330 Tab GLview 3D Plugin with the buttons Insert and Load
VTFx
www.3ds.com/tosca
SIMULIA
Tosca Structure
Tosca Structure.view
The VTFX file is loaded when the slide of the presentation is shown for the
first time. After that, returning to the slide from another one or even the restart
of the presentation (but not of Microsoft PowerPoint) does not cause the file
to be reloaded.
Remark:
If the Tab for Plugin inserton (GLvie 3D Plugin) does not appear in your Office
version, please check chapter 10.4.3 Add-Ins for Tosca Structure Report
Builder concerning the installation.
Using a simple VBA script, the user gains full control of the loading of a VTFX
file in the plug-in. As an example, a button in the presentation can be created
such that a certain file is loaded when the button is pressed. This behavior is
needed if the loading time of a VTFX file is large so that the user might wish
to skip it, or if different files are to be shown in the same plug-in (e.g., by clicking a button that corresponds to each file).
In order to create a button that opens a VTFX file, first insert the plug-in as
described in actions 1-3 above. Then, continue as follows:
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Postprocessing of Optimization Results
1. To add a button, select Command Button from the Control Toolbox in the
Developer tab, and drag a button into the slide. :
2. Double click the button (or right click and select "View Code") to edit its
<button name>_Click method in Microsoft Visual Basic editor (the
code which handles the click of the button).
3. Add a codeline that calls the Open() method of the plug-in as follows
(replace the argument test.vtfx with your VTFX file name):
Private Sub CommandButton1_Click()
GLview3DPlugIn1.Open ("test.vtfx")
End Sub
www.3ds.com/tosca
Remark:
Please note that advanced usage of the plug-in using VBA scripts requires
the use of Macros for this reason, PowerPoint presentations have to be
saved as PowerPoint Macro-Enabled presentation (*.pptm) files!
SIMULIA
Tosca Structure
Postprocessing with Tosca Extension for ANSYS/Workbench
<object
id="GLview3DPlugIn"
classid="clsid:D37577A1-960C-11D5-A482-006094EB12E8"
codebase="http://ceetron.com/plugins/
GLv3DPlugIn.cab#version=7,3,0"
type="application/x-oleobject"
width="900"
height="600" >
<param name="FileURL" value="model.vtfx">
<param name="TOOLBAR" value="ON">
<param name="SWRENDERING" value="OFF">
</object>
The plug-in is identified by classid. If the plug-in is not found locally on the
computer, it is loaded from the link given by codebase parameter. In this
manner, internet pages with embedded VTFX files can be made available for
interested external persons.
leads to
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Postprocessing of Optimization Results
www.3ds.com/tosca
SIMULIA
Tosca Structure
Postprocessing with Tosca Extension for ANSYS/Workbench
Besides the total nodal displacement, the directional nodal displacement can
be visualized as well. Right click on Solution in the Tree Outline and
then Insert | Deformation | Directional if you wish to visualize the
directional results.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Postprocessing of Optimization Results
10.4
www.3ds.com/tosca
To find the working directory easily, right click on the Solution item within
the Tree Outline and select Open Solver Files Directory.
There you find solution data files, the tosca.par-file, a vtfx-file for visualization
with Tosca Structure.view and much more information.
SIMULIA
Tosca Structure
Tosca Structure Report Builder
Fig. 333 Capture active view (left), quick capture or capture all viewcases
(right)
Animation sequences can be captured either as image, i.e. a screenshot of
the actual view, or as 3D model which can be included into the report using a
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
The capturing is done for either single (active) views or all available views,
thereby maintaining all actual settings (visualization settings, viewport,...)
SIMULIA
Tosca Structure
Postprocessing of Optimization Results
www.3ds.com/tosca
SIMULIA
Tosca Structure
Tosca Structure Report Builder
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Postprocessing of Optimization Results
A template defining layout, distances between the several objects and other
general settings has to be chosen. Further, select the repository file for the
report generation and choose an output file. With the Tosca Structure installation, some standard templates are provided which can be found in the subdirectory report/templates of the installation directory.
www.3ds.com/tosca
SIMULIA
Tosca Structure
Tosca Structure Report Builder
To allow the features of the GLview Report Builder Add-in for MS Word to
work and to avoid security messages by MS Word, please make sure that the
location where ReportBuilder.dotm was installed is added to MS Word
Trusted Locations.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Postprocessing of Optimization Results
This is done by accessing Word Options Trust Center Trust Center Settings Trusted Locations. When finished, your settings should look similar to
this:
www.3ds.com/tosca
Installation path
The macro ReportBuilder.ppam file is located in the same folder as the executable file for GLview Report Builder (tosca_install_dir\bin\<os_platform>).
Registry settings
The add-in for MS PowerPoint (ReportBuilder.ppam) must be registered by
adding entries to the AddIns folder of the registry settings of Office.
A new key named GLview Report Builder PowerPoint Add-in must be added
to the AddIns folder, and two new entries have to be added to this new key
(one for autoload, and one containing the path to the ReportBuilder.ppam).
Note that the internal version numbers for MS Office versions are as follows:
Office 2003: "11.0"
Office 2007: "12.0"
SIMULIA
Tosca Structure
Tosca Structure Report Builder
10.4.3.3 Templates
Standard templates for report generation are provided with your Tosca Structure installation and can be found in the subdirectory report of the Tosca
Structure installation directory. Creation of user specific templates is no Tosca
Structure feature and is documented in the report generator documentation
which can be accessed directly in the report builder.
2 - 610 User Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
When finished, your new registry entries should look similar to this:
SIMULIA
Tosca Structure
Postprocessing of Optimization Results
fixed value
www.3ds.com/tosca
The access to the database (i.e., to the analysis or optimization results) can
be precisely specified by:
Type of contents.
Definition of the selection area:
any node or element group.
Type of selection within the selection group:
minimum (MIN), average (AVERAGE) or maximum (MAX) value, sum
(SUM) or number of entries (COUNT) within the group.
Selection of the load case and type of the load case selection.
Besides direct database access, numerical variables can also be defined with
mathematical operators (DEF_TYPE = OPER) (ITEM VAR_OPER = ADD,
SUB, MULT, DIV, MIN, MAX, ABS or COMBINE) using 2 to 4 numerical variables (or up to 10 variables for COMBINE). Furthermore, the change for a
SIMULIA
Tosca Structure
Toolbox for Postprocessing
Allowed values for the logical variables are TRUE, FALSE and UNSET. The
value is determined by the comparison of two numerical variables
(DEF_TYPE = BASE) or by combining several logical variables (DEF_TYPE
= BOOLEAN).
The permitted operators for two numerical variables are: GE (= greater or
equal than), LE, GT, LT and EQ. The comparison of the two numerical variables, Var1 > Var2, sets the status TRUE, FALSE or UNSET depending on
whether Var1 > Var2, Var1 < Var2 or one of the variables is not defined. The
status can also be determined with an AND or OR condition using 1 to 4 logical variables. In this way very simple as well as very complex logical variables
can be constructed.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Postprocessing of Optimization Results
Examples
(Var1 Var2)
Var1
= AND
Var2
= OR
True
True
True
True
True
False
False
True
False
False
False
False
True
Unset
Unset
True
False
Unset
Unset
False
Unset
Unset
Unset
Unset
Table 40
In Table 40, the result of combination of two logical variables Var1 and Var2
using AND or OR operation is listed for all possible values of Var1 and Var2.
The logical variables are used in Tosca Structure, for example, for the definition of the stop conditions. It is also possible to control the dynamic model
modification (in OPT_PARAM) with logical variables.
Logical variables are defined with the LOGICAL command.
If one of the logical variables is UNSET, the second variable in AND operation
is ignored (see Table 40).
www.3ds.com/tosca
= stop_name
= logical_name
= opt_grp_name
END_
The stop condition ends the optimization for the selected optimization group
when the value for the assigned logical variable is TRUE. If several STOP
conditions have been defined for an optimization group, the optimization for
SIMULIA
Tosca Structure
Toolbox for Postprocessing
this group is ended when one of the stop conditions is fulfilled (corresponds to
a logical OR condition).
The logical variable can vary significantly. Before using the STOP command,
numerical and logical variables must be defined with the VARIABLE and
LOGICAL commands.
The flexibility is achieved by using various logical variables as the stop criteria. Logical operations AND or OR can also be included in the STOP command by defining the logical variables.
For shape optimization, typical stop conditions can be defined more directly
by an enhanced stop command:
STOP
ID_NAME
MOD_NDGR
MOD_TYPE
MOD_OPER
MOD_REF
OPTIMIZE
END_
=
=
=
=
=
=
stop_command
all_nodes
MAX, CTRL_INP_SHAPE
LE
0.01, MULT, FIRST
run
In this case, the optimization task "run" should stop when the maximum
equivalent stress (CTRL_INP_SHAPE) of the node group all_nodes is
smaller than 1% of the maximum equivalent stress of the first iteration.
Using this enhanced stop command, the extraction of variables and their logical comparison is performed internally by Tosca Structure and need no longer be specified manually by the user. For a detailed description of the
several items, refer to the commands manual.
If desired, the global upper limit for the maximum number of iterations can be
set with a separate, brief command. In this case, a definition of logical variables is not required.
STOP
ID_NAME
ITER_MAX
= STOP_CONDITION
= <value>
A global stop condition is integrated in the system to limit the maximum number of iterations for safety reasons. This stop condition is always active. The
default value for the maximum number of iterations is set to 40. As an example, the command
STOP
ID_NAME
ITER_MAX
= STOP_CONDITION
= 55
END_
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
END_
SIMULIA
Tosca Structure
Postprocessing of Optimization Results
Remarks
1. When the optimization is halted due to a stop condition, it is possible that
the desired results are not achieved. This is especially true for topological
optimization when stipulating the global tensile stiffness.
www.3ds.com/tosca
SIMULIA
Tosca Structure
Toolbox for Postprocessing
ID_NAME
FILE_NAME
FORMAT
ND_GROUP
TYPE
WRITE
=
=
=
=
=
=
my_user_file
ground.info
ASCII
nd_ground
NODE_MOVE_PATH
EVER
END_
Remarks
1. Experience has shown that certain user-defined command sequences are
often used to generate result files. Therefore, it is recommended that the
user collects these commands in a macro and saves this macro in a directory. These macros can then be loaded with the command INCLUDE
during the optimization preprocessing.
USER_FILE
ID_NAME
FILE_NAME
FILE_OPTION
FORMAT
WRITE
TYPE
SEPARATOR
DATA_TAB
DATA_TAB
DATA_TAB
END_
=
=
=
=
=
=
=
=
=
=
tab1
my_table
ADD
ASCII
EVER
TABULAR
COMMA
ITER
DRESP_MAX_MISES
...
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
DRESP
... (several DRESP definitions, e.g. DRESP_MAX_MISES)
VARIABLE
... (several variable definitions for later reference)
SIMULIA
Tosca Structure
Postprocessing of Optimization Results
=
=
=
=
=
=
=
=
UF_RSO
RSO_OUTPUT.TXT
VAR
ASCII
TITLE_1
all_nodes
CATIA_RSO
EVER
TAB
END_
www.3ds.com/tosca
USER_FILE
ID_NAME
FORMAT
ND_GROUP
TYPE
FILE_NAME
FILE_OPTION
WRITE
SEPARATOR
=
=
=
=
=
=
=
=
NX_DEFORM_ORG
ASCII
ALL_NODES
NX_DEFORM_ORG
NX_DEFORM_ORGINAL.DAT
FIX
NOW
COMMA
=
=
=
=
=
=
=
=
NX_DEFORM_MOD
ASCII
ALL_NODES
NX_DEFORM_MOD
NX_DEFORM_MODIFIED_MESH.DAT
VAR
EVER
COMMA
END_
USER_FILE
ID_NAME
FORMAT
ND_GROUP
TYPE
FILE_NAME
FILE_OPTION
WRITE
SEPARATOR
SIMULIA
Tosca Structure
Toolbox for Postprocessing
END_
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Solver Specific Features
This chapter describes the formats and functionalities of the different solvers
supported by Tosca Structure.
The topological and physical properties of the analysis model (finite element
input deck) are required for the optimization of an FE model. Normally, not all
information contained in the analysis model is necessary for an optimization.
The optimization module returns the modified model data to the FE solver.
The node coordinates are changed during shape and bead optimization. New
materials and element properties are generated during topology optimization
and the assignments of the elements to the material definitions and material
properties are changed. Therefore, there are very few restrictions to the FE
modeling (finite element input deck).
The FE input file (finite element input deck) is processed in two ways during
the optimization procedure. Initially, the optimization preprocessing step
reads the FE input file and all necessary information is written into the optimization database. Afterwards, in each optimization iteration only the properties
changing during the optimization will be modified in of FE input file.
The flow diagram shown in Fig. 338 is identical for all FE solvers. The optimization preprocessor TOSCA_PREP executes the program fem2onf. This program converts the FE-input-deck into a neutral file format (ONF). The
essential information regarding the FE-model is written in the neutral file. The
first file called <jobname>_req.onf contains the result requests. These are the
FE-results needed for the optimization module. The second file contains FEmodel (<jobname>_fem.onf) information, i.e. grid points, elements and etc.
The last file contains the group definitions (<jobname>_grp.onf).
The optimization iterations begin when the preprocessor is finished. No previous optimization iterations exist for the first optimization iteration. However,
fem_modif modifies the FE-input deck(s) (model1.<input>, model2.<input>,
...) which ensures that requested results are present after FE-analysis.
The chosen FE solver calculates the requested results (model1.<output>, ...).
The specific results required for the optimization are read by res2vtm and the
results are stored in the database (tosca_memory). Using these results the
optimizer TOSCA_OPT generates a modification file (<jobname>_mod.onf).
Afterwards, fem_modif once again modifies the original FE-input deck using
the modification file. The standard configuration ensures that the FE-input
decks will be stored for each optimization iteration in the directory
SAVE.<input>. The directory SAVE.<input> also contains the original input
www.3ds.com/tosca
SIMULIA
Tosca Structure
deck having the name model_org.<input>. The first and last FE results files
are stored in the directory SAVE.<output>.
TOSCA_PREP
fem2onf
model_req.onf
model_fem.onf
model_grp.onf
FEM_MODIF
SAVE<input>
model1.<input>,
model2.<input>,...
SOLVER
model1_<iter>.<input>
model2_<iter>.<input>
...
SAVE<output>
model1.<output>,
model2.<output>,...
RES2VTM
model1_<iter>.<output>
model2_<iter>.<output>
...
tosca_memory.idx
tosca_memory.vtm
model_mod.onf
Fig. 338 Detailed flow diagram for Tosca Structure. "input" and "output" is
the FE input deck extension and result output extension, respectively. The extension names correspond to the extensions given
by the FE solver. See supported file formats and extensions in
Table 41.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
TOSCA_OPT
SIMULIA
Tosca Structure
Solver Specific Features
Tosca Structure
supported input
Solver type
Abaqus
*.inp
Tosca Structure
supported output
*.fil or *.sim (see below)
*.odb
ANSYS
*.cdb
*.rst
*.dat
*.inp
Marc
*.dat
*.t16
MSC Nastran
*.bdf
*.op2
(*.dat)
PERMAS
*.uci
*.post
*.dat
Table 41
Tosca Structure supported file formats for the different solvers. See also flow diagram Fig. 338
Some Features in Tosca Structure are not available for all solver interfaces.
Sensitivity based
Optimizations
with contact
Frequency
Response
Optimizations
Use of internal
Forces
Abaqus
ANSYS
Marc
MSC Nastran
PERMAS
Table 42
www.3ds.com/tosca
Solver
SIMULIA
Tosca Structure
Abaqus
11.1 Abaqus
Solver type
Abaqus
Tosca Structure
supported input
.inp
Tosca Structure
supported output
.fil or .sim (see below)
.odb
Table 43
All FE input models (.inp) and FE results (.odb, .fil or .sim) are moved into
their corresponding SAVE directory, see flow diagram Fig. 338.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Solver Specific Features
ten. To achieve this, the following parameter must be set in the configuration
file abaqus_v6.env:
cae_no_parts_input_file=ON
Alternatively, the format my be switched during a Abaqus/CAE session:
MDB.MODELS[MODELNAME].SETVALUES(NOPARTSINPUTFILE=ON)
www.3ds.com/tosca
CONFIG
$fe_modif_add_call = "$fe_modif_add_call -format_matrices
sim";
$res2vtm_add_call = "$res2vtm_add_call -format_matrices
sim";
END_
If Abaqus versions older than 6.14-1 should be used, the additional command
line options --format_matrices sim should be removed from the settings
fem_modif_add_call and res2vtm_add_call.
Remarks:
1. The SIM-file can not be used for Tosca Structure 8.1.0 when using Abaqus
versions older than 6.14-1.
2. It is recommended to use the SIM-file due to significant lower CPU-time for
sizing optimization and for sensitivity based shape and bead optimization.
SIMULIA
Tosca Structure
Abaqus
PLANE_QUAD_4
Abaqus-element
type
CAX4
CAX4H
CAX4HT
CAX4I
CAX4IH
CAX4R
CAX4RH
CAX4RHT
CAX4RT
CAX4T
Design element
(see below)
C, S, F
C, S
C, S
C, S
C, S
C, S, F
C, S
C, S
C, S
C, S
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Tosca Structure-element
type
SIMULIA
Tosca Structure
Solver Specific Features
www.3ds.com/tosca
Tosca Structure-element
type
Abaqus-element
type
Design element
(see below)
PLANE_QUAD_4
CGAX4
CGAX4H
CGAX4HT
CGAX4R
CGAX4RH
CGAX4RHT
CGAX4RT
CGAX4T
C, S
C, S
C, S
C, S
C, S
C, S
C, S
C, S
PLANE_QUAD_4
CPE4
CPE4H
CPE4HT
CPE4I
CPE4IH
CPE4R
CPE4RH
CPE4RHT
CPE4RT
CPE4T
C, S, F
C, S
C, S
C, S
C, S
C, S, F
C, S
C, S
C, S
C, S
PLANE_QUAD_4
CPEG4
CPEG4H
CPEG4HT
CPEG4I
CPEG4IH
CPEG4R
CPEG4RH
CPEG4RHT
CPEG4RT
CPEG4T
C, S
C, S
C, S
C, S
C, S
C, S
C, S
C, S
C, S
C, S
PLANE_QUAD_4
CPS4
CPS4I
CPS4R
CPS4RT
CPS4T
C, S, F
C, S
C, S, F
C, S
C, S
SIMULIA
Tosca Structure
Abaqus
Abaqus-element
type
Design element
(see below)
PLANE_QUAD_8
CPE8RT
CPE8T
CPEG8
CPEG8H
CPEG8HT
CPEG8R
CPEG8RH
CPEG8RHT
CPEG8T
C, S
C, S
C, S
C, S
C, S
C, S
C, S
C, S
C, S
PLANE_QUAD_8
CPS8
CPS8R
CPS8RT
CPS8T
C, S, F
C, S, F
C, S
C, S
PLANE_QUAD_8
CAX8
CAX8H
CAX8HT
CAX8R
CAX8RH
CAX8RHT
CAX8RT
CAX8T
C, S, F
C, S
C, S
C, S, F
C, S
C, S
C, S
C, S
PLANE_QUAD_8
CGAX8
CGAX8H
CGAX8HT
CGAX8R
CGAX8RH
CGAX8RHT
CGAX8RT
CGAX8T
C, S
C, S
C, S
C, S
C, S
C, S
C, S
C, S
PLANE_QUAD_8
CPE8
CPE8H
CPE8HT
CPE8R
CPE8RH
CPE8RHT
C, S, F
C, S
C, S
C, S, F
C, S
C, S
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Tosca Structure-element
type
SIMULIA
Tosca Structure
Solver Specific Features
www.3ds.com/tosca
Tosca Structure-element
type
Abaqus-element
type
Design element
(see below)
PLANE_TRIANG_3
CAX3
CAX3H
CAX3T
C, S, F
C, S
C, S
PLANE_TRIANG_3
CGAX3
CGAX3H
CGAX3HT
CGAX3T
C, S
C, S
C, S
C, S
PLANE_TRIANG_3
CPE3
CPE3H
CPE3T
CPEG3
CPEG3H
CPEG3HT
CPEG3T
C, S, F
C, S
C, S
C, S
C, S
C, S
C, S
PLANE_TRIANG_3
CPS3
CPS3T
C, S, F
C, S
PLANE_TRIANG_6
CPE6H
CPE6M
CPE6MH
CPE6MHT
CPE6MT
C, S
C, S
C, S
C, S
C, S
PLANE_TRIANG_6
CPEG6
CPEG6H
CPEG6M
CPEG6MH
CPEG6MHT
CPEG6MT
C, S
C, S
C, S
C, S
C, S
C, S
PLANE_TRIANG_6
CPS6
CPS6M
CPS6MT
C, S, F
C, S
C, S
SIMULIA
Tosca Structure
Abaqus
Abaqus-element
type
Design element
(see below)
SOLID_BRICK_8
C3D8
C3D8H
C3D8HT
C3D8I
C3D8IH
C3D8R
C3D8RH
C3D8RHT
C3D8RT
C3D8T
SC8R
C, S, F
C, S
C, S
C, S
C, S
C, S, F
C, S
C, S
C, S
C, S
C, S
SOLID_BRICK_20
C3D20
C3D20H
C3D20HT
C3D20R
C3D20RH
C3D20RHT
C3D20RT
C3D20T
C, S, F
C, S
C, S
C, S, F
C, S
C, S
C, S
C, S
SOLID_TETRA_4
C3D4
C3D4H
C3D4T
C, S, F
C, S
C, S
SOLID_TETRA_10
C3D10
C3D10H
C3D10M
C3D10MH
C3D10MHT
C3D10MT
C, S, F
C, S
C, S
C, S
C, S
C, S
SOLID_PENTA_6
C3D6
C3D6H
C3D6T
SC6R
C, S, F
C, S
C, S
C, S
SOLID_PENTA_15
C3D15
C3D15H
C, S, F
C, S
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Tosca Structure-element
type
SIMULIA
Tosca Structure
Solver Specific Features
Abaqus-element
type
Design element
(see below)
SHELL_QUAD_4
M3D4
M3D4R
S4
S4R
S4R5
C, S, F
C, S, F
C, S, F, Z
C, S, F, Z
C
SHELL_QUAD_8
M3D8
M3D8R
S8R
S8R5
S8RT
C, S, F
C, S, F
C, S, F, Z
C
C, S
SHELL_TRIANG_3
M3D3
S3
S3R
STRI3
C, S, F
C, S, F, Z
C, S, F, Z
C, S, F
SHELL_TRIANG_6
M3D6
STRI65
C, S, F
C, Z (only supported
if user ensures, that
rotational DOFs are
written to ODB-file)
BEAM_2D
B21
B21H
R2D2
RAX2
RB2D2
T2D2
T2D2H
T2D2T
F
F
Beam elements are
only allowed as
restriction elements in
shape optimization
www.3ds.com/tosca
Tosca Structure-element
type
SIMULIA
Tosca Structure
Abaqus
Tosca Structure-element
type
BEAM_3D
Abaqus-element
type
B31
B31H
RB3D2
T3D2
T3D2H
T3D2T
SPRINGA
SPRING2(S)
MASS_1
MASS
DUMMY_ELEM_TYPE
Design element
(see below)
F
F
Beam elements are
only allowed as
restriction elements in
shape optimization
F
F
2. For frequency response the geometrical nonlinearities and the incompatible, modified and hybrid elements are not supported.
3. Shell elements are not admitted for stresses in topology optimization.
= <setname>
*ELSET, ELSET
= <setname>
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
1. It is important to note that in shape optimization the form of the shell structure is optimized and not its thickness. This means that the shell edges are
modified and that modifications on the shell level are not carried out.
SIMULIA
Tosca Structure
Solver Specific Features
*ELEMENT, ELSET
= <setname>
These groups are loaded from the Abaqus input file during the preprocessing
of the optimization execution. These groups and their group names are available for the definitions applied in the parameter file along with the groups
ALL_NODES and ALL_ELEMENTS. If node and element groups with identical names are defined in the Abaqus input file, the extensions "_NODE" and
"_ELEM" are added to the distinguish group names during importation. This
guarantees that each group is identically identified by Tosca Structure.
Blanks in the group name are ignored during the import in Tosca Structure.
Generally, groups that are required for definition of the optimization area
should already be defined in the Abaqus input file and be used in the parameter file without using a redefinition.
Example:
File ex1.inp (group definition in FE input deck):
...
*ELSET, ELSET=DESIGN_ELEM, GENERATE
1, 10000, 1
15000, 20000, 1
...
= dv_design_elements
= design_elem
www.3ds.com/tosca
END_
SIMULIA
Tosca Structure
Abaqus
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Solver Specific Features
The material card *PLASTIC is supported as design element, see also Fig.
339.
Supported for the type HARDENING=ISOTROPIC (default).
A main limitation is that each material point (gauss point) is only allowed to
be unloaded once and it should not be elastoplastic again. Meaning that
cyclic loading is not supported.
*CONCRETE is supported for design elements
www.3ds.com/tosca
Hyperelastic:
Some material cards of *HYPERELASTIC are supported as design elements, see also figure Fig. 339.
ARRUDA-BOYCE
MOONEY-RIVLIN
NEO HOOKE
OGDEN
POLYNOMIAL
REDUCED POLYNOMIAL
VAN DER WAALS
YEOH
Not supported as design elements:
MARLOW
USER
Using TEST DATA INPUT parameter in *HYPERELASTIC (that is usually
followed by *UNIAXIAL TEST DATA or other test data) is not allowed.
SIMULIA
Tosca Structure
Abaqus
Fig. 339 Some of the *PLASTIC (a), *HYPOELASTIC (b) and *HYPERELASTIC (c) cards in Abaqus are supported for design elements.
Dependency of temperature or other field variables (Parameter DEPENDENCIES).
Materials allowed in shape optimization:
All linear and non-linear elastic materials:
*ELASTIC
*HYPERELASTIC
*HYPERFOAM
*HYPOELASTIC
*POROUS ELASTIC
Plasticity
Remark
The use of nonlinear materials in an optimization is only permitted for users of
the Tosca Structure.nonlinear license. This applies for the commands and
parameters below:
*CONCRETE
*HYPERELASTIC
*HYPERFOAM
*HYPOELASTIC
*PLASTIC
*POROUSELASTIC
*VISCOELASTIC
If no license is held for this mode, the optimization stops once the parameters
or commands listed above are used.
2 - 634 User Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Solver Specific Features
and
www.3ds.com/tosca
*STEP, PERTURBATION
*STATIC
...
*END STEP
and
*STEP
*FREQUENCY
...
*END STEP
Remarks
1. If PERTURBATION is added then the step command *STEP will be recognized as a linear static solution in Tosca Structure. If PERTURBATION is
SIMULIA
Tosca Structure
Abaqus
not added then the analysis is non-linear. The sensitivity based algorithm
supports geometrical nonlinearities (NLGEOM) and contact for Abaqus.
2. Abaqus has no predefined numbers for the load cases. Therefore, the first
defined load case in the INP file is recognized as load case one, the
second defined load case in the INP file is recognized as load case two and
etc.
3. Computationally, it is recommended that the user defines the static load
cases in Abaqus using the load case command *LOAD CASE in one
*STEP and not be defining more steps using *STEP several times. Hence,
using the load case command *LOAD CASE will keep the CPU-time significant lower, e.g.
*STEP, PERTURBATION
*STATIC
*LOAD CASE
...
*END LOAD CASE
*LOAD CASE
...
*END LOAD CASE
...
*END STEP
4. The results of the finite element analysis can only be read from the ODB
file when the command *LOAD CASE is activated (default) and not the FIL
file.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
5. The user can decide to write to the FIL file only when *STEPS are defined
in the Abaqus input deck.
SIMULIA
Tosca Structure
Solver Specific Features
= ALL
END_
By default, this command is already included in the configuration file command.ini. Therefore it must not be defined explicitly in the parameter file.
Node restrictions defined in the FE-analysis (and maybe not used in the FE
analysis) can be used as restrictions for design variables for shape and bead
optimization (see command DVCON_SHAPE, DVCON_BEAD) to avoid optimization nodal displacements in specified places.
www.3ds.com/tosca
SIMULIA
Tosca Structure
Abaqus
Remarks
1. Default is PROCESSORS = SINGLE.
2. Design responses for reaction forces and internal forces can not be applied
when PROCESSORS = MULTI is activated.
Temperature loading
The following commands are supported for temperature loading in sensitivity
based topology optimization: *TEMPERATURE.
Remarks
1. When reading temperatures from the results or output database file (FILE)
then the temperature (FILE) should be the same in each optimization iteration.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
OPT_PARAM
....
PROCESSORS = MULTI
....
END_
SIMULIA
Tosca Structure
Solver Specific Features
Individual nodes and elements are changed during the optimization. Thus,
the commands used in Abaqus to define nodes and elements of transformations are invalid. The appearance of these keywords in the finite element
input deck leads to a termination of the optimization. Therefore, these definitions should be executed in a preprocessor so an explicit definition of the
nodes and elements are created.
When input files already exist then a data check should be carried out with
Abaqus. In this data check the nodes and elements are generated and written
in the output file (*.dat). The node and element definitions can then be copied
from the output file and inserted into a new input file.
*PARAMETER
*PARAMETER DEPENDENCE
*PARAMETER SHAPE VARIATION
Parametric inputs in the Abaqus input deck can not be used with Tosca Structure. A parameter check should be executed when parametric inputs exist.
This parameter check causes an evaluation and substitution of only the parametric inputs:
abaqus job=job-name parametercheck
www.3ds.com/tosca
Then a modified input file containing no parameter and parameter dependence table definitions and <parameter> instances is produced. Use the generated file named job-name.pes for optimization with Tosca Structure.
11.2
ANSYS
Solver type
ANSYS
Table 44
Tosca Structure
supported input
*.cdb, *.dat, *.inp
Tosca Structure
supported output
*.rst
SIMULIA
Tosca Structure
ANSYS
Error messages and warnings can be found in the *.err file. The input file
must be corrected if an error occurs.
As input file for the optimization loop TOSCA_PREP generates an ANSYS
CDB file from the ANSYS input file. Compared to a complete ANSYS input
file this file contains no solution strategy (/SOLU).
During the optimization procedure the analysis results are read from the *.rst
file.
Remarks
2. For a topology optimization with the controller algorithm using static finite
element analysis, which contains only solid elements, the iterative PCG
Solver of ANSYS should be used due to performance reasons. The solver
may be activated by adding the following command in the solution block of
the corresponding CDB file:
eqsl, pcg, 1.e-5
3. The iterative solver is not recommended for sensitivity based optimizations.
4. It is not allowed to define new nodes or elements after the first /SOLU
statement. (The solution part is cut off the .cdb file before the ANSYS
Preprocessing-run.)
5. In Tosca Structure configuration file tosca_ctrl.cfg (see also CONFIG) the
environment variable ANSWAIT=1 will be set, to let ANSYS wait for a free
license.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
1. The ANSYS interface will stop reading element and node definitions when
the first /SOLU definition in the input file occurs. Elements that are defined
after the first /SOLU (usually elements and nodes generated by macros)
are not known in Tosca Structure. In return this allows for more possibilities
of using macros and /PREP7 sections after a /SOLU definition. Most definitions after /SOLU are not modified by the interface.
SIMULIA
Tosca Structure
Solver Specific Features
6. In earlier versions of the ANSYS interface, for shape and bead optimization
the positions of nodes used to be modified using the special command
"NMODIF", which is unsupported by Tosca ANSA environment. This
prevented the user from visually inspecting the modified state of the model.
The interface now modifies directly the coordinates of the nodes, thus all
intermediate steps of the shape or bead optimization can be visualized with
Tosca ANSA environment.
ANSYS Files generated during a Tosca Structure optimization
During the optimization preprocessing the ANSYS model will be imported
to ANSYS and exported again to generate a standard blocked CDB file.
During this import/export step all macros in the ANSYS input file will be
executed in ANSYS and can no longer be found as macros in the input files
used during the Tosca Structure optimization.
The input file (model.cdb) is split into multiple files during the optimization
preprocessing (TOSCA_PREP):
- model_ans.cdb
Input file without solution /SOLU
- model_ans.head
File containing the ANSYS Header
- model_ans.solu
File containing the ANSYS Solution /SOLU. Eventually, existing load
case files *.s0X are copied into the optimization working directory. These
remain unchanged during the optimization process.
- model_ans.tosca
temporary file which is used for the generation of the model_ans.cdb file
www.3ds.com/tosca
SIMULIA
Tosca Structure
ANSYS
The newly created CDB file in blocked format is detected and analyzed
automatically by the optimization preprocessor. Thus, the FE model is
imported into Tosca Structure. The data of the ANSYS model (coordinates
of nodes, materials, properties and assignment of elements) in the CDB file
can be modified during the optimization. The load files contain the boundary restrictions which provide information about boundary movements for
shape optimization.
The solve section contains the solution strategy of the original input file,
checks and the definition of which kind of results must be written to the *.rst
files for shape and topology optimization, respectively. Thus, during the
ANSYS analysis only the results necessary for the optimization are written
to the result file.
During the optimization the data in the CDB file is modified. Afterwards the
three parts are merged and a new ANSYS analysis is performed. The load
files are not changed during the optimization.
BEAM_2D
ANSYS-element
type
BEAM23
LINK1
LINK10
LINK11
LINK180
LINK8
BEAM3
Design element
only allowed as
restriction element for
shape optimizations
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Tosca Structure-element
type
SIMULIA
Tosca Structure
Solver Specific Features
www.3ds.com/tosca
Tosca Structure-element
type
ANSYS-element
type
Design element
BEAM_3D
BEAM24
BEAM4
BEAM188
only allowed as
restriction element for
shape optimizations
MASS_1
MATRIX27
PLANE_QUAD_4
PLANE182
C, S, F
PLANE42
C, S, F
PLANE_TRIANG_6
PLANE146
C, S, F
PLANE_QUAD_8
PLANE145
PLANE183
PLANE82
C, S, F
SHELL_QUAD_4
SHELL143
SHELL181*
SHELL41
SHELL43
SHELL63
C, S, F
SHELL_QUAD_8
SHELL150
SHELL93
SHELL281*
C, S, F
SOLID_BRICK_8
SOLID185
SOLID45
C, S, F
SOLID_TETRA_4
SOLID285
C,S,F
SOLID_TETRA_10
SOLID148
SOLID187
SOLID92
C, S, F
SOLID_BRICK_20
SOLID147
SOLID186
SOLID95
C, S, F
SOLID_PYRAM_5
SOLID185
SOLID45
SIMULIA
Tosca Structure
ANSYS
Tosca Structure-element
type
ANSYS-element
type
SOLID_PYRAM_13
SOLID147
SOLID186
SOLID95
DUMMY_ELEM_TYPE
Design element
C
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Solver Specific Features
www.3ds.com/tosca
TB
Anisotropic Elastic Material
ANEL
Anisotropic Constants
ANISO
BISO
BKIN
CAST
Drucker-Prager Constants
DP
TBOPT
ISOTROPIC (*)
SIMULIA
Tosca Structure
ANSYS
TB
TBOPT
HYPER
BOYCE,
BLATZ,
FOAM,
GENT,
MOONEY,
NEO,
OGDEN,
POLY,
YEOH
KINH
PLASTIC (*)
MKIN
Multilinear Elastic Constants
MELAS
MISO
NLISO
VOCE (*),
POWER (*)
Plastic Strain
PLASTIC
MISO (*),
KINH (*)
Uniaxial Behaviour
UNIAXIAL
TENSION,
COMPRESSION
2. Tosca Structure needs different properties for different element types. For
example it is not allowed that a solid element and a shell element share the
same element property.
3. Geometrical non-linear modeling might cause convergence issues in the
FE-solver for the void elements (in topology optimization) because the void
elements might have semi definite or negative definite elemental matrices.
Especially, for geometrical non-linear modeling combined with nonlinear
material convergence issues emerge in the FE-solver. No unique solution
exists if convergence issues occur for the void elements. However, a
potential candidate for a solution could be to use SOFT_DELETE (see
chapter 5.8.1.4 Relation between relative density and stiffness or
OPT_PARAM) or increasing the relative minimum density (parameter
DENSITY_LOWER in OPT_PARAM). Additional, the user should check if
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Solver Specific Features
the most favorable settings for solving the non-linear equilibrium are
applied in the FE-solver.
4. With Tosca Structure 8.0 "SECBLOCK"-sections for shell elements are
supported in both sizing and topology optimization.
5. Shell properties for elements used for sizing must be defined using the
"SECBLOCK" keyword. Elements using only the RLBLOCK definition are
not admitted for sizing optimization with Tosca Structure. This implies that
only shell elements of type SHELL181 and SHELL281 are admitted for
sizing optimization.
www.3ds.com/tosca
ANTYPE,2
Only one set of the command LSSOLVE is allowed in each finite element file
(CDB). Furthermore, the load cases should be specified in an order starting
from 1 and then the numbering should be chronologically increasing. The
load cases are referred in the parameter file using the number of the load
case.
E.g. if two static load cases (LSSOLVE,1,2,1 and ANTYPE,0 in
file_fe_static.s01 and file_fe_static.s02) are defined in the file
file_fe_static_1.cdb and two eigenfrequency load cases (LSSOLVE,1,2,1 and
ANTYPE,2 in file_fe_dynamic.s01 and file_fe_dynamic.s02) are defined in
the file_fe_dynamic_1.cdb, they are defined in parameter file like:
FEM_INPUT
ID_NAME
FILE
FILE
= Two_files
= file_fe_static.cdb
= file_fe_dynamic.cdb
END_
SIMULIA
Tosca Structure
ANSYS
LC_SET
...
= STATIC,1,
END_
and
DRESP
...
LC_SET
...
= STATIC,2,
END_
= MODAL,10001,...
END_
and
DRESP
...
LC_SET
...
= MODAL,10002,.....
END_
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Remarks
SIMULIA
Tosca Structure
Solver Specific Features
= ALL
END_
Node fixations are created in ANSYS in the load files (*.sxx) of the analysis
model with the command:
D, NODE, LAB, VALUE, VALUE2, NEND, NINC, LAB2, LAB3, LAB4,
LAB5, LAB6
We recommend considering all fixed node during the reading of the model
with the command
www.3ds.com/tosca
READ_OPTION, SPC, ON
SIMULIA
Tosca Structure
ANSYS
Category
Element Name
Spars
LINK180
Beams
BEAM188
BEAM189
Pipes
PIPE288
PIPE289
2-D Solids
PLANE182
PLANE183
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Remark:
Nonlinear optimizations using pseudoloads with ANSYS versions < 14 are no
longer supported! If you want to use this kind of optimizations please make
sure you are using at least ANSYS 14.
Linear perturbations in ANSYS currently only allow the following element
types:
SIMULIA
Tosca Structure
Solver Specific Features
www.3ds.com/tosca
Category
Element Name
3-D Solids
SOLID185
SOLID186
SOLID187
SOLID285
Shells
SHELL181
SHELL208
SHELL209
SHELL281
Solid-Shell
SOLSH190
Interface
INTER192
INTER193
INTER194
INTER195
Contact
TARGE169
TARGE170
CONTA171
CONTA172
CONTA173
CONTA174
CONTA175
CONTA176
CONTA177
CONTA178
Specialty
COMBIN14
MASS21
MATRIX27
COMBIN39 (*)
SURF153
SURF154
SURF156
PRETS179
MPC184
MESH200
FOLLOW201
COMBI214
HSFLD241
HSFLD242
SIMULIA
Tosca Structure
Marc
11.3 Marc
Solver type
Marc
Table 45
Tosca Structure
supported input
*.dat
Tosca Structure
supported output
*.t16
Tosca Structure supported file formats for Marc. See flow diagram Fig. 338
Please Note:
For subsequent versions of Tosca Structure the Marc interface will be frozen
with functionality of Tosca Structure 7.0.1. The interface will be available in
the current version as as-is interface. No further developments and enhancements will be made for this interface.
Tosca Structure reads the results of the Marc FE calculation from the binary
result file modelname.t16. The optimization preprocessor automatically
enters the post codes necessary for the optimization (result requests) in the
input file (modelname.dat).
For stress evaluations Tosca Structure reads components of tensor 411 referenced in the binary result file modelname.t16.
For analysis with geometric nonlinearities the user has to ensure that this tensor is assigned with components of the CAUCHY STRESS TENSOR. It is
recommended to use the updated Lagrange approach for equilibrium conditions:
The Plasticity parameter with options 3,4 and 5 utilizes the updated
Lagrange procedure for elastic-plastic analysis.
The Elasticity parameter with option 2 utilizes the updated Lagrange procedure for large strain elasticity (Mooney, Ogden, etc.).
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Result Format
SIMULIA
Tosca Structure
Solver Specific Features
PLANE_QUAD_4
C, S
10
C, S, F
11
C, S, F
20
C, S
95
C, S
114
C, S, F
115
C, S, F
116
C, S
118
C, S
119
C, S
Design element
www.3ds.com/tosca
SIMULIA
Tosca Structure
Marc
PLANE_QUAD_8
26
C, S, F
27
C, S, F
28
C, S
32
C, S
33
C, S
34
C, S
53
C, S, F
54
C, S, F
55
C, S
56
C, S
58
C, S
59
C, S
60
C, S
63
C, S
66
C, S
67
C, S
73
C, S
74
C, S
96
C, S
C, S
C, S, F
155
C, S
156
C, S
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
PLANE_TRIANG_3
Design element
SIMULIA
Tosca Structure
Solver Specific Features
PLANE_TRIANG_6
124
C, S, F
125
C, S, F
126
C, S
128
C, S
129
C, S
18
C, S, F
22
C, S
68
C, S
75
C, S
80
C, S
81
C, S
82
C, S
83
C, S
139
C, S, F
140
C, S, F
30
C, S, F
72
C, S, F
SHELL_TRIANG_3
138
C, S, F
SOLID_BRICK_20
21
C, S, F
35
C, S
57
C, S, F
61
C, S
SHELL_QUAD_4
www.3ds.com/tosca
SHELL_QUAD_8
Design element
SIMULIA
Tosca Structure
Marc
SOLID_BRICK_8
C, S, F
84
C, S
117
C, S, F
120
C, S
127
C, S, F
130
134
C, S, F
157
C, S
can be used as
restriction element for
shape optimizations
can be used as
restriction element for
shape optimizations
can be used as
restriction element for
shape optimizations
52
can be used as
restriction element for
shape optimizations
SOLID_TETRA_4
BEAM_2D
DUMMY
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SOLID_TETRA_10
Design element
SIMULIA
Tosca Structure
Solver Specific Features
www.3ds.com/tosca
SIMULIA
Tosca Structure
Marc
Remarks
1. Marc has no predefined numbers for the load cases. Therefore, the first
defined load case in a specified DAT file is recognized as load case one,
the second defined load case in the specified DAT file is recognized as load
case two and etc.
2. One finite element files (*.dat)) is only allowed to contain a static analysis or
a dynamic analysis. Not both simulation types are allowed simultaneously
in the same finite element file (*.dat)).
3. Finite element models having nodes in local degree of freedom (DOF)
defined in a local coordinate system using the Marc command TRANSFORMATION is not supported for sensitivity based topology optimization.
Node fixations in the Marc input file are imported during optimization preprocessing if the following command is set:
READ_OPTION, SPC, ON
This command is set by default in the configuration file command.ini. Therefore, it must not be specified explicitly in the parameter file.
Node restrictions defined in the FE-analysis (and maybe not used in the FE
analysis) can be used as restrictions for design variables for shape optimization (see command DVCON_SH
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Solver Specific Features
Temperature loading
The following commands are supported for temperature loading in sensitivity
based topology optimization:
1. THERMAL_LOADS
2. POINT_TEMP
Solver type
MSC Nastran
*.bdf
Tosca Structure
supported output
*.op2
(*.dat)
Table 46
www.3ds.com/tosca
For sensitivity based topology optimization PARAM, POST, -4 is set in the first
iteration.
SIMULIA
Tosca Structure
MSC Nastran
PARAM,MAXRATIO,10.E10
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Solver Specific Features
www.3ds.com/tosca
Design
element
SOLID_BRICK_8
CHEXA
C, S, F
SOLID_BRICK_20
CHEXA
C, S, F
SOLID_TETRA_4
CTETRA
C, S, F
SOLID_TETRA_10
CTETRA
C, S, F
SOLID_PENTA_6
CPENTA
C, S, F
SOLID_PENTA_15
CPENTA
C, S, F
SHELL_QUAD_4
CQUAD4
CQUAD8
CQUAD
CQUADR
CSHEAR
CQUADX
C, S, F
C, S, F
C
C, S, F
C, S, F
SHELL_QUAD_8
CQUAD8
CQUAD
CQUADX
C, S, F
C
SHELL_TRIANG_3
CTRIA3
CTRIA6
CTRIAR
CTRIAX
CTRIAX6
C, S, F
C, S
C, S, F
C
SHELL_TRIANG_6
CTRIA6
CTRIAX
CTRIAX6
C, S, F
C
BEAM_3D
CBAR
CBEAM
CBEND
CBUSH
can be used
as restriction
element for
shape optimizations
GAP_2_ND
CGAP
SIMULIA
Tosca Structure
MSC Nastran
MASS_1
CONM1
CMASS1
DUMMY_ELEM_TYPE
Design
element
More solver specific information about the sensitivity based algorithm is found
in vol.2 chapter 11.4.7, Remarks for sensitivity based optimizations. For sensitivity based bead optimization, see vol.2 chapter 7.11, Special Remarks
Using Sensitivity Based Algorithm.
Remarks
1. Elements with linear or quadratic element formulations are supported.
Mixed elements types are not permitted. A model can contain linear as well
as quadratic elements.
2. It is important to note that shell structures are optimized in form and not in
thickness in shape optimization. This means that the "shell edges" need to
be modified and not the shell layers.
= CS_1
The above references the coordinate system id = 1 in the input deck. CS_0
is always the global rectangular coordinate system even if it is not defined in
the input deck.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Solver Specific Features
www.3ds.com/tosca
SIMULIA
Tosca Structure
MSC Nastran
However, a workaround exists for reducing the finite element analysis CPUtime for Nastran when having responses consisting of both static and modal
responses. Only the SOL 103 solution can be used when both the responses
from the static and frequency analysis are applied in the optimization formulation. This is done by adding static load cases in the SOL 103 solution. However, the eigenfrequency solutions of the structure are not allowed to be
prestressed (then convergence is not guaranteed). Thus, the user should
define a dummy load case which has no stresses and this dummy load case
is referenced in the eigenfrequency analysis. An example of combining several frequency analyses and several static analyses in SOL 103 is given the
following example:
SOL 103
...
SUBCASE 1
$ DYNAMIC LOADCASE 1
METHOD=....
SPC = ....
$
SUBCASE 2
$
DYNAMIC LOADCASE 2
METHOD=....
.......
SUBCASE 13
$
STATIC LOADCASE 1
SPC = ....
LOAD = ....
SUBCASE 14
$
STATIC LOADCASE 2
SPC = ...
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SPC = .....
SIMULIA
Tosca Structure
Solver Specific Features
LOAD = ...
..
SUBCASE 20
$
BEGIN BULK
..
ENDDATA
Remarks
1. Remember when defining the command DRESP in the parameter file to
distinguish between the different type of load cases (STATIC - MODAL)
and the number of eigenfrequencies.
2. Generally, laminate materials can not be designed in topology optimization.
However, laminate materials as design elements are allowed for MAT2,
MAT8 and MAT9 in Nastran.
Temperature loading
TEMPERATURE(LOAD) or TEMPERATURE(BOTH) in sub cases referring
the following types are supported for temperature loading using Tosca Structure:
www.3ds.com/tosca
1. TEMP
2. TEMPD
3. TEMPP1
4. TEMPRB
TEMPAX
Remarks
1. Note, that different sub case can have different temperature loading and
also some sub cases without temperature loading.
2. STRAIN_ENERGY as DRESP when having temperature loading is not
allowed for Nastran because Nastran is calculating the strain energy using
a wrong principle.
SIMULIA
Tosca Structure
MSC Nastran
END_
When the optimization boundary conditions have been written into a separate
sub case then the "Main SPC" number can be specified which has been
2 - 666 User Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Solver Specific Features
entered in the CASE CONTROL SECTION of the analysis bulk data file. All
SPC commands that are linked in the MSC Nastran input file with SPCADD
are also transferred to the optimization model. Specification of the sub case
number itself is not permitted.
www.3ds.com/tosca
SIMULIA
Tosca Structure
PERMAS
the METHOD card for RFORCE is applied then the METHOD card should
correspond to the mass element type chosen in PARAM,COUPMASS.
1. All kind of discrete damping elements and other kind of damping are
allowed outside the design domain as long as they are not of function of the
eigenfrequencies or eigenmodes. Meaning that modal damping e.g.
defined using SDAMPING is prohibited.
11.5 PERMAS
Solver type
PERMAS
Tosca Structure
supported input
*.uci
Tosca Structure
supported output
*.post
*.dat
Table 48
2 - 668 User Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Remarks:
SIMULIA
Tosca Structure
Solver Specific Features
www.3ds.com/tosca
Include statements are allowed in the PERMAS input. The include file will be
changed by Tosca Structure if node or element definitions are located in an
include file.
The main model file (*.dat) and the control file (*.uci) must have the same
base name.
Subcomponents as they are defined in PERMAS are not supported by Tosca
Structure as node and element numbers could be repeated several times.
System variants (e.g. variants with different materials) may not be defined in
the optimization model.
SIMULIA
Tosca Structure
PERMAS
Element
description
Design
element(*)
SOLID_TETRA_4
TET4
C, S, F
SOLID_TETRA_10
TET10
C, S, F
SOLID_BRICK_8
HEXE8
C, S, F
SOLID_BRICK_20
HEXE20
C, S, FX & S
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Tosca Structure
element type
SIMULIA
Tosca Structure
Solver Specific Features
www.3ds.com/tosca
Tosca Structure
element type
PERMAS
element
type
Element
description
Design
element(*)
SOLID_PENTA_6
PENTA6
C, S, F & S
SOLID_PENTA_15
PENTA15
C, S, F
PLANE_TRIANG_3
TRIA3
3 node triangular
shell element
C, S, F
PLANE_TRIANG_3
TRIA3K
C, S, F
PLANE_TRIANG_3
TRIM3
3 node triangular
plane membrane
element
C, S, F
PLANE_TRIANG_3
TRIMS3
3 node triangular
solid shell element
PLANE_TRIANG_6
TRIM6
6 node triangular
plane membrane
element
C, S, F
PLANE_TRIANG_6
TRIMS6
6 node triangular
solid shell element
PLANE_QUAD_4
QUAD4
4 node quadrilateral
shell element
C, S, F
PLANE_QUAD_4
QUAM4
4 node quadrilateral
plane membrane
element
C, S, F
PLANE_QUAD_4
QUAMS4
4 node quadrilateral
solid shell element
PLANE_QUAD_4
SHEAR4
4 node quadrilateral
plane shear panel
element
C, S, F
SIMULIA
Tosca Structure
PERMAS
PERMAS
element
type
Element
description
Design
element(*)
PLANE_QUAD_8
QUAM8
8 node quadrilateral
plane membrane
element
C, S, F
PLANE_QUAD_8
QUAMS8
8 node quadrilateral
solid shell element
PLANE_TRIANG_3
TRIAX3
3 node triangular
axis-symmetric solid
element
PLANE_TRIANG_6
TRIAX6
6 node triangular
axis-symmetric solid
element
PLANE_QUAD_4
QUAX4
4 node quadrilateral
axis-symmetric solid
element
PLANE_QUAD_8
QUAX8
8 node quadrilateral
axis-symmetric solid
element
BEAM_2D
BEAM2
BEAM_2D
BEAM2W
BEAM_2D
BECOC
BEAM_2D
BECOP
BEAM_2D
BECOS
BEAM_2D
BETAC
2 node straight
tapered thin-walled
tube
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Tosca Structure
element type
SIMULIA
Tosca Structure
Solver Specific Features
PERMAS
element
type
Tosca Structure
element type
Element
description
Design
element(*)
BEAM_2D
BETOP
2 node straight
tapered thin-walled
beam
BEAM_2D
FLA2
2 node straight
flange (rod)
BEAM_2D
FLAX2
MASS_1
MASS3
Point mass
DUMMY_ELEM_TY
PE
www.3ds.com/tosca
More solver specific information about the sensitivity based algorithm is found
in vol.2 chapter 11.5.8, Remarks for sensitivity based optimizations. For sensitivity based bead optimization, see vol.2 chapter 7.11, Special Remarks
Using Sensitivity Based Algorithm.
All other PERMAS element types are allowed in the PERMAS input deck but
are not considered in the optimization.
and
$COOR NSET=name
NAME=name
and
$ELEMENT ESET=name
SIMULIA
Tosca Structure
PERMAS
The groups can be used in Tosca Structure to define the optimization task. If a
node and an element set are defined with the same name then _ELEM is
attached to the element set name and _NODE is attached to the node set
name, respectively. This is done automatically by Tosca Structure and thus
the extensions should also be used when using the groups in the parameter
file.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Solver Specific Features
contains the boundary conditions (e.g. constraint and prescribed degrees of freedom).
System Variant:
Loading Variant:
Modification Variant:
Result Variant:
www.3ds.com/tosca
Contact definitions
Contact conditions are permitted in the analysis model for topology and
shape optimization. Defining a contact surface directly on the edge of the
design space is allowed in topology optimization. The shape optimization
algorithm has to be inverted (see command OPT_PARAM, Parameter
SCALE) if the design edge belongs to a contact surface in shape optimization. Convergence difficulties in the FE analysis may arise in cases of complex contact problems due to large changes in the model during optimization.
Node Restrictions for Shape Optimizations
Node fixations in the PERMAS input file are imported during optimization preprocessing when the following command is set:
READ_OPTION, SPC, ON
SIMULIA
Tosca Structure
PERMAS
In Unix, the databases generated by PERMAS are not deleted after a PERMAS run using standard settings. The standard settings must be changed in
either the file PERMAS.DFT or in a current .uci file in order to use the Tosca
Structure-PERMAS interface. The line SET DATABASE=DELETE must be
inserted.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Solver Specific Features
Input of MPCs
The ID in the definition of MPCs must be smaller than 10000.
Further Restrictions
The key words GSYS, ROTB, RSYSAX are in general allowed but are usually
not checked by Tosca Structure.
Only one single block $ENTER COMPONENT and $SYSTEM can exist in the
PERMAS input file
www.3ds.com/tosca
SIMULIA
Tosca Structure
Shape Optimization Based on a Durability Analysis
FE-fatigue
FEMSite
MSC.fatigue
LMS Virtual.Lab Durability
For more information about using the above durability programs with Tosca
Structure please contact your Tosca Structure sales representative.
It is also possible to use in-house durability codes with Tosca Structure, see
chapter 11.6.5 ONF.
11.6.2 Workflow
For the consideration of damage data during optimization, a durability analysis is performed after each finite element solver run in the optimization loop.
The results of the finite element analysis are directly read in the durability
solver and a damage calculation is performed. The results of the damage
analysis are provided in a special result block. Then Tosca Structure modifies
the components surface based on the damage distribution.
11.6.2.1 Preprocessing
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Solver Specific Features
PREPROCESSING
FE Preprocessor
Analysis model
Durability
Preprocessor
Control file
OptimizationPreprocessor
Optimization model
OPTIMIZATION LOOP
FE SOLVER
DAMAGE SOLVER
Tosca
Structure.shape
POSTPROCESSING
www.3ds.com/tosca
Fig. 340 Flowchart of the optimization with Tosca Structure, FE and Damage Solver
= FILE_INFO
= static_analysis.ext
= life_input.ext
SIMULIA
Tosca Structure
Shape Optimization Based on a Durability Analysis
Remarks
1. The name of LIFE_FILE may have any name.
2. The LIFE_FILE command may be repeated more times for life solvers that
support the ONF 601-format (DRESP TYPE = DAMAGE_LC).
For some life solvers it is often needed to add some extra files in working
directory - files that Tosca Structure not always recognizes as default files.
The easiest way to copy these files into the optimization working directory is
by using the COPY_FILE command.
FEM_INPUT
ID_NAME
FILE
LIFE_FILE
COPY_FILE
COPY_FILE
END_
=
=
=
=
=
FILE_INFO
static_analysis.ext
life_input.ext
some_extra_file.ext
some_other_extra_file.ext
DRESP
ID_NAME
DEF_TYPE
ND_GROUP
TYPE
GROUP_OPER
UPDATE
END_
=
=
=
=
=
=
OBJ_FUNC
ID_NAME
DRESP
TARGET
END_
= MINIMIZE_DAMAGE
= DRESP_DAMAGE
= MIN
DRESP_DAMAGE
SYSTEM
DESIGN_NODES
DAMAGE
MAX
EVER
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Solver Specific Features
www.3ds.com/tosca
Fig. 341 Starting Tosca Structure with life solver using Tosca ANSA environment
SIMULIA
Tosca Structure
Shape Optimization Based on a Durability Analysis
Fig. 342 Start of Tosca Structure with a durability analysis (Tosca Structure.gui)
Start on the command line
The damage solver must be specified using the --life flag on the command
line. Example with femfat:
tosca810 hole_damage --solver mscnastran --life femfat
After the optimization is finished, all Tosca Structure postprocessing capabilities are available (see vol.2 chapter 10, Postprocessing of Optimization
Results and vol.2 chapter 9, Result Transfer and Validation Run). Additionally,
the damage results may be used for postprocessing. The corresponding
result files are stored in the SAVE directories of the optimization system.
11.6.3 FEMFAT
11.6.3.1 General
For a shape optimization with Tosca Structure in combination with FEMFAT,
special results have to be requested in the FEMFAT preprocessing. The
requested result files may be read by Tosca Structure and allow the correct
interfacing of the two software packages.
The following result formats for Tosca Structure may be requested in FEMFAT:
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
11.6.2.5 Postprocessing
SIMULIA
Tosca Structure
Solver Specific Features
ONF 600
Tosca Structure optimization neutral file
This data block contains a node list and a damage value for each node.
ONF 601
Tosca Structure optimization neutral file with loadcase information.
This additionally data block contains load case information. This allows
several FEMFAT Basic calculations which may later be combined in Tosca
Structure.
Remark:
1. The type of DRESP determines the result format! Use:
TYPE = DAMAGE
TYPE = DAMAGE_LC
It is important that the result from the life analysis has the same name as the
life-solver input deck except for the file extension. I.e.:
<life_input_file>.ffj
(or <life_input_file>_601.onf)
www.3ds.com/tosca
If the latter file does not exist in the working directory of the Tosca Structure
Job, the optimization will stop due to missing results. A corresponding error
message will be output to the user.
SIMULIA
Tosca Structure
Shape Optimization Based on a Durability Analysis
For all design nodes that are used for shape optimization a damage value
has to be provided. So the area for damage calculation may be reduced to
the design area in order to save calculation time.
Changes in the FEMFAT FFJ file
During the fatigue life simulation preprocessing, the user selects the finite element solver result file interactively in FEMFAT. While exporting the ffj file, the
absolute path settings for the stress input file(s) are stored to the control file.
setValue {0 {{setValue {} {} StressFileDatasetNumber 0}}} {0
ok} StressInputFile C:\scratch\holeplate_dam.op2
This can be realized easily by exporting the ffj file from the FEMFAT application after the execution of the analysis.
The FEMFAT batch run should be tested before the complete optimization is
started. The command line for a FEMFAT batch run is the following:
Windows
<femfat_install>\lib\dll\femfat4exe
<femfat_install>\bin\bin\femfat.tbc -job=<jobname>.ffj
Unix
2 - 684 User Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Solver Specific Features
<femfat_install>\bin\bin\femfat4 -job=<jobname>.ffj
The resulting *.bifo file may then be used as input file in FEMFAT.
11.6.4 fe-safe
General
For a shape optimization with Tosca Structure in combination with fe-safe you
must be able to run your job as a batch job. This is done by setting up an fesafe analysis interactively and then exporting the necessary files or copying
the files from the fesafe project directory. For in depth information please see
the fe-safe documentation (fe-safe User Guide) about Saving analysis configuration settings and Running fe-safe from the command line.
The following assumes that the user understands the different files and command line arguments for fe-safe.
Exporting setup files from the fe-safe GUI
www.3ds.com/tosca
In a typical setup you need to export a .stlx and the .ldf files to a directory
from which you will start Tosca Structure and thus already have an FE-input
file there, e.g. Abaqus .inp file. You can typically find the necessary files after
having run fesafe interactively in the specified fesafe project directory.
Generating results
fe-safe writes life results per default. The user specifies the fe-safe output format in combination with Tosca Structure. Actually output format is set to .csv
format which is converted automatically to .onf format by Tosca Structure. As
Tosca Structure expects a "damage like" format the life results n are automatically inverted by csv_2_onf to 1/n.
Running fe-safe on command line
Test that fe-safe runs correctly on the command line by executing the fe-safe
job. Change to the directory where your .stlx file is saved and execute fesafe_cl. Example:
e:\Safe_Technology\fe-safe\version.6.4\exe\fe-safe_cl.exe -p
b=holeplate_dam.stlx o=.\holeplate_dam.csv j=refresh
mode=surface
SIMULIA
Tosca Structure
Shape Optimization Based on a Durability Analysis
Check that the .csv file is generated and has correct values (life values).
Configuration of fe-safe for Tosca Structure
The default setup by the installer is to use the .csv output of fe-safe which is
then converted to an ONF600 format by the executable csv_2_onf. Please
note that an additional inversion step is included which transfers the life
results (n) to damage results (1/n) automatically.
The standard configuration should then include these lines in the fe-safe configuration section:
if ($life_solver eq fesafe) {
...
$life_solver_cmdline = "-p ./SAVE.fesafe b=${__LIFE_FILE__}
LOGLIVES=0 mode=surface j=refresh o=./
${__LIFE_MODEL__}.csv";
# generate _600.onf file from csv file:
$pre_life2vtm = "$tosca/bin/csv_2_onf";
$pre_life2vtm_add_call = "${__LIFE_MODEL__}.csv";
macro file must write out a csv file with the same name as the macro, e.g.
result file holeplate_dam.csv
Macro-support is experimental. Please use .stlx for standard work flows.
Change in configuration to use macro file:
$life_solver_cmdline = "-p ./SAVE.fesafe
macro=${__LIFE_FILE__}";
# generate _600.onf file from csv file:
$pre_life2vtm = "$tosca/bin/csv_2_onf";
$pre_life2vtm_add_call = "${__LIFE_MODEL__}.csv";
Legacy .kwd files may also be used, but in that case the user is resposible for
copying the right files into the working directory and that command line is cor-
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Solver Specific Features
rect. The copying of files can be done using COPY_FILE in the FEM_INPUT
command.
Changes done by Tosca Structure in .stlx file
Tosca Structure runs in the working directory, therefore are all absolute paths
in the .stlx file substituted with a relative path to ensure that the current FEinput deck and results are used in the durability analysis. E.g. the following
files are assumed to be in current directory:
source file(s) (odb or fil)
ldf file and files referenced herein
kt file
msc file
11.6.5 ONF
11.6.5.1 General
This life option is for the users who may want to use their own fatigue program. The only requirement is that the program writes in ONF-format. This
format can be acquired by contacting FE-DESIGN GmbH.
The following variables must also be set in your Tosca Structure configuration:
The optimization run starts like the other fatigue codes with the solver run,
which results are first read into the Tosca Structure database. Then the
defined life-solver is called, and the ONF-results are then read by Tosca
Structure.
www.3ds.com/tosca
${life_solver_exe} = "<name_of_life_executable>";
${life_solver_cmdline}= "<parameters_for_program>";
SIMULIA
Tosca Structure
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Tosca Structure Control
www.3ds.com/tosca
SIMULIA
Tosca Structure
Program Sequence and Data Flow of Tosca Structure
The flow of optimization process is the same for all solver interfaces, only the
solver specific data and file formats are different (see vol.2 chapter 11, Solver
Specific Features).
Loading TOSCA
Configuration
Licensing
tosca_server.err
tosca_server.log
Controlling the
optimization
Directory jobname
Analysis model
FEM2ONF
Model specification in
ONF-format
Parameter file
TOSCA_PREP
optimization_data
base.vtm
Result requests
Start model
FE-Analysis
modell_xxx.res
RES2VTM
FE-Results
TOSCA_OPT
END
Fig. 344 Detailed optimization process with Tosca Structure and data flow
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Specification for
modifications
FEM_MODIF
SIMULIA
Tosca Structure
Tosca Structure Control
tosca_ansa_env
Tosca Structure.gui:
tosca_gui
Input
Option
--job
jobname
--opt
parfilename
--help
--loglevel
Version 8.1.0 Rev. 1 - 05.2014
NOTICE
www.3ds.com/tosca
Comment
INFO (default)
DEBUG
TRACE
--loglevel
_stdout
NOTICE (default)
INFO
DEBUG
TRACE
SIMULIA
Tosca Structure
Starting Tosca Structure
Option
Comment
--stderr
--ow
--restart
Restart of a Tosca Structure optimization job. The restarted optimization job starts with the finite element
analysis.
--solver
abaqus
ansys
marc
mscnastran
permas
--fe_solver_
version
fe solver version
--life
femfat
onf
--life_solver_
version
--type
test1
test2
test3
test4
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Input
SIMULIA
Tosca Structure
Tosca Structure Control
www.3ds.com/tosca
Input
Option
Comment
--smooth
--report
--view
--cpus
<number cpus>
--logfile
<filename>
--loglevels
_exes
<loglevel>:
<executable>,
<loglevel>:
<executable>
--print_
tosca_
includes
no (default)
yes
only
--reuse
Advanced option!
Reuse work directory with ONFfiles. Only changes in parameter file
are regarded. For testing purposes
only.
SIMULIA
Tosca Structure
Starting Tosca Structure
Input
Option
Comment
--restart2
Advanced option!
Restart assuming solver run was
successful.
--restart3
Advanced option!
Restart assuming life-solver run was
successful.
--docu
--run
nohup
--cdb2classic
--modification
_file
The --job name is mandatory, all other parameters are optional. A default
solver can be entered in the configuration file. Otherwise, --solver must be
set.
If only the jobname is given, the name of the parameter file is derived automatically (jobname.par) and the name of the analysis file is extracted from
the FEM_INPUT command in the parameter file.
Remark:
For backwards compatibility commandline parameters may be given with a
single minus, e.g.
--post
--temp
--restart2
--restart3
--aio
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Tosca Structure Control
--out
12.2.2 General
The minimal Tosca Structure call is
tosca810 <jobname>
The name of the parameter file can be derived directly from the jobname. The
file <jobname>.par is loaded in this case.
If it is needed that the jobname directory has a name different from the
parameter file name, use the command line option --opt as follows:
tosca810 <jobname> --opt <parameterfilename>
In this instance, the name of the working directory is specified by the jobname.
The file name for the input file of the FE analysis is entered in the parameter file using the command FEM_INPUT.
www.3ds.com/tosca
12.2.3 Logging
Logging is always done to the command shell and to the file <jobname>/
TOSCA.OUT-file. The following levels can be used.
- WARNING (not recommended) Only WARNINGs and ERRORs are
printed
- NOTICE Default output to STDOUT. Only the most important logging
- INFO
Default output to logfile TOSCA.OUT
- DEBUG
Very verbose output, mostly for support
- TRACE
(not recommended) Extremely verbose,
major performance los, only for developers
Using the command line option --stderr the errors are written on STDERR as
well. This concerns the output for messages with the following log-levels:
ERROR
FATAL
CRITICAL.
If this option is used and the stderr is written to stdout there will be double output for these messages.
SIMULIA
Tosca Structure
Starting Tosca Structure
12.2.3.1 TOSCA.OUT
The logfile TOSCA.OUT is the main logfile of Tosca Structure. The logfile is at
best viewed in a text editor that uses a fixed width font, e.g. Courier New.
The structure of the logging lines is:
(<log tag>) [<time stamp> | <executable>] <message>
Where:
<log tag>
=CRITICAL
=ERROR
=WARNING
=NOTICE
=DEBUG
=TRACE
<time stamp>
<executable>
Interpretation
CRITICAL
ERROR
WARNING
NOTICE
INFO
DEBUG
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Log-tags
SIMULIA
Tosca Structure
Tosca Structure Control
TRACE
www.3ds.com/tosca
Table 49
Extremely verbose output where a major performance los is to be expected. Only for developers
Description of loglevels
SIMULIA
Tosca Structure
Starting Tosca Structure
authorization.log
Logging from Tosca Structures authorization module tosca_server is written
to this file. In case of licensing/authorization problems please look into this file
for details.
signal.log
This logfile will only have a content if the user interrupts the optimization process with a SIGNAL, typically by pressing Ctrl-C in the command prompt.
Tosca Structure will then kill the running subprocess, optionally using a script
defined by the setting $killscripts. See CONFIG for details.
TOSCA_post.OUT
This logfile is generated when using the commandline flags --smooth or -report. This enables the user to generate SMOOTH or REPORT results during a running optimization.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
In Tosca ANSA environment you see the logging to the so-called STDOUT
which means the same as when you would have started Tosca Structure in a
command shell.
SIMULIA
Tosca Structure
Tosca Structure Control
Right click the item and select Edit and change the LOGLEVEL to either
INFO or DEBUG.
Fig. 347 Viewing the TOSCA.OUT logfile from Tosca Structure.gui. Also
highlighted how to request logging on debug level.
www.3ds.com/tosca
SIMULIA
Tosca Structure
Starting Tosca Structure
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Fig. 348 Viewing the TOSCA.OUT logfile from Tosca Extension for
ANSYS/WB.
SIMULIA
Tosca Structure
Tosca Structure Control
Alternatively, its possible to open the TOSCA.out file itself. Right click on
Toscas Solution in the Outline Tree and choose Open Solver Files
Directory, see Fig. 349. The logfile is located in \tosca\TOSCA.out.
Fig. 349 Opening the Solver Files Directory in Tosca Extension for
ANSYS/WB.
The loglevel can be changed in the Analysis Settings.
To increase the amount of output to the command shell set the parameter:
tosca810 --loglevel_stdout <new_loglevel>
www.3ds.com/tosca
Example:
1. Increase loglevel to INFO on the command shell and DEBUG output into
the logfile TOSCA.OUT
tosca810 --loglevel_stdout INFO --loglevel DEBUG ...
SIMULIA
Tosca Structure
Starting Tosca Structure
Runtime
You can view the runtime or elapsed time of each executable in a Tosca
Structure run by searching for the keyword "Elapsed":
(INFO ) [13:20:22|tosca_perl] Elapsed time of fem_include
: 00:00:00 - Actual time: 13:20:22
(INFO ) [13:20:24|tosca_perl] Elapsed time of fem2onf
: 00:00:02 - Actual time: 13:20:24
(INFO ) [13:20:29|tosca_perl] Elapsed time of tosca_prep
: 00:00:05 - Actual time: 13:20:29
(INFO ) [13:20:31|tosca_perl] Elapsed time of fem_modif
: 00:00:02 - Actual time: 13:20:31
(INFO ) [13:21:57|tosca_perl] Elapsed time of abaqus
: 00:01:26 - Actual time: 13:21:57
(INFO ) [13:21:59|tosca_perl] Elapsed time of odb2vtm
: 00:00:02 - Actual time: 13:21:59
(INFO ) [13:22:03|tosca_perl] Elapsed time of tosca_opt
: 00:00:04 - Actual time: 13:22:03
The time format is in HH:MM:SS. In this case we see that Abaqus has run 1
minute and 26 seconds, whereas the optimization module, tosca_opt, only
spent 4 seconds.
How is my FE-solver called?
All calls of executables are written in the logfile TOSCA.OUT. To see how a
certain executable (e.g. your FE-solver) is called, search the file for
"Calling". In the search results you will also see the FE-solver call, e.g.:
(INFO
) [13:29:59|tosca_perl] Calling(17048): "/store2/
app/bin/abaqus" job=shapeV2 analysis interactive --version
6.10-3
--loglevels_exes tosca_prep:debug,tosca_opt:debug
Second option is to use the configuration, see also CONFIG. To get the
same result as the commandline above write in the parameter file:
CONFIG
$loglevels{tosca_prep} = "debug";
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Tosca Structure Control
$loglevels{tosca_opt} = "debug";
END_
www.3ds.com/tosca
SIMULIA
Tosca Structure
Starting Tosca Structure
= <some_id_name>
=
=
=
=
SAVE.onf/<fe-input-file>_fem.onf
SAVE.onf/<last_result>.onf
SAVE.onf/groups.onf
TOSCA_POST/<smooth-id_name>.ext
The modified SMOOTH command is written to a file "<jobname>_post_000.par" in the working directory. After the optimization, Tosca
Structure.smooth is called by Tosca Structure control with this parameter file.
After optimization, a user may want to generate a Tosca Structure.smooth
result with different parameters. This is done by changing the parameters in
the parameter file (<jobname>.par) and calling Tosca Structure as follows:
tosca810 <jobname> --smooth
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SMOOTH
ID_NAME
...
MODEL
RESULT
GROUP_FILE
OUTPUT_FILE
END_
SIMULIA
Tosca Structure
Tosca Structure Control
Templates are found in the installation directory <tosca> in the directory marcos
<tosca>/macros/smooth_template_bead.mac
<tosca>/macros/smooth_template_shape.mac
<tosca>/macros/smooth_template_topo.mac
More information about macro-files are found in the documentation of the
CONFIG-command.
www.3ds.com/tosca
For the first test level, it is required that the following files exist:
SIMULIA
Tosca Structure
Starting Tosca Structure
*.ext
FE-Analysis
Optimization Module
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Test level 1
Optimization Preprocessor
SIMULIA
Tosca Structure
Tosca Structure Control
carried out at this test level, a saving of 70% to 90% in CPU time is achieved
compared with the time needed for a single optimization loop including a FE
analysis of large models.
*.par
*.ext
Test level 2
Optimization Preprocessor
*.ext_res
FE-Analysis
Optimization Module
In this way, several variations can be tested effectively (e.g. different parameter files such as file1.par and file2.par) using an analysis model with the
respective result file before the real optimization is started:
tosca810 job_name --type test2 --opt file1.par
tosca810 job_name --type test2 --opt file2.par
*.par
*.ext
Optimization Preprocessor
Test level 3
www.3ds.com/tosca
FE-Analysis
*.ext
Optimization Module
SIMULIA
Tosca Structure
Starting Tosca Structure
Example:
tosca810 job_name --type test3
Remarks
1. If the same analysis model is to be used several times for test level 3, it is
better to switch to test level 2. To do this, the result file of the FE analysis
has to be copied into the start directory of the optimization from the
SAVE.<res_ext> directory and renamed as <modelname>.<res_ext>.
(During saving in the optimization process, the result files are automatically
given an iteration number this extension must be deleted from the file
name)
2. This test level is not available for sensitivity based topology optimization!
*.par
*.ext
Test level 4
Optimization Preprocessor
*.ext
FE-Analysis
Optimization Module
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Tosca Structure Control
www.3ds.com/tosca
SIMULIA
Tosca Structure
Starting Tosca Structure
insufficient hard disk space and there is no possibility to create more space
on the hard disk, the complete job directory can be transferred to another
hard disk and a restart can be made from there.
After optimization has been stopped, the files that were created during the
optimization can be found either in the directory jobname/DB_ERROR or
(when the control job has been interrupted) in the working directory
(jobname).
At the beginning of a restart, all data is copied into the working directory
(jobname).
Various methods are available for a restart:
Mode: -restart (recommended)
This is the standard restart mode.
Program call:
tosca810 <jobname> -restart
The standard restart is always started with a finite element analysis. This
means, after the required data has been copied, the finite element analysis is
started using the analysis model that was modified last and the optimization
task is then carried out.
Mode: -restart2 (not recommended)
Restart2 is used when the finite element analysis sequence has been completed without any errors but an interruption occurred in the optimization module. The computing time needed for the FE analysis can be saved in this case
and the last result file is used by Tosca Structure for the optimization.
Program call:
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Tosca Structure Control
Remark
1. In order to use the parameter --docu, Adobe Acrobat Reader must be
installed. When installing Tosca Structure, the path for Adobe Acrobat
Reader has to be specified.
www.3ds.com/tosca
Instead of performing only one finite element analysis, Tosca Structureautomatically runs multiple finite element analyses in the order of FILE = ...
parameters in FEM_INPUT. In the example above, first the static analysis and
then the modal analysis are performed.
SIMULIA
Tosca Structure
Configuration
Remarks
1. The model information of the different input files (nodes, elements, groups)
has to be identical. The loads may be different for the different input files.
2. The modifications of the geometry that occur during the optimization are
applied to all input files at once.
12.3 Configuration
The complete program is controlled by a system of variables. To allow user
and model-specific variations, the necessary variables are loaded from several configuration files. The different configuration commands are described
in volume 3: CONFIG.
Remarks
1. The current settings of the environment variables can be checked using the
command
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Tosca Structure Control
tosca -help
and then choosing the heading Information about the Tosca Structure
configuration.
Before starting the program, the system settings are loaded. During installation of the optimization program system, the settings for the variables
used to control the optimization call are made and saved in the file
$tosca/bin/tosca_ctrl.cfg
The system configuration file tosca_ctrl.cfg must contain all necessary
environment variables.
2. The configuration file is written completely in Perl syntax. If you change the
configuration file, take care to follow Perl syntax.
Each user has the possibility to create a user-specific configuration file in
his home directory. Usually user-specific details (e.g. the scope of type of
data back-up during optimization and search paths for macros) are set. The
file is automatically loaded by Tosca Structure before the control program is
called in case that the file
$HOME/tosca_ctrl.cfg
www.3ds.com/tosca
SIMULIA
Tosca Structure
Configuration
Configurable environment
variables
Description
tosca
FED_LICENSE_SERVER_TYPE
FED_LICENSE_FILE
FED_DSLS_LICENSE_CONFIG
FED_DSFLEX_LICENSE_CONFIG
FED_TOSCA_SERVER_OPTIONS
ANSA_SRV
ANSWAIT
home
vtm_cache_size
Internal variables
FED_PRODUCT
COMMON_ENV__
TOSCA_OSDIR
ORIG_DEFAULT_LIB
Description
TSTRUCT
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Tosca Structure Control
Internal variables
Description
LD_LIBRARY_PATH
COMMON_ENV_REPLACE__
fem2onf
tosca_interface
life_interface
tosca_size
FED_ASSERT_DEBUG
www.3ds.com/tosca
SIMULIA
Tosca Structure
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Tosca Structure Control
Configuration
pre_prep
FEM2ONF
post_fem2onf
TOSCA_PREP
post_prep
pre_fem_modif
pre_fem_modif_matrix
FEM_MODIF
post_fem_modif
post_fem_modif_matrix
pre_solver
pre_solver_matrix
FE-Analysis
RES2VTM
post_solver
post_solver_matrix
pre_res2vtm
pre_res2vtm_matrix
post_res2vtm
post_res2vtm_matrix
pre_life
Life-Analysis
www.3ds.com/tosca
post_life
LIFE2VTM
pre_opt
pre_matrix
TOSCA_OPT
post_opt
post_matrix
post_eval
END
Fig. 350 Scripting entry points in Tosca Structure
SIMULIA
Tosca Structure
Script Entry Points
The user may specify an absolute or relative path to a script that is located in
the network. Note that, if relative paths are used, the execution directory is
always the working directory of Tosca Structure.
All user scripts hooks like pre_prep accept _add_call after the hook name.
This means the scripts should contain only the script name with or without
leading path. Parameters submitted to the user script are added in the
_add_call definition:
$pre_prep = "pre_prep_script.pl";
$pre_prep_add_call = "1 2 argument3";
The user may also specify command line calls directly using Perl variables in
scripts. On UNIX systems, one has to be careful to set the command in
quotes in order to avoid problems with the blanks in the command line definition. As the script entry variables are defined in the Perl command syntax of
the configuration, the command line has to be additionally set between \"
signs:
Example:
${pre_prep} = "\" echo just before TOSCA_PREP \"";
Remarks
1. It is not possible anymore to have in the definition of the hook the script
name and the parameters, what was possible in versions prior 7.2. If the
old behaviour is used an ERROR message is thrown informing that the
format has changed.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Tosca Structure Control
=
=
=
=
fem_input
my_solver_file.ext
file1.ext
file2.ext
In both cases "file1.ext" and "file2.ext" must exist in the starting directory and
both files are copied into the working directory right after starting Tosca Structure.
www.3ds.com/tosca
12.5.1 TOSCA_PREP
In optimization preprocessing (TOSCA_PREP), the analysis model and the
commands used to define the optimization problem (see vol.2 chapter 3.1
and vol.3 Commands Manual) are loaded in order to create the optimization
model.
The analysis model exists as a solver input model and is converted before
loading into ONF format using FEM2ONF module.
The optimization problem is defined by either using Tosca ANSA environment, Tosca Structure.pre or an editor.
After the data has been loaded, an internal check run is carried out to ensure
that the optimization model is complete. If the check run is completed successfully, an optimization database is created which is always referred to during the optimization.
When the optimization preprocessor starts, the control program loads the file
$tosca/command.ini automatically. This file contains the pre-settings for the
optimization.
SIMULIA
Tosca Structure
Solver Run
Output protocol file of the optimization in the directory TOSCA_POST (see vol.2 chapter 12.5)
jobname_org.ext
TOSCA_DB
The FE-solver selected using the option --solver in Tosca Structure command line is started after the optimization preprocessing has been successfully completed. The correct paths must be set in order for the program to
start. The paths are set during installation. If the program does not start,
please ask the system administrator for advice or look in the protocol file of
the solver in order to search for possible errors.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Tosca Structure Control
12.7.1 RES2VTM
The program RES2VTM loads the results generated by the solver into the
VTM (Virtual TOSCA Memory) database file.
12.7.2 TOSCA_OPT
The optimization module requires not only the result file from the previous
calculation in ONF format, but also the loads as well as the necessary model
and control information found in the optimization database. The optimization
module is responsible for specifying the model modifications in ONF format.
The optimization loop is completed when the optimization target is achieved
or when a stop condition (e.g., the maximum number of iterations) is fulfilled.
12.7.3 FEM_MODIF
FEM_MODIF module generates the modified analysis model by combining
the initial model with the instructions from TOSCA_OPT. The optimization
database is updated in each iteration.
www.3ds.com/tosca
After the optimization loop has been completed, the directory jobname is
cleaned up. First, all unnecessary files are deleted. The configuration files
determine which files and in what scope (NEVER, FIRST_LAST or EVER)
files are saved or deleted. (see vol.2 chapter 12.3). Different decisions for
wildcards can be made in the configuration files (copy, delete etc.). Further
details can be found in the specification of the CONFIG command.
SIMULIA
Tosca Structure
Completion of the Optimization Process
SAVE.ext: contains the files of the single iterations, with ext being a file
extension. In addition to solver-specific data (input files, protocol files,
result files etc.), solver-independent files (VRML, STL, ONF, etc.) can also
be saved.
TOSCA_POST: Contains the files for postprocessing the optimization
results. In addition, the protocol file TOSCA.OUT can be found in this directory (see vol.2 chapter 12.5). The results of Tosca Structure.smooth are
normally saved in this directory as well.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Troubleshooting
13 Troubleshooting
This section describes methods of identifying and correcting errors that occur
when the program aborts during optimization.
The search of error messages is depending upon when the program stopped
(see Fig. 352) which can be easily identified using the main logfile
TOSCA.OUT in the job-directory (see also vol.2 chapter 12.2.3, Logging). If a
licensing problem is detected the log file authorization.log may be of
interest (see also chapter 12.2.3.2 Special logfiles). In case that the FE-solver
has not completed the analysis one has to look into the respective FE-solvers
log-files.
When the program aborts, all files required for the error search are moved to
the subdirectory DB_ERROR in the jobname directory (see vol.2 chapter
12.8.1). The most frequent sources of errors and the methods for correction
are described in the following sections.
www.3ds.com/tosca
DB_ERROR directory
When the program cancels an optimization, a directory named DB_ERROR
is created in the jobname directory in order to facilitate the error search. This
directory contains all files that are necessary to find the error. These include
the protocol file TOSCA.OUT of the optimization and the protocol files of the
FE solver. In addition, the initial model, parameter file and all files and macros
are present in this directory.
Log files
The most important files used to search for error messages are the log files
(see vol.2 chapter 12.5):
TOSCA.OUT of the optimization: All errors that occur in TOSCA_PREP or
TOSCA_OPT are documented in this file; search it for entries containing
the words CRITICAL, ERROR or WARNING.
authorization.log (see also vol.2 chapter 12.2.3.2, Special logfiles) of the
authorization process (located in the start directory of the optimization):
configuration and licensing information is written to this file.
SIMULIA
Tosca Structure
Determining the Point of Program Termination
SIMULIA
Tosca Structure
Troubleshooting
(INFO
) [20:28:44|tosca_perl] Modifying solver input files
(INFO
) [20:28:44|tosca_perl] Calling(21480): "/store2/develop/tosca/
7.1.0/bin/fem_modif" --loglevel INFO --cycle 004 --solver ansys clip.ans
(INFO
) [20:28:44|fem_modif] TOSCA Structure.fem_modif "
(INFO
) [20:28:44|fem_modif] Reading ONF Mod file clip_mod.onf
(INFO
) [20:28:44|fem_modif] TOSCA Structure.fem_modif successfully
finished
(INFO
) [20:28:44|tosca_perl] Elapsed time of fem_modif
:
00:00:00 - Actual time: 20:28:44
(NOTICE ) [20:28:44|tosca_perl] Starting Ansys analysis - design cycle 4
(INFO
) [20:28:44|tosca_perl] Calling(21496): "/store2/app/bin/ansys"
b -i clip.ans -o clip.erg -s noread -p ansys --version 13.0
(INFO
) [20:28:47|tosca_perl] Elapsed time of ansys
:
00:00:03 - Actual time: 20:28:47
(INFO
) [20:28:47|tosca_perl] Reading results
(INFO
) [20:28:47|tosca_perl] Calling(21604): "/store2/develop/tosca/
7.1.0/bin/res2vtm" --loglevel INFO --cycle 4 --solver ansys clip
(INFO
) [20:28:47|res2vtm] TOSCA Structure.res2vtm - version 7.1.0"
(WARNING ) [20:28:47|res2vtm]
no rst file with basename clip found
(ERROR
) [20:28:47|res2vtm] **** TOSCA Structure ERROR ****
(ERROR
) [20:28:47|res2vtm] emat file clip.emat not found
(ERROR
) [20:28:47|res2vtm] TOSCA Structure.res2onf finished with exit
code 128
www.3ds.com/tosca
Fig. 351 Trouble shooting in TOSCA.OUT. Here, the result reader res2vtm
stop because of missing result files. This reason for this error
should be found in the logfiles of the FE_solver (this case ANSYS)
which has terminated incorrectly.
The following four points of optimization system are known to be the most frequent in which an error may occur:
1. Stop at the start of the program (configuration, licensing and control start).
2. Stop in a preprocessing step (TOSCA_PREP).
3. Stop during a FE analysis.
4. Stop in an optimization step (RES2VTM, TOSCA_OPT, FEM_MODIF).
For a more detailed description of the program sequence please see Fig.
344. When the program is started, the configuration is first loaded and the
licenses are checked. Information regarding this can be found in the protocol
file authorization.log (see also Special logfiles).
Afterwards, the Tosca Structure control program will be started. Protocol information will be printed to the display and to the file TOSCA.OUT.
SIMULIA
Tosca Structure
Determining the Point of Program Termination
The sequence of configuration files that are read in the beginning of the optimization will be logged to TOSCA.OUT:
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
.
------------------------------------------------------------------------|
_______
____
_____
_____
|
|__
__| / __ \ / ____| / ____|
/\
|
| |
| | | || (___ | |
/ \
|
| |
| | | | \___ \ | |
/ /\ \
|
| |
| |__| | ____) || |____ / ____ \
|
|_|
\____/ |_____/ \_____|/_/
\_\
|
|
_____ _
_
|
/ ____| |
| |
|
| (___ | |_ _ __ _
_ ___| |_ _
_ _ __ ___
|
\___ \| __| '__| | | |/ __| __| | | | '__/ _ \
|
____) | |_| | | |_| | (__| |_| |_| | | | __/
|
|_____/ \__|_|
\__,_|\___|\__|\__,_|_| \___|
|
------------------------------------------------------------------------|
|
Starting: OPTIMIZATION CONTROL TOSCA Structure.control
|
TOSCA Structure by FE-DESIGN GmbH
|
TOSCA Structure.topo, TOSCA Structure.shape and
|
TOSCA Structure.bead are registered trademarks and service
|
marks of the FE-DESIGN GmbH
|
|
Copyright(c) 2011 by FE-DESIGN GmbH, all rights reserved
|
------------------------------------------------------------------------|
PERL execution control
|
|
Version 8.1.0
|
|
FE-DESIGN GmbH, Karlsruhe, Germany
|
http:://www.fe-design.de
|
------------------------------------------------------------------------Logging to STDOUT at loglevel NOTICE
Logging appended to log-file "clip/TOSCA.OUT" at loglevel INFO
Generating working directory "clip"
The directory "clip" exists and will be deleted
Logfile: clip/TOSCA.OUT
SIMULIA
Tosca Structure
Troubleshooting
For each module that is started by the control program and finishes, an entry
with information concerning the running time of the module can be found. For
example, in TOSCA_OPT in the fourth iteration:
(NOTICE
www.3ds.com/tosca
The course of the individual processes and cycles can be seen in Fig. 352
and can be followed in the protocol file TOSCA.OUT.
Several points should be checked depending on where the program stop
occurred. These are illustrated in the diagram below (Fig. 352) together with
the protocol files where the error messages are saved. Different error messages, their causes and possible ways of correcting these errors are also
SIMULIA
Tosca Structure
Program Abort at the Start of the Optimization
1. Program start
2. Preprocessing
3. FE analysis
4. Optimization
Installation correct?
Settings correct?
License available?
File names and
command line
parameters correct?
(vol.2 chapter
13.3.1)
authorization.
log
Parameter file:
Syntax correct?
Task completely
defined?
TOSCA.OUT
Error in analysis
model?
License found?
Path settings correct?
Solver
protocol file
TOSCA.OUT
Results available?
Is there enough
storage space?
License available?
TOSCA.OUT
End
Fig. 352 Search for errors when a program is aborted
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Troubleshooting
www.3ds.com/tosca
--------------------------------------------------------------environment TOSCA
: T:\Tosca810
environment HOME
: h:\user
--------------------------------------------------------------jobname
: hole
fe-input File
: hole.bdf
parameter file
: hole.par
fe_solver
: nastran
fe_solver_exe
: "c:/Programme/msc/msc2001/i386/nastran.ex
fe_solver_cmdline
: hole.bdf notify=no old=no
opt_type
: test1
--------------------------------------------------------------Prep-module: "C:/Programme/Tosca810/bin/tosca_prep"
Opt -module: "C:/Programme/Tosca810/bin/tosca_opt"
--------------------------------------------------------------Act Directory : C:/scratch/work/test
jobname
: hole
Workdir
: C:/scratch/work/test/hole
Generate working directory "C:/scratch/work/test/hole"
The directory "C:/scratch/work/test/hole" exists and will be del
SIMULIA
Tosca Structure
Program Abort at the Start of the Optimization
-----------------------------------------------------------------Causes:
Files do not exist
Incorrect Jobname or file name in command line arguments
To locate the error:
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Check for the existence of the necessary files (also the INCLUDE files) in
the local directory or in a directory with the path specified in the parameter
file
SIMULIA
Tosca Structure
Troubleshooting
www.3ds.com/tosca
Messages in TOSCA.OUT
SIMULIA
Tosca Structure
Program Abort in TOSCA_PREP
At the end of TOSCA.OUT file, the list of commands that failed during the
optimization preprocessing is written. Usually the first command in the list has
caused the error. The following commands fail because they reference the
first command.
Causes (as follows from TOSCA.OUT file):
Incorrect or missing definitions in the parameter file (syntax error):
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Troubleshooting
If the result file of the FE program has not been generated, the following error
message appears:
www.3ds.com/tosca
SIMULIA
Tosca Structure
Program Abort During FE Analysis
Message:
(INFO
(INFO
(INFO
(ERROR
(ERROR
(ERROR
(ERROR
)
)
)
)
)
)
)
Cause:
Error in the analysis model
To locate the error:
Check the analysis model using a simple FE analysis (not using optimization-specific entries)
Check if all necessary files for the optimization have been created (e.g.,
op2 file from MSC Nastran) and check the optimization-specific entries in
the analysis model. vol.2 chapter 11 gives a description of the required FE
program-specific settings.
Correction:
Modify the analysis model.
Remark:
USER
FATAL
MESSAGE 9050 (SEKRRS)
RUN TERMINATED DUE TO EXCESSIVE PIVOT RATIOS IN MATRIX KLL.
This could be solved (see chapter 11.4.1 Files and Formats) by changing
the MAXRATIO parameter in the bulk data section of the input deck like,
e.g.:
PARAM,MAXRATIO,10.E10
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Troubleshooting
www.3ds.com/tosca
The path settings for the solver are set in the configuration file during the
installation of Tosca Structure (see Installation Manual and vol.2 chapter
12.3). If the solver is not found, then a check run should be made. Tosca
Structure.gui loads these settings from the configuration file. In Edit Configuration screen of Tosca Structure.gui, press "Reset to Defaults" button in order
to view these settings. In case that different settings are to be used, they have
to be set manually in this window.
SIMULIA
Tosca Structure
Program Abort in the Optimization Module
-------------------------------------------------------ERROR in TOSCA_OPT
In TOSCA.OUT:
Cause:
Strongly distorted elements can appear in shape optimization if the displacements are too large or the mesh modification caused by the displacements of the design nodes is done in an unfavorable manner. It causes the
solver to fail during FE analysis.
Locating the error:
First check the error file of the solver to see if any information concerning
the distorted elements is available.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Troubleshooting
Check the mesh in the FE preprocessor, find the place where it became
distorted. Usually, more information can be found from the analysis of the
incorrectly calculated iterations. It should be checked if the optimization
boundary conditions have been set correctly (care should be taken with the
AUTO_FIX function, as all surface nodes that do not have DOF restrictions
will be fixed).
Correction:
Reduce the limits for displacements.
If none of these methods help: mesh the model in such a way that the surface changes only lead to a slight distortion of the mesh.
www.3ds.com/tosca
SIMULIA
Tosca Structure
Tosca ANSA environment Specific Tips
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Troubleshooting
4. When selecting groups in Tosca ANSA environment, make sure that the
objects you select (nodes or elements) match the type of the group. If the
caption of the field where the group name is to be selected says ND_GROUP
(as in DESIGN_AREA command for shape or bead optimization), set the
selection mode to node selection by highlighting the line in Database
corresponding to nodes; if it says EL_GROUP (as in DESIGN_AREA
command for topology optimization), the elements should be selected and
thus the line Elements of Database should be highlighted. To highlight a
line in Database, simply click it once; in case of selecting elements, make
sure that the check box in the line is checked, otherwise the elements are
hidden. If a group of inappropriate type is selected, an empty group will
appear in Tosca Structure parameter file, and Tosca Structure run will fail.
www.3ds.com/tosca
SIMULIA
Tosca Structure
Tosca ANSA environment Specific Tips
8. The options of Tosca ANSA environment are edited in the dialog opened by
Windows | Options... menu command (Fig. 355). The buttons "Save"
and "Save as" in Settings panel allow to save the configuration of Tosca
ANSA environment, including the paths to Tosca Structure and the solvers.
Saving the settings in a temporary file is a quick way to check the current
configuration.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Appendix
14 Appendix
This chapter specifies functionalities covered by Tosca Structure.advanced
Licensing. Further limits of Tosca Structure are listed and the macros provided in the installation are described.
www.3ds.com/tosca
SIMULIA
Tosca Structure
Additional Tosca Structure optimization modules
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Appendix
Limited by
Number of nodes
unlimited
authorization
Number of elements
unlimited
authorization
999
program
20.000
program
20.000
program
unlimited
program
Limits of Optimization
www.3ds.com/tosca
Number
Limited by
unlimited
program
unlimited
program
500
program
40
60
program
500
60
program
50
program
10
program
999
program
Shape optimization
Number
Limited by
SIMULIA
Tosca Structure
Predefined Output Macros
unlimited
program
unlimited
program
Topology optimization
Number
Limited by
unlimited
authorization
500
program
Bead optimization
Number
Limited by
500
program
500
program
Description
Stop condition: Variation of
ctrl_inp is smaller than 1% of
start value or maximum optimization displacement is smaller
than 1% of start displacement
Output Files
no output, program stops
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Appendix
Description
Output Files
stop_2.mac
uf_elem_prop.mac
ELEM_PROP.TXT
uf_group_onf.mac
GROUPS.onf
uf_model_onf.mac
MODEL_fem.onf
uf_model_onf_last.mac
LAST_MODEL_fem.onf
uf_model_onf_ever.mac
MODEL_xxx.onf
uf_shape_onf.mac
SHAPE_xxx.onf
uf_topo_onf.mac
TP_xxx.onf
uf_bead_onf.mac
BEAD_xxx.onf
uf_sizing_onf.mac
SIZING_xxx.onf
www.3ds.com/tosca
Name of Macro
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Predefined Output Macros
Volume III
Commands Manual
www.3ds.com/tosca
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
SIMULIA
Tosca Structure
CONFIG
CONFIG
The CONFIG commands are used to set and overwrite the Tosca Structure
8.1.0 configuration parameters. The different configuration files (installation,
user defined, job defined) are overwritten. For more detailed information see
vol.2 chapter 12.3, Configuration.
General Information
Configuration
Parameter
Example
Remarks
${tosca}
${tosca} =
"/app/tosca/
Tosca810";
www.3ds.com/tosca
${tosca} =
$ENV{tosca};
${tosca_prep}
${tosca_prep} =
"${tosca}/bin/
tosca_prep";
${tosca_prep_add_call
}
${tosca_prep_add_call
}="";
${tosca_opt}
${tosca_opt} =
"${tosca}/bin/
tosca_opt";
${tosca_opt_add_call}
${tosca_opt_add_call}
="";
${ask_before_delete}
${ask_before_delete}=
"yes";
${ask_before_delete})
="no";
${__FE_FILE__}
${__LIFE_MODEL__}
Commands Manual 3 - 3
SIMULIA
Tosca Structure
${__LIFE_FILE__}
Example
1. See the global configuration tosca_ctrl.cfg. The above variables are used
for every call to FE-solvers and LIFE-solvers.
2. Calling a script before the solver is called with the name of the FE-input
deck:
$pre_solver = "my_script";
$pre_solver_add_call = " ${__FE_FILE__}";
The resulting call from Tosca Structure running the example "holeplate.par"
for Abaqus:
> my_script holeplate.inp
Configuration
Parameter
Example
Remarks
${fe_solver}
${fe_solver} =
"abaqus";
Specification of the finite element solver interface. The following solvers are supported:
Abaqus, ANSYS, MSC Nastran, PERMAS, Marc.
${fe_solver_exe}
${fe_solver_exe} =
"C:/solver/solver.exe";
3 - 4 Commands Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
FE Solver Information
SIMULIA
Tosca Structure
CONFIG
Example
Remarks
${fe_solver_cmdline}
${fe_solver_cmdline} =
"job=
${__FE_MODEL__}";
${fe_solver_add_call}
${fe_solver_add_call}
= "mem = 100Mb";
${fe_check_file}
${fe_check_file}=
"${__FE_MODEL__}.
f06";
${fe_check_string}
${fe_check_string}=
"FATAL MESSAGE";
${fe_check_type}
${fe_check_type} =
"failed";
$fe_check_file =
"succeeded";
www.3ds.com/tosca
Configuration
Parameter
Remark
1. The solver call is assembled by the $fe_solver_exe, $fe_solver_cmdline
and $fe_solver_add_call variables during the runtime, i.e.:
> $fe_solver_exe $fe_solver_cmdline $fe_solver_add_call
Commands Manual 3 - 5
SIMULIA
Tosca Structure
Configuration
Parameter
Example
Remarks
${life_solver}
${life_solver} =
"femfat";
${life_solver_exe}
${life_solver_exe} =
"/app/..";
${life_solver_add_call}
${life_solver_add_call}
= "/scratch";
${life_ini}
${life_ini} = "...";
3 - 6 Commands Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Durability Information
SIMULIA
Tosca Structure
CONFIG
Remark
The LIFE solver call is assembled by the $life_solver_exe,
$life_solver_cmdline and $life_solver_add_call variables during the runtime
in the same way as FE-solver, see previous example.
> $life_solver_exe $life_solver_cmdline
$life_solver_add_call
www.3ds.com/tosca
Configuration
Parameter
Example
Remarks
${fem_modif}
${fem_modif} =
"${tosca}/bin/
fem_modif";
${fem_modif_
add_call}
${fem_modif_add_
call} =
" --loglevel warning
--logfile
TOSCA.OUT\@info";
${fem2onf}
${fem2onf} =
"${tosca}/bin/fem2onf";
${fem2onf_add_call}
${fem2onf_add_call} =
" --loglevel warning logfile
TOSCA.OUT\@info";
${res2vtm}
${res2vtm} =
"${tosca}/bin/res2vtm";
${res2vtm_add_call}
${res2vtm_add_call} =
" --loglevel warning logfile
TOSCA.OUT\@info";
${life2vtm}
${life2vtm} =
"${tosca}/bin/life2vtm";
${life2vtm_add_call}
${life2vtm_add_call} =
" --loglevel warning logfile
TOSCA.OUT\@info";
Commands Manual 3 - 7
SIMULIA
Tosca Structure
Remarks
1. To make fem2onf skip the PARAM,POST,-1 check in Nastran Interface you
can add the CONFIG-block:
$fem2onf_add_call = "--ignore_ppr 1";
The above setting is NOT recommended.
2. Changing the default result reading for Abaqus from FIL-file to SIM-file is
done adding the following command in the parameter file or generally,
adding the command in the tosca_ctrl.cfg:
CONFIG
...
$fem_modif_add_call = "--format_matrices sim";
$res2vtm_add_call = "--format_matrices sim";
...
END_
Using the SIM-file is recommended for Abaqus 6.13 or higher and for sizing
and sensitivity based shape and bead optimization.
${tosca_smooth}
${tosca_smooth} =
"${tosca}/bin/
tosca_smooth";
${tosca_smooth_
add_call}
${tosca_smooth_add_
call} = " -logfile
TOSCA.OUT\@info";
${tosca_report}
"${tosca}/bin/
tosca_report";
${tosca_report_add_c
all}
${tosca_report_add_
call} = " -logfile
TOSCA.OUT\@info";
$post_file_replacemen
ts{text_to_find} =
"replace_text";
$post_file_replacemen
ts{__JOB_NAME__} =
"\$jobname";
3 - 8 Commands Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
CONFIG
${post_overwrite} =
"<option>";
${post_overwrite}
="yes";
Remarks
1. Tosca Structure will execute Tosca Structure.report and Tosca Structure.smooth automatically at the end of a successfull optimization. If
REPORT or SMOOTH commands are present these will be executed.
Also, if the OPTIONS DEFAULT_REPORT=ON or
DEFAULT_SMOOTH=ON Tosca Structure will create files called
tosca_structure_report.par, tosca_structure_smoothing_vol.par or
tosca_structure_smoothing_iso.par. These files are based on the configuration file in macro-directory in installation:
tosca_def_smooth_report_template.mac.
2. The above files all include the string __JOBNAME__. This string is replaced
with the $jobname according to the jobname of the running REPORT or
SMOOTH job.
www.3ds.com/tosca
List definitions
Configuration
Parameter
Example
Remarks
set_move_per_iter_list
(lab1, lab2, lab3 )
set_move_per_iter_list
("ever", "SAVE.fil",
"name.ext");
Commands Manual 3 - 9
Configuration
Parameter
Example
Remarks
add_move_per_iter_
list (lab1, lab2, lab3)
add_move_per_iter_
list("first_last",
"SAVE.fil",
"name.ext");
set_move_per_iter_
xxx_list(lab1, lab2,
lab3 )
set_move_per_iter_
xxx_list("ever",
"SAVE.fil",
"name.ext");
add_move_per_iter_
xxx_list (lab1, lab2,
lab3)
add_move_per_iter_
xxx_list("first_last",
"SAVE.fil",
"name.ext");
set_copy_solver_info_
list (lab1, lab2, lab3)
set_copy_solver_info_
list("first_last",
"SAVE.fil",
"name.ext");
add_copy_solver_
info_list (lab1, lab2,
lab3)
add_copy_solver_
info_list("first_last",
"SAVE.fil",
"name.ext");
set_move_after_opt_
list (lab1, lab2, ...,
labn)
set_move_after_opt_
list("SAVE.wrl",
"*.wrl");
add_move_after_opt_
list (lab1, lab2, ...,
labn)
add_move_after_opt_
list("SAVE.txt",
"liste.txt",
"result_*.txt");
set_opt_db_list(lab1,
..., labn)
set_opt_db_
list("TOSCA.DB");
add_opt_db_list(lab1,
..., labn)
add_opt_db_
list("TOSCA.DB");
set_include_search_
path(lab1, ..., labn)
set_include_search_
path("$tosca/bin/
macros");
3 - 10 Commands Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
SIMULIA
Tosca Structure
CONFIG
Configuration
Parameter
Example
Remarks
add_include_search_
path(lab1, ..., labn)
add_include_search_
path("$tosca/bin/
macros");
set_delete_after_opt_
list(lab1, ..., labn)
set_delete_after_opt_
list("*.log", "*.temp");
add_delete_after_opt_
list(lab1, ..., labn)
add_delete_after_opt_
list("*.log", "*.temp");
set_delete_per_iter_
list(lab1, ..., labn)
set_delete_per_iter_
list("*.MASTER",
"*.DBALL" )
add_delete_per_iter_
list(lab1, ... , labn)
add_delete_per_iter_
list("*.MASTER",
"*.DBALL" )
Configuration
Parameter
Example
Remarks
${pre_prep}
${pre_prep} =
"<script-name>";
${pre_prep}
${pre_prep_add_call}
${post_fem2onf}
${post_fem2onf} =
"<script-name>";
${post_prep}
${post_prep} =
"<script-name>";
${pre_fem_modif}
${pre_fem_modif} =
"<script-name>";
${post_fem_modif}
${post_fem_modif} =
"<script-name>";
www.3ds.com/tosca
Script calls
Commands Manual 3 - 11
Configuration
Parameter
Example
Remarks
${pre_solver}
${pre_solver} =
"<script-name>";
${post_solver}
${post_solver} =
"<script-name>";
${pre_res2vtm}
${pre_res2vtm} =
"<script-name>";
${post_res2vtm}
${post_res2vtm} =
"<script-name>";
${pre_life}
${pre_life} =
"<script-name>";
${pre_lifepre_life_add
_call}
${pre_life_add_call}=""
;
Options
${post_life}
${post_life} =
"<script-name>";
${post_life_add_call}
${post_life_add_call}=
"";
Options
${pre_opt}
${pre_opt} =
"<script-name>";
${pre_opt_add_call}
${pre_opt_add_call}="
";
Options
3 - 12 Commands Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
SIMULIA
Tosca Structure
www.3ds.com/tosca
CONFIG
Configuration
Parameter
Example
Remarks
${post_opt}
${post_opt} =
"<script-name>";
${post_opt_add_call}
${post_opt_add_call}=
"";
Options
${post_eval}
${post_eval} =
"<script-name>";
${post_eval_add_call}
${post_eval_add_call}
="";
Options
${pre_smooth}
${pre_smooth}=
"<script-name>";
${pre_smooth_add_ca
ll}
${pre_smooth_add_ca
ll}="";
Options
${post_smooth}
${post_smooth}=
"<script-name>";
${post_smooth_add_c
all}
${post_smooth_add_c
all}="";
Options
${pre_report}
${pre_report}=
"<script-name>";
${pre_report_add_call}
${pre_report_add_call}
="";
Options
${post_report}
${post_report}=
"<script-name>";
${post_report_add_cal
l}
${post_report_add_cal
l}="";
Options
${pre_fem_modif_
matrix}
${pre_fem_modif_
matrix} =
"<script-name>";
${pre_fem_modif_matr
ix_add_call}
${pre_fem_modif_matr
ix_add_call}="";
Options
Commands Manual 3 - 13
Configuration
Parameter
Example
Remarks
${post_fem_modif_
matrix}
${post_fem_modif_
matrix} =
"<script-name>";
${post_fem_modif_ma
trix_add_call}
${post_fem_modif_ma
trix_add_call}="";
Options
${pre_solver_matrix}
${pre_solver_matrix} =
"<script-name>";
${pre_solver_matrix_a
dd_call}
${pre_solver_matrix_a
dd_call}="";
Options
${post_solver_matrix}
${post_solver_matrix}
= "<script-name>";
${post_solver_matrix_
add_call}
${post_solver_matrix_
add_call}="";
Options
${pre_res2vtm_matrix}
${pre_res2vtm_matrix}
= "<script-name>";
${pre_res2vtm_matrix
_add_call}
${pre_res2vtm_matrix
_add_call}="";
Options
${post_res2vtm_
matrix}
${post_res2vtm_
matrix}=
"<script-name>";
${post_res2vtm_matri
x_add_call}
${post_res2vtm_matri
x_add_call}="";
Options
${pre_matrix}
${pre_matrix} =
"<script-name>";
${pre_matrix_add_call
}
${pre_matrix_add_call
}="";
Options
${post_matrix}
${post_matrix} =
"<script-name>";
${post_matrix_add_cal
l}
${post_matrix_add_cal
l}="";
Options
3 - 14 Commands Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
SIMULIA
Tosca Structure
CONFIG
Configuration
Parameter
Example
Remarks
${fe_solver_script}
${fe_solver_script} =
"<script-name>";
${execute_as_ perl_ext} =
"<script extension>";.
${life_solver_script}
${life_solver_script} =
"<script-name>";
www.3ds.com/tosca
${execute_as_ perl_ext} =
"<script extension>";.
${fe_solver_submit_ch
eck}
${fe_solver_submit_ch
eck}= "<script-name>";
User-implemented script.
Returns:
0 - Job successfully completed
1 - Job ended with an error
5 - Job is still running
${fe_solver_submit_ch
eck_cmdline}
${fe_solver_submit_ch
eck_cmdline}=
"<options>";
${fe_solver_submit_int
erval}
${fe_solver_submit_int
erval} = 30
${fe_solver_submit_ti
me_out}
${fe_solver_submit_ti
me_out} = 3600
${life_solver_submit_c
heck}
${life_solver_submit_c
heck}= "<scriptname>";
User-implemented script.
Returns:
0 - Job successfully completed
1 - Job ended with an error
5 - Job is still running
Not allowed for MSC.Fatigue
and Falancs
${life_solver_submit_c
heck_cmdline}
${life_solver_submit_c
heck_cmdline}=
"<options>";
Commands Manual 3 - 15
SIMULIA
Tosca Structure
Configuration
Parameter
Example
Remarks
${life_solver_submit_i
nterval}
${life_solver_submit_i
nterval} = 30
${life_solver_submit_ti
me_out}
${life_solver_submit_ti
me_out} = 3600
Remarks
1. See also the Fig. 350 for a graphical view of where in the Tosca Structure.control workflow the scripts are called.
2. All scripts should be in the starting directory ($startdir). The script will be
executed within the Tosca Structure working directory, similar to:
> cd $workdir
> $start_dir/$your_script <arguments ...>
3. For the reason above your script should not use any absolute paths.
4. Versions of Tosca Structure prior 7.2 allowed to use the following syntax,
which will now lead to an error message( "Wrong configuration settings"):
THIS IS NOT ALLOWED:
$pre_prep = "echo 1 & echo 2 & my_script.cmd 3";
$pre_prep = "pre_prep_script.pl";
$pre_prep_add_call = "1 2 argument3";
3 - 16 Commands Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
5. With Tosca Structure 8.1.0 you should make a script which contains all
these 3 calls using perl scripts or native OS scripts.
If you need additional parameters to be supplied to your script by your
configuration use the newly introduced _add_call for user scripts:
THIS IS THE CORRECT WAY:
SIMULIA
Tosca Structure
CONFIG
Example:
CONFIG
${execute_as_perl_ext} ="pl";
${fe_solver_script} = "fe_solver_script_queing.pl";
END_
www.3ds.com/tosca
Commands Manual 3 - 17
SIMULIA
Tosca Structure
especially by large files. Please contact your local Tosca Structure support
for further information.
10.The keyword DEPENDENT_FILE in FEM_INPUT can be used together
with ${fe_solver_submit_check} and ${life_solver_submit_check} to ensure
that dependent steps are performed in the right order. Please contact your
local Tosca Structure support for further information.
Additional variables
These variables may only be used for new definitions. They should not be
overwritten.
${startdir}
${jobname}
${parfile}
${modelfile}
${parname}
${modelname}
${opt_ext}
Other settings
add_files_to_work_dir
("file1.ext","file2.txt");
Obsolete: Use
FEM_INPUT COPY_FILE
instead.
lab1 - labn: Sets the list of files
that additionally should be
copied into the working directory. Wild card (*) is NOT
allowed. The files must exist
by Tosca Structure 8.1.0 start.
set_dos2unix_
list(lab1, ..., labn);
set_dos2unix_
list("*.par");
add_dos2unix_
list(lab1, ..., labn);
add_dos2unix_
list("*.par");
3 - 18 Commands Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
add_files_to_work_
dir(lab1, ..., labn);
SIMULIA
Tosca Structure
CONFIG
$allow_absolute_
include_paths= <int>;
$allow_absolute_
include_paths =1;
$print_tosca_includes
= "no";
tosca <jobname>
print_tosca_includes
only.
$TOSCA_KEEP_
BACKSLASH =
<string>;
www.3ds.com/tosca
${script} =
"USE_DEFAULT_
SCRIPT";
$TOSCA_KEEP_
BACKSLASH
="TOSCA_KEEP_
BACKSLASH";
${pre_fem_modif_
matrix} =
"USE_DEFAULT_
SCRIPT";
is NOT recommended!
$filename =~ /
${script}/i;
The found script with name
"$filename" will be called.
${execute_as_
perl_ext} =
"<script extension>";
${execute_as_
perl_ext} ="pl";
Commands Manual 3 - 19
SIMULIA
Tosca Structure
$killscripts{<executable name} =
"<action>"
$killscripts{abaqus} =
"${fe_solver_exe}
job=__FE_MODEL__
terminate";
Certain solvers may have special ways of terminating on interupt signals. Tosca Structure
searches the $killscripts keys
(<executable name>) and
calls the given <action> if one
is derfined. The default action
is to pass the interupt signal
on the the child process (fesolver, life-solver, optimization
module etc.)
$copy_tosca_out_on_
success = "yes"/"no";
$copy_tosca_out_on_
success = "yes";
Remarks
1. The Tosca Structure configuration is completely defined in PERL syntax. It
is important to generate correct perl codes when creating user defined
configuration settings.
The variable values are enclosed in quotation marcs. Each command must
end with a semicolon.
All Perl statements (i.e. if, ...) may be used in the configuration files.
A more detailed perl documentation may be found in the world wide web:
www.perl.com.
installation configuration
$tosca/bin/tosca_ctrl.cfg
user configuration
$HOME/tosca_ctrl.cfg
job configuration
parameter file
3 - 20 Commands Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
CONFIG
www.3ds.com/tosca
Commands Manual 3 - 21
SIMULIA
Tosca Structure
Hereby are all Tosca Structure.control variables accesible. All variables can
be seen in the "tosca.restart" file if the optimization has not ended correctly.
The most important arrays are @{$::cf{model_list}} and @{$::cf{life_list}}
which lists the FE-solver and life-solver input decks, respectively.
If the script has arguments they will be parsed to the usual @ARGV variable and available as when calling the perl script on the command line.
Examples
CONFIG
add_move_per_iter_list("first_last", "SAVE.op2",
"my_model.op2");
add_move_after_opt_list("SAVE.txt", "my_results.txt");
$fe_solver_exe
= "/usr/bin/nastran";
$fe_solver_call = "$fe_solver_exe $modelfile -batch=no notify=no";
END_
CONFIG
$pre_prep = "my_test.pl will now test my perl-script";
$execute_as_perl_ext = "pl";
END_
The above configuration will then print the following line the logfile before the
preprocessor:
1 : now
2 : test
3 : my
4 : perl-script
3 - 22 Commands Manual
$abaqus_datacheck =
"yes";
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
0 : will
SIMULIA
Tosca Structure
CONFIG
$flatten_abaqus_input
= "yes";
www.3ds.com/tosca
$flatten_abaqus_input
= <option>;
Commands Manual 3 - 23
SIMULIA
Tosca Structure
CONSTRAINT
Definition of an equality or inequality (less or equal/ greater or equal) constraint. The constraint is defined with respect to a design response. For more
detailed information see vol.2 chapter 4.3, Constraints
ID_NAME
= <name_of_constraint>
DRESP
= <name_of_dresp>
MAGNITUDE = ABS
= REL
EQ_VALUE
= <value>
GE_VALUE
= <value>
LE_VALUE
= <value>
Remarks
1. Only one ITEM of the following list of ITEMs can be used within a constraint
definition:
3 - 24 Commands Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
- EQ_VALUE
- GE_VALUE
- LE_VALUE
SIMULIA
Tosca Structure
CONSTRAINT
=
=
=
=
my_constraint
volume_part_1
REL
0.8
END_
ID_NAME
DRESP
MAGNITUDE
EQ_VALUE
=
=
=
=
bead_height_constraint
dresp_bead_height
ABS
20.0
END_
www.3ds.com/tosca
CONSTRAINT
Commands Manual 3 - 25
SIMULIA
Tosca Structure
CONTOURPLOT
The CONTOURPLOT command combines result data to a fringe plot later
referenced in a postprocessing report (REPORT command). For more
detailed information see vol.2 chapter 10.1, Generation of Postprocessing
Data.
=
<id_name_of_contourplot>
TITLE
= <title>
DESCRIPTION
TYPE_
PROPERTY
This parameter is
required in every contour
plot described in the
parameter file:
model
model with groups
relative material value
continuous value for elements
shell element thickness
shell thickness change
continuous nodal value
displacement for nodes
FRINGE_
RESULT
DISP_
RESULT
= <displacement result
name>
FILTER
= <min>
= <max>
FRINGE
= <min>
= <max>
Default: AUTO
3 - 26 Commands Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
ID_NAME
SIMULIA
Tosca Structure
www.3ds.com/tosca
CONTOURPLOT
GROUP_
FILE
GROUP
= <name of group>
ITERATION
= <sequence of numbers in
TOSCA numbering style>
e.g. 3,4-9:2,17
= ALL
= ORIGINAL
= LAST
LEGEND_
TITLE
= <name of legend>
REVERT_
LEGEND_
COLORING
=YES
=NO
ADD_UNDEFORMED
_MODEL
=YES
=NO
Examples
For topology optimization:
CONTOURPLOT
ID_NAME
= TOPO_MAT
TYPE_PROPERTY = ELEMENT_FILL_FILTER
TITLE
= "Relative Material Distribution,
soft elements filtered"
DESCRIPTION
= "TOSCA Structure.topology
Commands Manual 3 - 27
SIMULIA
Tosca Structure
FRINGE_RESULT
FILTER
ITERATION
GROUP_FILE
Optimization Result"
= MAT_PROP_NORMALIZED
= 0.05,1
= ALL
= "SAVE.onf/GROUPS.onf"
END_
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
END_
3 - 28 Commands Manual
SIMULIA
Tosca Structure
CS_DEF
CS_DEF
Defines coordinate systems with reference to an existing coordinate system
or three nodes. For more information refer to vol.2 chapter 3.8, Coordinate
Systems (CS_DEF).
ID_NAME
= <name_of_coord_system>
CS_TYPE
= RECTANGULAR
= CYLINDRICAL
= SPHERICAL
DEF_TYPE
= LOCAL
= NODE
CS_REF
= <name_of_coord_system>
ORIGIN_123
= <coord_1>, <coord_2>,
<coord_3>
ROTATION_
321
www.3ds.com/tosca
CS_AXIS
NODE_
ORIGIN
= X_XZ
= Z_XZ
= <node_id_of_origin>
Commands Manual 3 - 29
SIMULIA
Tosca Structure
NODE_AXIS
= <node_id_on_axis>
NODE_
PLANE
= <node_id_on_plane>
Remarks
1. The rotation angle in the command ROTATION_321 is in degrees. The
single rotations are carried out around the axis of the global cartesian coordinate system.
Examples
The following command defines a cylindrical coordinate system with origin
(10,20,0) with respect to the global cartesian coordinate system CS_0. The
polar axis and longitudinal axis are obtained by rotating the x-axis and z-axis
of CS_0 respectively by 45 around the z-axis and by 15 around the y-axis of
CS_0.
CS_DEF
ID_NAME
CS_TYPE
DEF_TYPE
CS_REF
ORIGIN_123
ROTATION_321
=
=
=
=
=
=
my_cs_01
CYLINDRICAL
LOCAL
cs_0
10.0, 20.0, 30.0
45.0, 15.0, 0.0
END_
CS_DEF
ID_NAME
CS_TYPE
DEF_TYPE
CS_AXIS
NODE_ORIGIN
NODE_AXIS
NODE_PLANE
END_
3 - 30 Commands Manual
=
=
=
=
=
=
=
my_cs_02
RECTANGULAR
NODE
X_XY
10
100
101
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
The following command defines a rectangular (cartesian) coordinate system with origin through the node with ID number 10. The x-axis is defined
by the nodes 10 and 100. Node 101 defines a point in the xy-plane.
SIMULIA
Tosca Structure
DRESP
DRESP
The Design Response command defines the system response for the current
analysis model. The DRESP command extracts one scalar value from a given
result field. Permitted dimensions can be load case independent or load case
dependent (parameter DEF_TYPE = SYSTEM) as well as certain combinations of values (parameter DEF_TYPE = OPER).
The design responses are referenced in the definition of the constraints and
the objective functions. For a general overview of design responses see vol.2
chapter 4.4, Design Responses, more detailed information about their use
can be found in vol.2 chapter 5, Topology Optimization, vol.2 chapter 6,
Shape Optimization and vol.2 chapter 7, Bead Optimization in the Tosca
Structure 8.1.0 user manual.
ID_NAME
= <id_name_of_dresp>
DEF_TYPE
= SYSTEM
= OPER
www.3ds.com/tosca
LIST
TYPE
No output of values.
= LIST
= LIST_HIS
Commands Manual 3 - 31
SIMULIA
Tosca Structure
TOPO_CONTROLLER
ABQ_ND_
PEEQ
TOPO_S
TOPO_SENSITIVITY
SHAPE_C
BEAD_HEIGHT
BEAD_C
CENTER_
GRAVITY_X
TOPO_S
SIZE
BEAD_S
TOPO_S
SIZE
BEAD_S
CENTER_
GRAVITY_Y
TOPO_S
SIZE
BEAD_S
TOPO_S
SIZE
BEAD_S
CENTER_
GRAVITY_Z
TOPO_S
SIZE
BEAD_S
TOPO_S
SIZE
BEAD_S
SHAPE_C
DAMAGE
3 - 32 Commands Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
TOPO_C
Description
SIZING_SENSITIVITY
BEAD_SENSITIVITY
usable as
OBJ_FUNC
SIZE
BEAD_S
usable as
CONSTRAINT
SHAPE_CONTROLLER
Selection
area
SHAPE_C
Loadcase
dependent
BEAD_CONTROLLER
Variable Type
BEAD_C
SIMULIA
Tosca Structure
www.3ds.com/tosca
DENSITY_
MEASURE
Description
Selection
area
usable as
OBJ_FUNC
Loadcase
dependent
DAMAGE_LC
usable as
CONSTRAINT
Variable Type
DRESP
SHAPE_C
TOPO_S
TOPO_S
Measurement of the
amount of intermediate densities.
DISP_ABS
BEAD_S
SIZE
TOPO_S
BEAD_S
SIZE
TOPO_S
DISP_X
BEAD_S
SIZE
TOPO_S
BEAD_S
SIZE
TOPO_S
Nodal displacement
in x-direction for
global coordinate
system or in an user
defined coordinate
system.
DISP_X_ABS
BEAD_S
SIZE
TOPO_S
BEAD_S
SIZE
TOPO_S
DISP_Y
BEAD_S
SIZE
TOPO_S
BEAD_S
SIZE
TOPO_S
Nodal displacement
in y-direction for
global coordinate
system or in an user
defined coordinate
system.
DISP_Y_ABS
BEAD_S
SIZE
TOPO_S
BEAD_S
SIZE
TOPO_S
Commands Manual 3 - 33
Loadcase
dependent
Selection
area
usable as
CONSTRAINT
usable as
OBJ_FUNC
Description
DISP_Z
BEAD_S
SIZE
TOPO_S
BEAD_S
SIZE
TOPO_S
Nodal displacement
in z-direction for
global coordinate
system or in an user
defined coordinate
system.
DISP_Z_ABS
BEAD_S
SIZE
TOPO_S
BEAD_S
SIZE
TOPO_S
DYN_FREQ
BEAD_S
SIZE
TOPO_S
BEAD_C
BEAD_S
SHAPE_C
SIZE
TOPO_S
Eigenfrequency from
modal analysis.
DYN_FREQ_
KREISSEL
BEAD_S
SHAPE_C
SIZE
TOPO_S
SIZE
TOPO_S
SIZE
TOPO_S
Energy stiffness
measure
ENERGY_
STIFF_
MEASURE
INERTIA_XX
TOPO_S
SIZE
BEAD_S
TOPO_S
SIZE
BEAD_S
Moment of inertia
around x-x-direction.
INERTIA_XY
TOPO_S
SIZE
BEAD_S
TOPO_S
SIZE
BEAD_S
Moment of inertia
around x-y-direction.
INERTIA_XZ
TOPO_S
SIZE
BEAD_S
TOPO_S
SIZE
BEAD_S
Moment of inertia
around x-z-direction.
INERTIA_YY
TOPO_S
SIZE
BEAD_S
TOPO_S
SIZE
BEAD_S
Moment of inertia
around y-y-direction.
3 - 34 Commands Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Variable Type
SIMULIA
Tosca Structure
SIMULIA
Tosca Structure
usable as
OBJ_FUNC
Description
TOPO_S
SIZE
BEAD_S
TOPO_S
SIZE
BEAD_S
Moment of inertia
around y-z-direction.
INERTIA_ZZ
TOPO_S
SIZE
BEAD_S
TOPO_S
SIZE
BEAD_S
Moment of inertia
around z-z-direction.
INTERNAL_
FORCE_ABS
NE
BEAD_S
SIZE
TOPO_S
BEAD_S
SIZE
TOPO_S
INTERNAL_
FORCE_X
NE
BEAD_S
SIZE
TOPO_S
BEAD_S
SIZE
TOPO_S
INTERNAL_
FORCE_
X_ABS
NE
BEAD_S
SIZE
TOPO_S
BEAD_S
SIZE
TOPO_S
INTERNAL_
FORCE_Y
NE
BEAD_S
SIZE
TOPO_S
BEAD_S
SIZE
TOPO_S
INTERNAL_
FORCE_
Y_ABS
NE
BEAD_S
SIZE
TOPO_S
BEAD_S
SIZE
TOPO_S
www.3ds.com/tosca
Selection
area
E
Loadcase
dependent
INERTIA_YZ
Variable Type
usable as
CONSTRAINT
DRESP
Commands Manual 3 - 35
usable as
CONSTRAINT
usable as
OBJ_FUNC
Description
NE
BEAD_S
SIZE
TOPO_S
BEAD_S
SIZE
TOPO_S
INTERNAL_
FORCE_Z_ABS
NE
BEAD_S
SIZE
TOPO_S
BEAD_S
SIZE
TOPO_S
INTERNAL_
MOMENT_ABS
NE
BEAD_S
SIZE
TOPO_S
BEAD_S
SIZE
TOPO_S
INTERNAL_
MOMENT_X
NE
BEAD_S
SIZE
TOPO_S
BEAD_S
SIZE
TOPO_S
Nodal internal
moment around xdirection for global
coordinate system or
in an user defined
coordinate system.
INTERNAL_
MOMENT_X_
ABS
NE
BEAD_S
SIZE
TOPO_S
BEAD_S
SIZE
TOPO_S
INTERNAL_
MOMENT_Y
NE
BEAD_S
SIZE
TOPO_S
BEAD_S
SIZE
TOPO_S
Nodal internal
moment around ydirection for global
coordinate system or
in an user defined
coordinate system.
INTERNAL_
MOMENT_Y_
ABS
NE
BEAD_S
SIZE
TOPO_S
BEAD_S
SIZE
TOPO_S
3 - 36 Commands Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Selection
area
INTERNAL_
FORCE_Z
Variable Type
Loadcase
dependent
SIMULIA
Tosca Structure
SIMULIA
Tosca Structure
Selection
area
usable as
CONSTRAINT
usable as
OBJ_FUNC
Description
INTERNAL_
MOMENT_Z
NE
BEAD_S
SIZE
TOPO_S
BEAD_S
SIZE
TOPO_S
Nodal internal
moment around zdirection for global
coordinate system or
in an user defined
coordinate system.
INTERNAL_
MOMENT_Z_
ABS
NE
BEAD_S
SIZE
TOPO_S
BEAD_S
SIZE
TOPO_S
REACTION_
FORCE_ABS
BEAD_S
SIZE
TOPO_S
BEAD_S
SIZE
TOPO_S
REACTION_
FORCE_X
BEAD_S
SIZE
TOPO_S
BEAD_S
SIZE
TOPO_S
REACTION_
FORCE_
X_ABS
BEAD_S
SIZE
TOPO_S
BEAD_S
SIZE
TOPO_S
REACTION_
FORCE_Y
BEAD_S
SIZE
TOPO_S
BEAD_S
SIZE
TOPO_S
REACTION_
FORCE_
Y_ABS
BEAD_S
SIZE
TOPO_S
BEAD_S
SIZE
TOPO_S
www.3ds.com/tosca
Variable Type
Loadcase
dependent
DRESP
Commands Manual 3 - 37
usable as
CONSTRAINT
usable as
OBJ_FUNC
Description
BEAD_S
SIZE
TOPO_S
BEAD_S
SIZE
TOPO_S
REACTION_
FORCE_Z_ABS
BEAD_S
SIZE
TOPO_S
BEAD_S
SIZE
TOPO_S
REACTION_
MOMENT_ABS
BEAD_S
SIZE
TOPO_S
BEAD_S
SIZE
TOPO_S
REACTION_
MOMENT_X
BEAD_S
SIZE
TOPO_S
BEAD_S
SIZE
TOPO_S
Nodal reaction
moment around xdirection for global
coordinate system or
in an user defined
coordinate system.
REACTION_
MOMENT_X_
ABS
BEAD_S
SIZE
TOPO_S
BEAD_S
SIZE
TOPO_S
REACTION_
MOMENT_Y
BEAD_S
SIZE
TOPO_S
BEAD_S
SIZE
TOPO_S
Nodal reaction
moment around ydirection for global
coordinate system or
in an user defined
coordinate system.
REACTION_
MOMENT_Y_
ABS
BEAD_S
SIZE
TOPO_S
BEAD_S
SIZE
TOPO_S
3 - 38 Commands Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Selection
area
REACTION_
FORCE_Z
Variable Type
Loadcase
dependent
SIMULIA
Tosca Structure
SIMULIA
Tosca Structure
Selection
area
usable as
CONSTRAINT
usable as
OBJ_FUNC
Description
REACTION_
MOMENT_Z
BEAD_S
SIZE
TOPO_S
BEAD_S
SIZE
TOPO_S
Nodal reaction
moment around zdirection for global
coordinate system or
in an user defined
coordinate system.
REACTION_
MOMENT_Z_
ABS
BEAD_S
SIZE
TOPO_S
BEAD_S
SIZE
TOPO_S
ROT_ABS
BEAD_S
SIZE
TOPO_S
BEAD_S
SIZE
TOPO_S
Absolute rotation.
ROT_X
BEAD_S
SIZE
TOPO_S
BEAD_S
SIZE
TOPO_S
ROT_X_ABS
BEAD_S
SIZE
TOPO_S
BEAD_S
SIZE
TOPO_S
ROT_Y
BEAD_S
SIZE
TOPO_S
BEAD_S
SIZE
TOPO_S
ROT_Y_ABS
BEAD_S
SIZE
TOPO_S
BEAD_S
SIZE
TOPO_S
www.3ds.com/tosca
Variable Type
Loadcase
dependent
DRESP
Commands Manual 3 - 39
Loadcase
dependent
Selection
area
usable as
CONSTRAINT
usable as
OBJ_FUNC
Description
ROT_Z
BEAD_S
SIZE
TOPO_S
BEAD_S
SIZE
TOPO_S
ROT_Z_ABS
BEAD_S
SIZE
TOPO_S
BEAD_S
SIZE
TOPO_S
SIG_1
E/N
SHAPE_C
Maximum principal
stress.
SIG_2
E/N
SHAPE_C
SIG_3
E/N
SHAPE_C
Minimum principal
stress.
SIG_11
E/N
SHAPE_C
11-component of
stress tensor.
SIG_22
E/N
SHAPE_C
22-component of
stress tensor.
SIG_33
E/N
SHAPE_C
33-component of
stress tensor.
SIG_12
E/N
SHAPE_C
12-component of
stress tensor.
SIG_23
E/N
SHAPE_C
23-component of
stress tensor.
SIG_13
E/N
SHAPE_C
13-component of
stress tensor.
SIG_ABS_123
E/N
SHAPE_C
Maximum of the
absolute value of the
principal stresses.
SIG_ABS_3
E/N
SHAPE_C
3 - 40 Commands Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Variable Type
SIMULIA
Tosca Structure
SIMULIA
Tosca Structure
Loadcase
dependent
Selection
area
usable as
OBJ_FUNC
Description
usable as
CONSTRAINT
Variable Type
www.3ds.com/tosca
DRESP
SIG_BELTRAMI
E/N
SHAPE_C
Beltrami stress
hypothesis.
SIG_CONTACT
_PRESSURE
SHAPE_C
SIG_CONTACT
_SHEAR
SHAPE_C
SIG_CONTACT
_SHEAR_X
SHAPE_C
Shear X Contact
stress.
SIG_CONTACT
_SHEAR_Y
SHAPE_C
Shear Y Contact
stress.
SIG_CONTACT
_TOTAL
SHAPE_C
SIG_DRUCKER
_PRAGER
E/N
SHAPE_C
Drucker-Prager
stress hypothesis.
SIG_GALILEI
E/N
SHAPE_C
SIG_KUHN
E/N
SHAPE_C
SIG_
MARIOTTE
E/N
SHAPE_C
Mariotte stress
hypothesis.
SIG_MISES
E/N
SHAPE_C
SIG_TOPO_
MISES
TOPO_S
SIG_SANDEL
E/N
SHAPE_C
Sandel stress
hypothesis.
SIG_SAUTER
E/N
SHAPE_C
SIG_TRESCA
E/N
SHAPE_C
STRAIN_
ELASTIC
SHAPE_C
Elastic Strain.
Only Abaqus and
ANSYS
TOPO_S
Commands Manual 3 - 41
usable as
OBJ_FUNC
Description
STRAIN_
PLASTIC
SHAPE_C
Plastic Strain.
Only Abaqus and
ANSYS
STRAIN_
TOTAL
SHAPE_C
STRAIN_
ENERGY
E/N
BEAD_C
BEAD_S
SIZE
TOPO_C
TOPO_S
Strain energy.
STRAIN_
ENERGY_
DENS
E/N
SHAPE_C
BEAD_S
SIZE
TOPO_S
VOLUME
SHAPE_C
SIZE
TOPO_C
TOPO_S
SIZE
TOPO_S
Volume of element.
WEIGHT
SHAPE_C
SIZE
TOPO_S
SIZE
TOPO_S
Weight of element.
EL_GROUP
= <name_of_element_group>
Name of an element
group in which the value
of the design response is
to be determined.
ND_GROUP
= <name_of_node_group>
3 - 42 Commands Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Selection
area
usable as
CONSTRAINT
Loadcase
dependent
Variable Type
SIMULIA
Tosca Structure
SIMULIA
Tosca Structure
DRESP
ELEM
= <number_of_element>
Number of an element to
be used for the design
response (alternative to
EL_GROUP).
NODE
= <number_of_node>
Number of a node to be
used for the design
response (alternative to
ND_GROUP).
CS_REF
= <coordinate_system>
GROUP_
OPER
= MIN
= SUM
= COUNT
www.3ds.com/tosca
STATIC
Static analysis
MODAL
Modal analysis
NONLINEAR
Non-linear analysis
Commands Manual 3 - 43
SIMULIA
Tosca Structure
DAMAGE
Durability analysis
<loadcase>
Load case
ALL
<no_of_loadcase>
<substep>
Substep
ALL
<no_of_substep>
<shell_layer>
TOP
Top-layer of shell
MID
BOT
MAX
MIN
= MAX
= MIN
= SUM
VAR_
OPER
Subtraction
A-B
= SUB_ABS
|A-B|
3 - 44 Commands Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
LC_SEL
SIMULIA
Tosca Structure
DRESP
Operator with up to 10
operands
= COMBINE
weighted sum of up to
10 Variables
Var1*w1 +
Var2*w2 +...
VAR_A
= <var_id_a>
VAR_B
= <var_id_b>
VARIABLE
Specification of operands
for COMBINE with their
ID_NAME
= <var_id>,<weight>
www.3ds.com/tosca
Operators with 2 to 4
operands
= ADD
Addition
A+B+C+D
= MULT
Multiplication
A*B*C*D
= MIN
Minimun
min(A,B,C,D)
= MAX
Maximum
max(A,B,C,D)
= SUB
Subtraction
A-B
= DIV
Division
A/B
Commands Manual 3 - 45
= ABS
absolute value
abs(A)
= SIN
Sinus
sin(A)
= COS
Cosinus
cos(A)
= CUT_OFF
Cutoff Operator
to remove peaks
(parameters are
specified with
additional settings)
max
(CUT_OFF_LOW,
min(A,CUT_OFF
_HIGH))
= TAN
Tangens
tan(A)
= LOG
Common logarithm
log(A)
= EXP
Exponential
function
exp(A)
= FILTER
filter(A)
= LN
Nat. Logarithm
ln(A)
= NORM
= NORM_FIRST
3 - 46 Commands Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
SIMULIA
Tosca Structure
www.3ds.com/tosca
DRESP
= NPOWER
N-th power to A
(parameter is
specified with
EXPONENT
Item)
= NROOT
N-th root
(parameter is
specified with
EXPONENT
Item)
= SQRT
Square root
sqrt(A)
= INT
Integer
int(A)
= NINT
Nearest integer
number
nint(A)
= SIGN
Sign function
sign(A)
= DELTA_1
Difference
between
2 iterations
A(i) - A(i-1)
= DELTA_2
Difference
between
2 iterations
A(i) - A(i-2)
= DELTA_3
Difference
between
2 iterations
A(i) - A(i-3)
= DELTA_4
Difference
between
2 iterations
A(i) - A(i-4)
= DELTA_5
Difference
between
2 iterations
A(i) - A(i-5)
= DELTA_6
Difference
between
2 iterations
A(i) - A(i-6)
Operators with up to 10
operands
operands
defined by item
VARIABLE
Commands Manual 3 - 47
SIMULIA
Tosca Structure
= COMBINE
weighted addition
w1*VAR1 +
w2*VAR2 ...
VAR_B
= <var_id_b>
VAR_C
= <var_id_c>
VAR_D
= <var_id_d>
See also:
RADIUS
= <radius value>
real value
EXPONENT
= <exponent value>
real value
(default:1.0)
SIGMA
= <value>
real value
vol.2 chapter
6.8.4, Filter
function for the
optimization
displacements
(FILTER)
= <value>
real value
CUT_OFF_
HIGH
= <value>
real value
3 - 48 Commands Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
VAR_A
SIMULIA
Tosca Structure
DRESP
VARIABLE
= <var_id_1>,
<weight1>
ID_NAME of
variable VAR1
with weight factor w1 (default 1)
for combination
Remarks
1. No variables with TYPE FIX are permitted, i.e. DESIGN RESPONSE is
determined using SYSTEM or OPER type.
2. DESIGN RESPONSES are a special type of VARIABLES with a limited set
of possible types and definition types
3. Relative DESIGN RESPONSES can be created by defining two design
responses with the same type and def_type and with the definition of an
OPER design response which creates the difference in the values of the
first two design responses. The node- or element groups can only contain
one node or element per definition.
www.3ds.com/tosca
Commands Manual 3 - 49
SIMULIA
Tosca Structure
=
=
=
=
=
volume
SYSTEM
VOLUME
SUM
all_elements
=
=
=
=
=
first_eign_freq
SYSTEM
DYN_FREQ
MIN
MODAL,1, ALL
END_
ID_NAME
DEF_TYPE
TYPE
LC_SEL
LC_SET
NODE
=
=
=
=
=
=
disp_x_first_node
SYSTEM
DISP_X
MAX
STATIC,1, ALL
3399
=
=
=
=
=
=
disp_x_second_node
SYSTEM
DISP_X
MAX
STATIC,1, ALL
3398
END_
DRESP
ID_NAME
DEF_TYPE
TYPE
LC_SEL
LC_SET
NODE
END_
DRESP
3 - 50 Commands Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
DRESP
SIMULIA
Tosca Structure
DRESP
ID_NAME
DEF_TYPE
VAR_A
VAR_B
VAR_OPER
=
=
=
=
=
relative_displacement
OPER
disp_x_first_node
disp_x_second_node
SUB_ABS
END_
=
=
=
=
=
mean_displacement
OPER
disp_x_first_node,0.5
disp_x_second_node,0.5
COMBINE
www.3ds.com/tosca
END_
Commands Manual 3 - 51
SIMULIA
Tosca Structure
DVCON_AUTO_SHAPE
Automatic generation of design variable constraints (DVCON_SHAPE commands) with link conditions (LINK_SHAPE command) for shape optimization.
ID_NAME
=<id_family_name_
dvcon_shape>*
Name of the
DVCON_AUTO_SHAPE
definition. This ID_NAME
will also be used as family name for the
DVCON_SHAPE definitions.
ND_GROUP
_FAMILY
= <nd_group_family_name>*
CHECK_
LINK
= <link_shape_name>
Name of the
LINK_SHAPE definition
Remarks
3 - 52 Commands Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
DVCON_BEAD
DVCON_BEAD
www.3ds.com/tosca
= <name_of_dvcon_shape>
Name of the
DVCON_BEAD definition
ND_GROUP
= <name_of_node_group>
CHECK_
SOLID
= <solid_name>
CHECK_
ELGR
= <name_of_element_group>
CHECK_
GROW
= <grow_value>
CHECK_
SHRINK
= <shrink_value>
CHECK_BC
= YES
= NO
CHECK_DOF
= <cs_name>,<dof1>,<dof2>,
<dof3>
(<dof*> = FIX, FREE)
CHECK_LINK
= <link_shape_name>
Assign a LINK_BEAD
definition.
Commands Manual 3 - 53
SIMULIA
Tosca Structure
Remarks
1. CHECK_SOLID (up to 6 operators with CHECK_SOLID are permitted) is
the name of a solid already defined (SOLID). All nodes are checked for
penetration in the solid (restricted solid) and against leaving the solid area
(variational solid).
2. CHECK_ELGR (up to 6 operators with CHECK_ELGR are permitted) is the
name of an element group already defined. All nodes in the node group
(ND_GROUP) are checked for penetrating the element group.
3. CHECK_BC (optional): YES -> The boundary conditions that are loaded
with OPTIONS,READ_BC = ALL, are considered for the nodes of the node
group. NO -> The BC entries are not considered.
4. CHECK_DOF (optional): Fixing the named node coordinates with FIX to
the given coordinate system.
5. When several CHECK_* entries are specified in a DVCON_BEAD definition, they are used in the following sequence: CHECK_GROW,
CHECK_SOLID, CHECK_ELGR, CHECK_SPC, CHECK_DOF. If there are
conflicts in the sequence of the CHECK_* entries, the last entry overwrites
the previous one. If there are no conflicts in the sequence of the CHECK_*
entries, all the defined restrictions are considered.
6. CHECK_LINK can only be called with the design variable node-group
(defined in DV_BEAD)
Examples
ID_NAME
ND_GROUP
CHECK_DOF
CHECK_GROW
=
=
=
=
my_dvcon_bead_01
nd_side_a
csys1, FREE, FIX, FIX
5.0
END_
DVCON_BEAD
ID_NAME
CHECK_LINK
ND_GROUP
END_
3 - 54 Commands Manual
= my_bead_symmetry_link
= my_link_condition
= my_design_variables
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
DVCON_BEAD
SIMULIA
Tosca Structure
DVCON_SHAPE
DVCON_SHAPE
Defines restrictions of the design variables in shape optimization. For more
detailed information see vol.2 chapter 6.3.3, Restrictions (DVCON_SHAPE)
in the Tosca Structure 8.1.0 user manual.
ID_NAME
= <name_of_dvcon_shape>
Name of the
DVCON_SHAPE definition
ND_GROUP
= <name_of_node_group>
CHECK_
GROW
= <grow_value>
CHECK_
SHRINK
= <shrink_value>
www.3ds.com/tosca
( shrink_value 0 )
CHECK_
MIN_MEM
= <radius>
CHECK_
MAX_MEM
= <radius>
CHECK_
SOLID
= <solid_name>
CHECK_
ELGR
= <name_of_element_group>
CHECK_
NDGR
=<membersize_check_node_gro
up>
Commands Manual 3 - 55
SIMULIA
Tosca Structure
CHECK_BC
= YES
= NO (default)
CHECK_DOF
= <cs_name>,<dof1>,<dof2>,
<dof3>
(<dof*> = FIX, FREE)
CHECK_
SLIDE
= <link_shape_name>
CHECK_LINK
= <link_shape_name>
Assign a LINK_SHAPE
definition.
FEASIBLE_
START
= YES (default)
= NO
TOLERANCE
=<tolerance_value>
Remarks
3 - 56 Commands Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
DVCON_SHAPE
6. When several CHECK_* entries are specified in a DVCON_SHAPE definition, they are used in the following sequence: CHECK_GROW /
CHECK_SHRINK, CHECK_MAX_MEM, CHECK_MIN_MEM,
CHECK_SOLID, CHECK_ELGR, CHECK_SPC, CHECK_DOF,
CHECK_LINK. If there are conflicts in the sequence of the CHECK_*
entries, the last entry overwrites the previous one. If there are no conflicts
in the sequence of the CHECK_* entries, all the defined restrictions are
considered.
7. Apart from CHECK_SOLID and CHECK_ELGR entries (which can be used
up to 6 times) only one entry of each other type is admitted in a
DVCON_SHAPE definition. That means, e.g., that I cannot combine two
CHECK_LINK entries in one DVCON_SHAPE definition but have to define
two DVCON_SHAPE entries instead. On the other hand, one
CHECK_LINK and CHECK_SPC entry, for example, can be combined.
Examples
DVCON_SHAPE
ID_NAME
ND_GROUP
CHECK_DOF
CHECK_GROW
=
=
=
=
my_dvcon_shape_01
nd_side_a
csys1, FREE, FIX, FIX
5.0
www.3ds.com/tosca
END_
Commands Manual 3 - 57
SIMULIA
Tosca Structure
DVCON_SIZING
Defines restrictions of the design variables in sizing optimization. For more
detailed information see vol.2 chapter 8.3.2, Manufacturing conditions and
geometrical restrictions in the Tosca Structure 8.1.0 user manual.
ID_NAME
= <name_of_dvcon_sizing>
Name of the
DVCON_SIZING definition
EL_GROUP
= <name_of_element_group>
Name of an element
group already defined
with which
DVCON_SIZING should
react.
= FROZEN
= THICKNESS_BOUNDS
= CLUSTER_GROUPS
= MIN_CLUSTER_WIDTH
= LINK_SIZING
Definition of symmetry
and link conditions
MAGNITUDE = REL
= ABS
3 - 58 Commands Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
CHECK_
TYPE
SIMULIA
Tosca Structure
DVCON_SIZING
LOWER_
BOUND
=<lower_bound>
UPPER_
BOUND
=<upper_bound>
= <width>
www.3ds.com/tosca
CHECK_
LINK
= <name_of_link_sizing>
RADIUS
= <radius>
Remarks
1. The element group which should be restricted must be a subset of the
referenced element group of DV_SIZING, i.e. all elements that should to be
restricted must lie in this design area.
2. For CHECK_TYPE = CLUSTER_GROUPS multiple element groups can
be assigned using EL_GROUP parameter several times.
3. For CHECK_TYPE = THICKNESS_BOUNDS relative values (positive real
values) can be used to create lower and upper bounds based on the initial
shell thickness. In this case the shell thicknesses can vary between
Commands Manual 3 - 59
SIMULIA
Tosca Structure
=
=
=
=
=
=
my_dvcon_sizing_01
my_element_group
THICKNESS_BOUNDS
REL
0.8
1.2
=
=
=
=
my_dvcon_sizing_02
my_element_group1
my_element_group2
CLUSTER_GROUPS
END_
DVCON_SIZING
ID_NAME
EL_GROUP
EL_GROUP
CHECK_TYPE
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
END_
3 - 60 Commands Manual
SIMULIA
Tosca Structure
DVCON_TOPO
DVCON_TOPO
www.3ds.com/tosca
= <Id_name_of_dvcon_topo>
Name of the
DVCON_TOPO-definition
EL_GROUP
= <name_of_element_group>
Name of an element
group already defined
with which
DVCON_TOPO should
react.
CHECK_
TYPE
= FROZEN
= CAST
= MIN_MEMBER
= MAX_MEMBER
= LINK_TOPO
Definition of symmetry
and link conditions
= <thickness>
= <thickness>
Maximum thickness of
the structure
Commands Manual 3 - 61
SIMULIA
Tosca Structure
DISTANCE
= <distance value>
MIN_
THICKNESS
= <thickness>
CHECK_
LINK
= <name_of_link_topo>
RADIUS
= <radius>
PULL_DIR
= <X_COMP>, <Y_COMP>,
<Z_COMP>
ANGLE
= <draft_angle>
CHECK_
GROUP
= <name_of_element_group>
3 - 62 Commands Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
DVCON_TOPO
MID_PLANE
no definition of a central
plane, i.e. the elements
are only deformed in the
direction of PULL_DIR
= AUTO
Automatic determination
of the central plane.
Using the central plane
as the starting point. The
elements are removed
either in the direction of
the deformation or in the
opposite direction.
= AUTO_TIGHT
= POINT, <X_COMP>,
<Y_COMP>, <Z_COMP>
= SURFACE
= STAMP
= <name_of_coordinate_system>
www.3ds.com/tosca
PULL_CS
= NONE
Commands Manual 3 - 63
SIMULIA
Tosca Structure
RADIUS
= <radius>
CREATE_
PULL_
GROUP
= YES
= NO
FILTER_MAT
= NO | YES
Remarks
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
DVCON_TOPO
www.3ds.com/tosca
= my_dvcon_topo_01
= el_grp_startarea
= FROZEN
END_
DVCON_TOPO
ID_NAME
EL_GROUP
CHECK_TYPE
= my_dvcon_topo_02
= el_grp_cast
= CAST
Commands Manual 3 - 65
SIMULIA
Tosca Structure
CHECK_GROUP
PULL_DIR
MID_PLANE
= ALL_ELEMENTS
= 0.,0.,1.
= NONE
END_
DVCON_TOPO
ID_NAME
EL_GROUP
CHECK_TYPE
THICKNESS
MIN_THICKNESS
DISTANCE
=
=
=
=
=
=
my_dvcon_topo_03
el_grp_max_membersize
MAX_MEMBER
10.
2.
20.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
END_
3 - 66 Commands Manual
SIMULIA
Tosca Structure
DV_BEAD
DV_BEAD
Definition of the design nodes for bead optimization. For more detailed information see vol.2 chapter 7.3.1, Design variables (DV_BEAD) in the Tosca
Structure 8.1.0 user manual.
ID_NAME
= <id_name_of_dv_shape>
ND_GROUP
= <name_of_node_group>
Remarks
1. Only surface nodes are regarded as being DESIGN_NODES.
2. Single standing nodes are not regarded as being DESIGN_NODES.
3. Midside nodes are not considered to be DESIGN_NODES. The midside
nodes will be placed between the edge nodes at the end of the design
cycle.
4. Only nodes at shell elements may be defined as DESIGN_NODES
Examples
DV_BEAD
ID_NAME
ND_GROUP
= my_dv_bead
= design_node_grp
www.3ds.com/tosca
END_
Commands Manual 3 - 67
SIMULIA
Tosca Structure
DV_SHAPE
Definition of the design nodes for shape optimization. For more detailed information see vol.2 chapter 6.3.1, Design variables (DV_SHAPE) in the Tosca
Structure 8.1.0 user manual.
ID_NAME
= <id_name_of_dv_shape>
ND_GROUP
= <name_of_node_group>
Remarks
1. Only surface nodes are regarded as being DESIGN_NODES.
2. Single standing nodes are not regarded as being DESIGN_NODES.
3. Midside nodes are not considered to be DESIGN_NODES. The midside
nodes will be placed between the edge nodes at the end of the design
cycle.
Examples
DV_SHAPE
ID_NAME
ND_GROUP
= my_dv_shape
= design_node_grp
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
END_
3 - 68 Commands Manual
SIMULIA
Tosca Structure
DV_SIZING
DV_SIZING
Definition of the design elements for sizing optimization. For more detailed
information see vol.2 chapter 5.3.1, Design variables in the Tosca Structure
8.1.0 user manual.
ID_NAME
= <id_name_of_dv_sizing>
EL_GROUP
= <name_of_element_group>
Remarks
1. All elements in the element group may be modified during optimization.
2. Only certain types of elements (for more information see vol.2 chapter 11,
Solver Specific Features) are permitted to be optimization elements. Tosca
Structure.sizing supports only single layered shells. All elements not
permitted are removed from the group.
Examples
DV_SIZING
ID_NAME
EL_GROUP
= dv_sizing_name
= design_elem_grp
www.3ds.com/tosca
END_
Commands Manual 3 - 69
SIMULIA
Tosca Structure
DV_TOPO
Definition of the design elements for topology optimization. For more detailed
information see vol.2 chapter 5.3.1, Design variables in the Tosca Structure
8.1.0 user manual.
ID_NAME
= <id_name_of_dv_topo>
EL_GROUP
= <name_of_element_group>
INITIAL_DV_
FIELD
= <name_of_file>
Remarks
1. All elements in the element group may be modified during optimization.
2. Only certain types of elements (for more information see the User Manual
or the Interface Manual) are permitted to be optimization elements. All
elements not permitted are removed from the group.
3. The INITIAL_DV_FIELD option is only available for sensitivity based optimization.
3 - 70 Commands Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
DV_TOPO
Examples
DV_TOPO
ID_NAME
EL_GROUP
= dv_topo_name
= design_elem_grp
www.3ds.com/tosca
END_
Commands Manual 3 - 71
SIMULIA
Tosca Structure
FEM_INPUT
ID_NAME
= <id_name_of_fem_input>
Name of the
FEM_INPUT definition
FILE
= <name_of_input_file>,
<fe-solver>
LIFE_FILE
= <name_of_input_file>,
<life-solver>
TEMPERATURE_FILE
= <name_of_input_file>,
<fe-solver>
ADD_FILE
= <name_of_add_input_
file>
COPY_FILE
= <name_of_copy_file>
FILE_
SOLVER_
EXE
= <fe_solver_executable>
FE-solver executable
FILE_
CMDLINE
FILE_ADD_
CALL
LIFE_FILE_
SOLVER_
EXE
=
<life_solver_executable>
LIFE-solver executable
LIFE_FILE_
CMDLINE
LIFE_FILE_
ADD_CALL
3 - 72 Commands Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Specifies the Finite Element Input Files for the optimization. Also additional
files with nodes and elements for defining restrictions can be imported. For
more detailed information see vol.2 chapter 3.4, Loading FE Data in the
Tosca Structure 8.1.0 user manual.
SIMULIA
Tosca Structure
FEM_INPUT
DEPEN
DENT_FILE
= <name_of_input_file>
Name of a previously
defined FILE or
LIFE_FILE.
Remarks
1. The item FILE can be repeated several times. The first file in the list of files
will be handled as master file, which means that the configuration of the
finite element model will be read from this file. The second and all later
referenced files will be used to perform a finite element calculation. The
model in these files have to be identical to the original FE model. The files
will be modified during the optimization.
2. Second label in FILE item can be used to define the FE-solver. It may be
used instead of commandline:
"-solver <fe-solver>"
Only one FE-solver and one kind of input decks are allowed.
3. The item LIFE_FILE can be repeated several times, but only for life solvers
that support ONF 601-block (femfat, femsite, ... ). The files will not be
modified during the optimization.
4. The item TEMPERATURE_FILE may be used to define a temperature preanalysis. This feature is currently only supported with Abaqus.
5. The item ADD_FILE can be repeated several times. All nodes and
elements stored in the file referenced with this item will not be used for the
optimization. This item can be used for the specification of neighboring
elements for the definition of manufacturing constraints.
www.3ds.com/tosca
6. The item COPY_FILE can be repeated several times. The file(s) are copied
in to the working directory at the start of the optimization. See also configuration possibility "add_files_to_work_dir".
7. All files must differ in the filenames without suffix.
FEM_INPUT
FILE
ADD_FILE
ADD_FILE
END_
= MODEL.INP
= MODEL.ADD
! WRONG
= MODEL_ADD.INP ! CORRECT
Commands Manual 3 - 73
SIMULIA
Tosca Structure
9. LIFE_FILE_SOLVER_EXE, LIFE_FILE_CMDLINE,
LIFE_FILE_ADD_CALL must be defined after a LIFE_FILE-item.These
statements are analogue to $life_solver_exe, $life_solver_cmdline,
$life_solver_add_call in the configuration but relates ONLY to the last
LIFE_FILE-statement before this command.
10.DEPENDENT_FILE can be used when having parallel submit scripts, that
have dependencies on each other. One or more FILEs can have dependency only on 1 FILE. It would mean that they can be called simultaneously, if the submit script setup allows this. (See information about
${fe_solver_submit_check} and ${life_solver_submit_check} in CONFIG)
Please note: DEPENDENT_FILE can only be used in combination with
submit scripts (${fe_solver_submit_check} or ${life_solver_submit_check}
is set). In standard setup without submit scripts this entry is ignored.
Default is DEPENDENT_FILE = None, which means the FILE (or
LIFE_FILE) has no dependencies. Please contact your local Tosca Structure support for further information.
Examples
FEM_INPUT
ID_NAME
FILE
ADD_FILE
ADD_FILE
=
=
=
=
my_finite_element_models
my_fe_model.bdf
restriction_elements_left.bdf
restriction_elements_right.bdf
END_
FEM_INPUT
ID_NAME = model
FILE = input1.inp
FILE_ADD_CALL = cpus=24
FILE = input2.inp
FILE_ADD_CALL = cpus=12 globalmodel=input1.odb
FILE = input3.inp
FILE_ADD_CALL = cpus=12 globalmodel=input1.odb
END_
3 - 74 Commands Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
If you have three Abaqus jobs where the first one is a pre-load step which is
to be used in the two following jobs. Also, the first job is run with 24 CPUs, the
other ones with just 12 CPUs. Your FEM_INPUT command could then look
like the following:
SIMULIA
Tosca Structure
GROUP_AUTO_DEF
GROUP_AUTO_DEF
Automatic definition of node groups. For more detailed information see vol.2
chapter 3.6.5, Automatic node group definition (GROUP_AUTO_DEF) in the
Tosca Structure 8.1.0 user manual.
ND_GROUP
= <name_of_node_group>
CS
= <name_of_coord_system>
TOL
SEARCH
_TYPE
Search criterion
SEARCH_
DIR
= CONTINUOUS
Continuous search
= DISCRETE
Discrete search
= CS_MULTI
= <cs_dir>
Search direction
www.3ds.com/tosca
<cs_dir> =
+1, -1, +2, -2, +3, -3
SEARCH_
LEN
= <value>
Search length
DISCRETE_
LEN
= <value>
Discrete length
SEARCH_
CS
= <name_of_search_cs>
Remarks
1. The command is applied only to nodes that have been selected. The child
node group only contains the necessary parent nodes for the case the
parent nodes are also selected.
2. The command GROUP_AUTO_DEF does not have its own ID_NAME.
Commands Manual 3 - 75
SIMULIA
Tosca Structure
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
GROUP_AUTO_DEF
SEARCH_TYPE=DISCRETE, the command SEARCH_CS is not necessary. A total of up to 32 separate SEARCH_CS entries can be accepted.
The second to the 32th entry is optional. It is recommended that all coordinate systems CS and SEARCH_CS are the same type, that is either cartesian, cylindrical or spherical.
11.Note: Using the command DVCON_AUTO_SHAPE, DVCON_SHAPE
entries for node groups with the same name log can be generated automatically.
Examples
GROUP_AUTO_DEF
ND_GROUP
CS
TOL
SEARCH_TYPE
SEARCH_DIR
SEARCH_LEN
DISCRETE_LEN
=
=
=
=
=
=
=
my_nodes_01
cs_1
0.1, 1.0, 0.1
CONTINUOUS
+2
360
45
www.3ds.com/tosca
END_
Commands Manual 3 - 77
SIMULIA
Tosca Structure
GROUP_DEF
Manual definition of groups by lists of elements or nodes, materials or properties or by assigning a previously defined selection. For more detailed information see vol.2 chapter 3.6.4, Manual group definition in Tosca Structure.gui in
the Tosca Structure 8.1.0 user manual.
ID_NAME
= <Id_name_of_group>
TYPE
= ELEM
= NODE
FORMAT
= SELECTED
= LIST
= LIST_MAT
= LIST_PROP
= LIST_ND_ALL
= LIST_ND_ANY
= LIST_NDGR_ALL
= LIST_NDGR_ANY
LIST_BEGIN
List entries
Remarks
3 - 78 Commands Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
GROUP_DEF
GROUP_DEF
www.3ds.com/tosca
ID_NAME
TYPE
FORMAT
LIST_BEGIN
7
= my_elem_group
= ELEM
= LIST_MAT
END_
Commands Manual 3 - 79
SIMULIA
Tosca Structure
ID_NAME
TYPE
FORMAT
= my_surface_node_group
= NODE
= SELECTED
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
END_
3 - 80 Commands Manual
SIMULIA
Tosca Structure
GROUP_IMPORT
GROUP_IMPORT
Import of groups from files in different group definition formats.
ID_NAME
= <name_of_group_import>
FORMAT
= M4W
= FEMAP
= ONF
<file_name>
FILE_NAME
Remarks
On using the file name (operator FILE_NAME):
1. File names are used in the given style of writing. Using capital letters is not
necessary.
On loading the M4W neutral files:
1. The complete model must be written in the file otherwise the allocation of
group names will not occur.
2. Groups must be evaluated, i.e. the group entities must exist in a list in a
neutral file.
www.3ds.com/tosca
3. Group names are changed to group name_E and group name_N as long
as the groups contain nodes and elements.
Examples
Loading group information from the file GROUPS.NEU. The file is written in
ASCII format in MSC Nastran for Windows and is given in the current directory.
GROUP_IMPORT
FILE_NAME
FORMAT
= DESIGN.NEU
= M4W
END_
Commands Manual 3 - 81
SIMULIA
Tosca Structure
INCLUDE
Integration of other files which contain complex or repetitive commands. If no
path is given, the current directory is searched. The multistage path is then
searched which can be set with the command PATH. For more detailed information see vol.2 chapter 3.5, Include Files.
INCLUDE, filename, path
filename
File name
path
Remarks
1. The command INCLUDE allows nesting of three stages. This means, a
loaded (stage 1) can occur again in INCLUDE (stage 2) whereby this file
can also be contained in an INCLUDE command (stage 3). In the directories where INCLUDE files exist, path allocations must be set (e.g. with
PATH).
Examples
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
3 - 82 Commands Manual
SIMULIA
Tosca Structure
LINK_BEAD
LINK_BEAD
Defines link conditions (coupling conditions) for nodes in shape optimization.
For more detailed information see vol.2 chapter 7.3.2.6, Symmetry conditions
(CHECK_LINK) in the Tosca Structure 8.1.0 user manual.
ID_NAME
= <Id_name_of_link_bead>
Name of LINK_BEAD
definition
CS
= <name_of_coord_system>
TYPE
= POINT_SYM
= ROTATIONAL_SYM, AXIS_1
= ROTATIONAL_SYM, AXIS_2
= ROTATIONAL_SYM, AXIS_3
Remarks
www.3ds.com/tosca
= MY_LINK_01
= PLANE_SYM, AXIS_3
= CS_0
Commands Manual 3 - 83
SIMULIA
Tosca Structure
LINK_SHAPE
Defines link conditions (coupling conditions) for nodes in shape optimization.
For more detailed information see vol.2 chapter 6.3.3.8, Assigning link/coupling conditions (CHECK_LINK) in the Tosca Structure 8.1.0 user manual.
= <Id_name_of_link_shape>
MASTER
CLIENT
3 - 84 Commands Manual
Name of LINK_SHAPE
definition
= MAX
= MIN
= NODE, <node_nr>
= NDGR, <ndgr_name>
Master is determined
from the nodegroup
<ndgr_name>. From
each link-shape group,
one node must exist in
the master group. Only
allowed for the following
CLIENT types:
PLANE_SYM
POINT_SYM
ROTATION_SYM
DIRECTION
DISP_CS
SURF_TURN
FREE_FORM
VECTOR
LENGTH
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
ID_NAME
SIMULIA
Tosca Structure
www.3ds.com/tosca
LINK_SHAPE
= PLANE_SYM, AXIS_1
= PLANE_SYM, AXIS_2
= PLANE_SYM, AXIS_3
= POINT_SYM
= ROTATION_SYM, AXIS_1
= ROTATION_SYM, AXIS_2
= ROTATION_SYM, AXIS_3
A rotational symmetric
displacement of the
nodes referring to the
given axis of the coordinate system is enforced.
= VECTOR
= VECTOR,ON/OFF,ON/OFF,ON/
OFF
= DIRECTION
= LENGTH
= DISP_CS
= DISP_CS,ON/OFF,ON/OFF,ON/
OFF
Commands Manual 3 - 85
SIMULIA
Tosca Structure
=SURF_STAMP, AXIS_1
=SURF_STAMP, AXIS_2
=SURF_STAMP, AXIS_3
Conserve a stampable
surface. The stamping
direction is defined via
the axis of the coordinate system.
=SURF_TURN, AXIS_1
=SURF_TURN, AXIS_2
=SURF_TURN, AXIS_3
=SURF_DRILL, AXIS_1
=SURF_DRILL, AXIS_2
=SURF_DRILL, AXIS_3
=SURF_DEMOLD, AXIS_1
=SURF_DEMOLD, AXIS_2
=SURF_DEMOLD, AXIS_3
Conserve a demoldable
surface for casting. The
demold direction is
defined via the coordinate system axis.
3 - 86 Commands Manual
= PLANE_SYM
=ROTATION_SYM
Conserve a rotational
symmetric surface with
rotational symmetric
mesh. Symmetry groups
are determined automatically according to the
axis specified by
CLIENT_DIR parameter.
=SURF_PLANE_SYM
=SURF_CYCLIC_SYM
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
=SURF_CYCLIC_PLANE_SYM
=SURF_STAMP
Conserve a stampable
surface. The stamping
direction is defined via
the CLIENT_DIR parameter. An additional
demold direction can be
defined using
DEMOLD_DIR.
=SURF_TURN
=SURF_DRILL
=SURF_DEMOLD
Conserve a demoldable
surface for casting. The
demold direction is
defined via the
DEMOLD_DIR parameter. (CLIENT_DIR is also
supported, but not recommended).
=FREE_FORM
www.3ds.com/tosca
LINK_SHAPE
Commands Manual 3 - 87
CLIENT_DIR
DEMOLD_DIR
CS
= <name_of_coord_system>
TOL
3 - 88 Commands Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
SIMULIA
Tosca Structure
LINK_SHAPE
SURF_
PARAM
SURF_SYM_
TYPE
=PLANE_SYM, AXIS_1
=PLANE_SYM, AXIS_2
=PLANE_SYM, AXIS_3
= POINT_SYM
SURF_SYM_
CS
= <name_of_coord_system>
SURF_SYM_
NDGR
= <name_of_nodegroup>
ANGLE
= <real>
UNDERCUT_TOL
= <real>
CHECK_GROUP
www.3ds.com/tosca
Commands Manual 3 - 89
SIMULIA
Tosca Structure
ANGLE
= <real>
CYCLIC_SYM_
START
Remarks
1. The allocation is only permitted for design nodes (defined via the command
DV_SHAPE) and mesh smooth nodes (second order design nodes).
Case 1
Case 2
Case 3
Case 4
ALL_GROWTH
ALL_SHRINK
MORE_SHRINK
MORE_GROWTH
max_growth
min_growth
OBJ_FUNC
max_growth
max_growth
OBJ_FUNC
min_shrink
OBJ_FUNC
max_shrink
max_shrink
OBJ_FUNC
max_shrink
MASTER
MAX
max_growth
min_shrink
max_growth
max_growth
MIN
min_growth
max_shrink
max_shrink
max_shrink
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
www.3ds.com/tosca
LINK_SHAPE
Commands Manual 3 - 91
SIMULIA
Tosca Structure
= DISP_CS:
The optimization displacement of the master nodes based upon the FE
displacement coordinate system is transferred directly in the FE displacement coordinate system of the client nodes. The coupled FE displacement
coordinate systems must be of the same kind, i.e. either cartesian, cylindrical or spherical. With DISP_CS=ON/OFF, ON/OFF, ON/OFF these coordinates that are activated are transferred. The coordinates deactivated
remain unchanged.
= SURF_PLANE_SYM:
The nodes are checked to be symmetric with respect to the given
symmetry plane in symmetric but non-symmetric meshed models. The
node corrections are applied in node normal direction only.
= SURF_CYCLIC_SYM
Couples nodes in a not neccessary symmetric mesh that reoccur in a cyclic
manner around a rotational axis.
= SURF_CYCLIC_PLANE_SYM
Combination of SURF_CYCLIC_SYM and SURF_PLANE_SYM. Nodes
are first coupled in a cyclic manner and then plane symmetry is enforced
within each cyclic section. The position of the plane symmetric sections is
controlled with the CYCLIC_SYM_START parameter.
=SURF_STAMP:
The nodes are linked to keep a stampable surface. Master nodes are
determined automatically.
=SURF_TURN:
The nodes are linked to keep a turnable surface. Master nodes are determined automatically.
=SURF_DRILL:
The nodes are linked to keep a turnable surface. Master nodes are determined automatically. The drill restriction is a special combination of the turn
and demold restriction.
=SURF_DEMOLD:
The nodes are linked to keep a castable surface.
4. The CLIENTS PLANE_SYM, ROTATION_SYM, SURF_STAMP,
SURF_TURN, SURF_DRILL, SURF_DEMOLD, SURF_CYCLIC_SYM,
SURF_PLANE_SYM, SURF_CYCLIC_PLANE_SYM can be used without
the AXIS_* parameter. Thus, an arbitrary axis direction <x,y,z> can be
3 - 92 Commands Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
= LENGTH:
The absolute value of displacement of the master nodes is calculated. The
displacement of the client nodes is scaled so the absolute value of the
obtained displacement of the master node remains.
SIMULIA
Tosca Structure
LINK_SHAPE
www.3ds.com/tosca
LINK_SHAPE
ID_NAME
MASTER
CLIENT
CS
TOL
=
=
=
=
=
my_link_01
MAX
PLANE_SYM, AXIS_3
cs_0
0.01, 0.01, 0.01
=
=
=
=
=
DEMOLD_AREA
MAX
SURF_DEMOLD, AXIS_2
cs_0
1.5
END_
LINK_SHAPE
ID_NAME
MASTER
CLIENT
CS
ANGLE
Commands Manual 3 - 93
SIMULIA
Tosca Structure
TOL
CHECK_GROUP
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
END_
3 - 94 Commands Manual
SIMULIA
Tosca Structure
LINK_SIZING
LINK_SIZING
Definition of symmetry and link conditions for sizing optimization. For more
detailed information see vol.2 chapter 5.3.2.7, Symmetry conditions in the
Tosca Structure 8.1.0 user manual.
ID_NAME
= <Id_name_link_sizing>
www.3ds.com/tosca
TYPE
= POINT_SYM
= PLANE_SYM, AXIS_1
= PLANE_SYM, AXIS_2
= PLANE_SYM, AXIS_3
= ROTATION_SYM, AXIS_1
= ROTATION_SYM, AXIS_2
= ROTATION_SYM, AXIS_3
Rotational symmetry
referring to the axis of the
coordinate system. The
angle for the repeating
segments may be
defined by the user.
= CYCLIC_SYM, AXIS_1
= CYCLIC_SYM, AXIS_2
= CYCLIC_SYM, AXIS_3
= LINK_SYM
CS
= <name_of_coordinate_system>
IGNORE_
FROZEN
= FALSE, TRUE
ANGLE
= <angle>
Commands Manual 3 - 95
SIMULIA
Tosca Structure
= <translation>
GROUP_
MASTER
= <name_of_element_group>
CS_CHILD
= <name_of_coordinate_system>
MASTER
= AUTO
= AVG
= GROUP
LINK_SIZING
ID_NAME
TYPE
CS
= PLANE_SYMMETRY
= PLANE_SYM, AXIS_2
= CS_0
END_
LINK_SIZING
ID_NAME
TYPE
CS
GROUP_MASTER
CS_CHILD
CS_CHILD
END_
3 - 96 Commands Manual
=
=
=
=
=
=
LINK_CONDITION
LINK_SYM
CS_0
EL_MASTER
CS_CHILD1
CS_CHILD2
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Examples
SIMULIA
Tosca Structure
LINK_TOPO
LINK_TOPO
Definition of symmetry and link conditions for topology optimization. For more
detailed information see vol.2 chapter 5.3.2.7, Symmetry conditions in the
Tosca Structure 8.1.0 user manual.
ID_NAME
= <Id_name_of_link_topo>
www.3ds.com/tosca
TYPE
= POINT_SYM
= PLANE_SYM, AXIS_1
= PLANE_SYM, AXIS_2
= PLANE_SYM, AXIS_3
= ROTATION_SYM, AXIS_1
= ROTATION_SYM, AXIS_2
= ROTATION_SYM, AXIS_3
Rotational symmetry
referring to the axis of the
coordinate system. The
angle for the repeating
segments may be
defined by the user.
= CYCLIC_SYM, AXIS_1
= CYCLIC_SYM, AXIS_2
= CYCLIC_SYM, AXIS_3
= LINK_SYM
CS
= <name_of_coordinate_system>
IGNORE_
FROZEN
= FALSE, TRUE
ANGLE
= <angle>
Commands Manual 3 - 97
SIMULIA
Tosca Structure
= <translation>
GROUP_
MASTER
= <name_of_element_group>
CS_CHILD
= <name_of_coordinate_system>
MASTER
= AUTO
= MAX
= AVG
= GROUP
3 - 98 Commands Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
LINK_TOPO
CS
CS_CHILD
Examples
LINK_TOPO
ID_NAME
TYPE
CS
= PLANE_SYMMETRY
= PLANE_SYM, AXIS_2
= CS_0
END_
ID_NAME
TYPE
CS
GROUP_MASTER
CS_CHILD
CS_CHILD
=
=
=
=
=
=
LINK_CONDITION
LINK_SYM
CS_0
EL_MASTER
CS_CHILD1
CS_CHILD2
END_
www.3ds.com/tosca
LINK_TOPO
Commands Manual 3 - 99
SIMULIA
Tosca Structure
LIST
List compilation of information during optimization preprocessing
LIST, object, info Information (info) is given about the objects (object). Only
objects selected with the command SELECT are considered.
Node and element information
info
= NODE
Information referring to
nodes, nodes selected
from the node list
NO
SF
LOC
BC
VEC
= ELEM
Element ID (default)
ND
PROP
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
object
SIMULIA
Tosca Structure
LIST
QUAL
VOL
selection
= CS
Coordinate systems
= ELGR
= ALL
= <cs_name>
Element group
= (no entry)
= ALL
= <element_group_name>
www.3ds.com/tosca
= EPROP
Element Property
Sets
= (no entry)
= ALL
= <element_property_number>
= ETYPE
Element type
= (no entry)
SIMULIA
Tosca Structure
= ALL
= <element_type_name>
= MAT
Material
= (no entry)
= ALL
All materials
= <material_number>
Specified material
= NDGR
Node group
= (no entry)
= ALL
= <node_group_name>
= SOLID
Solid definitions
= (no entry)
= ALL
All solids
= <solid_name>
Solid entered
Object specific information (objects not selectable with the SELECT command)
object
selection
= CONSTRAINT
Constraint information
= ALL
= <constraint_name>
Specified constraint
= DRESP
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
LIST, object, selection (objects not selectable with the SELECT command)
SIMULIA
Tosca Structure
LIST
= <dresp_name>
= DVCON_
SHAPE
= <dvcon_shape_name>
= <dvcon_shape_family>*
= DVCON_
TOPO
= <dvcon_topo_name>
= <dvcon_topo_family>*
= DV_
SHAPE
www.3ds.com/tosca
Specified design
response definition
= <dv_shape_name>
= DV_TOPO
= <dv_topo_name>
SIMULIA
Tosca Structure
= LINK_
SHAPE
= <link_shape_name>
= LOGICAL
= <logical_name>
= MESH_
SMOOTH
= <mesh_smooth_name>
= OBJ_
FUNC
= <obj_func_name>
= OPTIMIZE
= ALL
= <optimize_name>
= OPT_
PARAM
Opt_param information
= ALL
= <opt_param_name>
Specified Optimization
parameter definition
= STOP
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Optimize information
SIMULIA
Tosca Structure
LIST
= ALL
= <stop_name>
= USER_
FILE
= <user_file_name>
= VARIABLE
Variable information
All variable definitions
(default)
= <variable_name>
www.3ds.com/tosca
= ALL
SIMULIA
Tosca Structure
LIST, info
General information
info
= AUTHOR
Authorization
= PATH
Selected PATH
= PRINT_OPTION
= READ_OPTION
= SIZE
Examples
Listing of the adjusted model limits:
LIST, SIZE
Listing of the coordinate values of the nodes 1-10:
SELECT, NODE, S, NODE, 1, 10, 1
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
LOGICAL
LOGICAL
Definition of logical variables. For more detailed information see vol.2 chapter
10.5.2, Logical variables (LOGICAL) in the Tosca Structure 8.1.0 user manual. .
ID_NAME
= <Id_name_of_logical_
variable>
DEF_TYPE
= BASE
Definition of a logical
variable by comparison of
existing numerical variables
= BOOLEAN
OPER
DEF_TYPE = BASE:
= GE
= LE
= GT
= LT
= EQ
www.3ds.com/tosca
DEF_TYPE = BOOLEAN:
= AND
and-linkage of logical
variable LOG_A to
LOG_D
= OR
VAR_A
<name_of_1st_variable>
Name of a defined
numerical variable
VAR_B
<name_of_2nd_variable>
Name of a defined
numerical variable
SIMULIA
Tosca Structure
FIX_VAL
<value>
Real-value
LOG_A
<name_of_1st_logical
_variable>
LOG_B
<name_of_2nd_logical
_variable>
LOG_C
<name_of_3rd_logical
_variable>
LOG_D
<name_of_4th_logical
_variable>
Remarks
1. The direct definition of logical variables (DEF_TYPE = BASE) can be done
by a comparison of two numerical variables or one numerical variable and
a fixed value. The numerical variables must already be defined.
2. Definitions relating to Boolean operations (DEF_TYPE = BOOLEAN) must
include at least two already defined logical variables that are referenced. A
maximum of up to four logical variables may be combined.
Examples
LOGICAL
END_
=
=
=
=
=
my_logical_01
BASE
LT
volume_part_a
100.0
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
ID_NAME
DEF_TYPE
OPER
VAR_A
FIX_VAL
SIMULIA
Tosca Structure
MESH_SMOOTH
MESH_SMOOTH
Definition of parameters for the mesh smoothing algorithm for shape optimization. For more detailed information see vol.2 chapter 6.3.2, Mesh smoothing (MESH_SMOOTH) in the Tosca Structure 8.1.0 user manual.
ID_NAME
= <name_of_mesh_SMOOTH>
Name of the
MESH_SMOOTH definition
EL_GROUP
= <name_of_element_group>
MS_LAYER
= <name_of_node_group>,
<number_of_elementlayers>
FREE_SF
= FIX
= FIX, <number_of_node_layers>
= FREE
= FIX
= FREE
= CONSTRAINED_LAPLACIAN
= LOCAL_GRADIENT
www.3ds.com/tosca
BOUNDARY
STRATEGY
LEVEL_QUAL
QUAL_LIST
= YES
= NO
QUAD_LOW_
ANGLE
= <value>
QUAD_HIGH_
ANGLE
= <value>
TRIA_LOW_
ANGLE
= <value>
TRIA_HIGH_
ANGLE
= <value>
TETRA_LOW_
ASPECT
= <value>
TETRA_
HIGH_
ASPECT
= <value>
SOLVER_
CHECK
= YES
= NO
= YES
Optimization will be
stopped if quality criteria
are not satisfied.
= NO
No stop
Q4TAPER
= <value>
Q4SKEW
= <value>
SOLVER_
STOP
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
SIMULIA
Tosca Structure
MESH_SMOOTH
TETRAAR
= <value>
T3SKEW
= <value>
www.3ds.com/tosca
LEVEL_CONV
Convergence parameter
of mesh_smooth
LEVEL_
DVCON
CORRECT_
ELEMENTS
= YES, NO
CE_CORREC
TION_FACTO
R
CE_CORREC
TION_LOOPS
= <int_value>
CE_FAIL_
ACTION
= RESET, CONTINUE
FEATURE_
RECOGNITION
= <value>
SIMULIA
Tosca Structure
Remarks
1. In MESH_SMOOTH certain elements are not permitted (e.g. beam
elements, for more information please refer to the User Manual). From the
user-defined element group a system-defined element group with the
name Mesh_smooth_id_name_'ELEM' is created in which the nonpermitted elements are eliminated and a system-defined node group
Mesh_smooth_id_name_'NODE' is generated that contains all the necessary boundary nodes.
2. The calculation time for MESH_SMOOTH increases with an increase in the
number of iterations, i.e. LEVEL_CONV=LOW is faster as HIGH. A higher
convergence parameter gives a better result in MESH_SMOOTH. The aim
for the user is: to work with the lowest convergence parameter as possible
and only switch to the next highest convergence parameter when having
problems.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
MESH_SMOOTH
www.3ds.com/tosca
should work with the lowest parameter possible and only switch to the next
highest parameter when problems arise. With LEVEL_QUAL=NOT the
entries for QUAL_LIST, QUAD_LOW_ANGLE, QUAD_HIGH_ANGLE,
TRIA_LOW_ANGLE, TRIA_HIGH_ANGLE, TETRA_LOW_ASPECT,
TETRA_HIGH_ASPECT do not have any influence.
7. Determining quality:
To determine the quality of an element, the angle of the element is determined. Tetrahedron elements have the additional quality determination of
the aspect ratio. The value of quality is between 1 (the best element
quality) and 0 (the worst element quality).
QUAD surfaces (QUAD element, side surfaces from HEXA elements):
Optimal angle is 90 degrees -> Quality=1.
Angle less than and equal to QUAD_LOW_ANGLE -> Quality=0.
Angle greater than and equal to QUAD_HIGH_ANGLE ->
Quality=0.
TRIA surfaces (TRIA elements, side surfaces from TETRA elements):
Optimal angle is 60 degrees -> Quality=1.
Angle less than and equal to TRIA_LOW_ANGLE -> Quality=0.
Angle greater than and equal to TRIA_HIGH_ANGLE -> Quality=0.
TETRA elements:
Optimal aspect ratio is 1.33 degrees -> Quality=1.
Aspect ratio less than and equal to TETRA_LOW_ASPECT ->
Quality=0.
Aspect ratio greater than and equal to TETRA_HIGH_ASPECT ->
Quality=0.
Using the parameter QUAL_LIST the list of specifications of the worst
elements are controlled with a quality of zero. Important: The internal
quality determination in MESH_SMOOTH is coupled with the determination
of the quality that is activated with READ_OPTION, ELEM_QUALITY, ON
for the complete model. The values shown with the help of QUAL_LIST are
only internal values for MESH_SMOOTH and are different from the global
values that are given from the Patran interface or via the command LIST,
ELEM, QUAL.
8. Solver criteria of quality:
SOLVER_CHECK must be activated so SOLVER_STOP can be executed.
With SOLVER_CHECK=NO the entries SOLVER_STOP, Q4TAPER,
Q4SKEW, TETRAAR, T3SKEW have no effect. The values found in Tosca
Structure should be identical to the values which have been set in the
solver. A meaningful program stop in Tosca Structure due to bad mesh
quality is better than having errors in the solver!
SIMULIA
Tosca Structure
Example
MESH_SMOOTH
ID_NAME
EL_GROUP
FREE_SF
= my_mesh_smooth
= all_alements
= FIX, 3
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
END_
SIMULIA
Tosca Structure
MORPH
MORPH
Definition of morphing tasks for creation of model variants. In this commands
different predefined morphing areas are connected to an experiment plan
defining the changes for the morphing areas. For more detailed information
see vol.2 chapter 6.10, Morphing in the Tosca Structure 8.1.0 user manual. .
ID_NAME
= <Id_name_of_morph>
OPTIMIZE
= <optimization_name>
MORPH_
AREA
= <name_of_morph_area>
Morphing area
MORPH_
PARAM_
FILE
= <morph_csv_file_name>
NUMBER_
OF_
PARALLEL_
JOBS
= <number_of_parallel_jobs>
SMOOTHING
= YES | NO
Optional parameter to
switch on/off surface
smoothing of the nodes
in the moved morphing
areas.
Remarks
www.3ds.com/tosca
=
=
=
=
My_morph_job
My_optimization_job
MORPH1
MORPH2
SIMULIA
Tosca Structure
MORPH_AREA
= ...
MORPH_PARAM_FILE=morphing_experiment_plan.csv
NUMBER_OF_PARALLEL_JOBS=6
SMOOTHING = NO
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
END_
SIMULIA
Tosca Structure
MORPH_AREA
MORPH_AREA
Defines a single morph area (node group) and the type of morphing to be
done with this area. Currently, only NORMAL is supported, where all nodes in
ND_GROUP are moved in node-normal direction.
For more detailed information see vol.2 chapter 6.10.1.1, Morphing areas in
the Tosca Structure 8.1.0 user manual.
ID_NAME
= <Id_name_of_morph_area>
ND_GROUP
= <morph_area_nd_group>
TYPE
= NORMAL
TRANSITION_
ZONE
= <number>
Remarks
1. For one optimization several independent (non-intersecting) morphing
areas can be defined.
2. All nodes in any MORPH_AREA-area must be part of the design area.
Examples
MORPH_AREA
ID_NAME
=
ND_GROUP
=
TYPE
=
TRANSITION_ZONE
MORPH1
Morphing_zone1
NORMAL
= 0
END_
www.3ds.com/tosca
SIMULIA
Tosca Structure
OBJ_FUNC
Defines the objective function of the optimization. For more detailed information see vol.2 chapter 4.2, Objective Function in the Tosca Structure 8.1.0
user manual.
ID_NAME
= <Id_name_of_OBJ_FUNC>
DRESP
TARGET
<name_of_DRESP>
<weight_fact>
<ref_val>
reference value
= MIN
= MAX
= MINMAX
Remarks
1. The item DRESP can be repeated several times.
3. The reference value is only used for the MINMAX formulation. The default
value is 0.0.
4. The parameters norm_operator and cut_off are only available for controller
based optimization.
Examples
For BEAD:
Minimize the design response dresp_compliance
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
2. The weight factor has a default value of 1.0. If more than one DRESP entry
is specified in the objective function the weight factor defines the weight of
the particular entry of the objective function.
SIMULIA
Tosca Structure
OBJ_FUNC
OBJ_FUNC
ID_NAME
DRESP
TARGET
= objective
= dresp_compliance
= MIN
END_
For SHAPE:
Minimize the design response maximum_stress
OBJ_FUNC
ID_NAME
DRESP
TARGET
= objective
= maximum_stress
= MIN
END_
=
=
=
=
objective
volume
DISP_X_ND_113,1.5
MIN
END_
Minimize the maximum difference of the DRESP entry to the specified reference value for the entered DRESP.
ID_NAME
DRESP
DRESP
DRESP
TARGET
=
=
=
=
=
objective
FREQ_1,1.0, 100.0
FREQ_2,1.0, 120.0
FREQ_3,1.0, 130.0
MINMAX
END_
www.3ds.com/tosca
OBJ_FUNC
SIMULIA
Tosca Structure
OPTIMIZE
ID_NAME
=<Id_name_of_OPTIMIZE>
DV
=<name_of_DV_TOPO> |
<name_of_DV_SHAPE> |
<name_of_DV_BEAD> |
<name_of_DV_SIZING>
Name of a DV_TOPO,
DV_SHAPE, DV_BEAD,
or DV_SIZING entry
OBJ_FUNC
=<name_of_OBJ_FUNC>
DVCON
=<name_of_DVCON_TOPO>
<name_of_DVCON_SHAPE>
<name_of_DVCON_BEAD>
<name_of_DVCON_SIZING>
Name of a
DVCON_TOPO,
DVCON_SHAPE,
DVCON_BEAD or
DVCON_SIZING entry or
a
name log followed by '*'.
<family_name_
dvcon_entries>*
CONSTRAINT
=<name_of_CONSTRAINT>
Name of a CONSTRAINT
definition
MESH_
SMOOTH
=<name_of_MESH_SMOOTH>
Name of a
MESH_SMOOTH definition
STRATEGY
=<Optimization strategy>
BEAD_SENSITIVITY
BEAD_CONTROLLER
SIZING_SENSITIVITY
SHAPE_CONTROLLER
TOPO_SENSITIVITY
TOPO_CONTROLLER
Remarks
1. Several DVCON entries can be referenced together. It is possible to only
enter the name log followed by '*' . For example, DVCON = MY_DVCON_*
means the same as DVCON = MY_DVCON_1, DVCON=MY_DVCON_2,
DVCON=MY_DVCON_XXX etc.
2. There is only one CONSTRAINT for controller based shape, bead and
topology optimization.
3. For sensitivity based topology, bead and sizing optimization there are
several entries for the item CONSTRAINT possible.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Defines the optimization task. For more detailed information see vol.2 chapter
5.2, The Optimization Task for topology optimization, vol.2 chapter 6.2, The
Optimization Task for shape optimization or vol.2 chapter 7.2, The Optimization Task for bead optimization in the Tosca Structure 8.1.0 user manual.
SIMULIA
Tosca Structure
OPTIMIZE
www.3ds.com/tosca
Examples
OPTIMIZE
ID_NAME
DV
DVCON
OBJ_FUNC
CONSTRAINT
MESH_SMOOTH
STRATEGY
END_
=
=
=
=
=
=
=
SHAPE_OPTIMIZATION
DESIGN_NODES
DVCON_FIX_*
MISES_STRESS
CONSTANT_VOLUME
EL_OF_MESH_SMOOTH
SHAPE_CONTROLLER
= TOPOLOGY_OPTIMIZATION
SIMULIA
Tosca Structure
DV
DVCON
DVCON
OBJ_FUNC
CONSTRAINT
STRATEGY
END_
=
=
=
=
=
=
DESIGN_ELEMENTS
DVCON_FROZEN
DVCON_CAST
MIN_ENERGY
CONSTR_VOLUME
TOPO_CONTROLLER
TOPOLOGY_OPTIMIZATION
DESIGN_ELEMENTS
DVCON_FROZEN
DVCON_CAST
MIN_ENERGY
CONSTR_VOLUME
CONSTR_DISP_X_113
CONSTR_REACTFORCE_1
TOPO_SENS
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
OPTIMIZE
ID_NAME
DV
DVCON
DVCON
OBJ_FUNC
CONSTRAINT
CONSTRAINT
CONSTRAINT
STRATEGY
END_
SIMULIA
Tosca Structure
OPTIONS
OPTIONS
Determines the attributes (nodal boundary conditions) of the FE model which
should be loaded in TOSCA_PREP and TOSCA_OPT and which other
actions should be considered during loading (e.g. automatic determination of
the surface nodes). This command has to be defined before the FEM_INPUT
command in the parameterfile to be known during model import.
By default in TOSCA_PREP only the nodes and elements are loaded with the
command FEM_INPUT. In TOSCA_OPT all required stresses and displacements are loaded.
Additionally, parameters for the output of information during the optimization
may be defined. For more detailed information see vol.2 chapter 3.4.7,
Options for loading FE Data (OPTIONS) in the Tosca Structure 8.1.0 user
manual.
Remark:
OPTIONS command must be before FEM_INPUT command in parameter
file.
Read Parameters
= ON
= OFF
READ_SF_
MIDNODE
= ON
= OFF
www.3ds.com/tosca
READ_SF_
IDENT
READ_BC
SIMULIA
Tosca Structure
= ALL
= NOT
No boundary conditions
are read.
READ_LOAD
= ON
= OFF
READ_ELEM_
QUALITY
= ON
= OFF
Optimization is stopped if
results are missing.
= IGNORE
IGNORE_
NUM_OF_
CONSTRAINTS
= YES
= NO
IGNORE_
NUM_OF_
OBJF_TERMS
= YES
= NO
IGNORE_
OBJ_FUNC_
TYPE
= YES
= NO
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
READ_
RESULTS
SIMULIA
Tosca Structure
www.3ds.com/tosca
OPTIONS
SHAPE_
FORCE_
VOLUME
= ON
= OFF
Shape optimization
forces volume constraint
in first design cycle.
It is not recommended to
turn this setting OFF. If
the mesh is distorted in
first iteration, your volume constraint is probably too small/large.
Changing this to OFF will
simply cause more
design cycles before the
mesh is corrupted.
SHAPE_AUT
O_REMOVE_I
NNER_NODE
S
= ON
= OFF
Shape optimization
removes inner nodes
from design area automatically. Inner nodes
may still cause trouble by
certain DVCON_SHAPE
whwre inner nodes are
not allowed.
SHAPE_FOR
CE_MIDSIDE_
INTERPOL
= YES
= NO
IGNORE_UNK
NOWN_NODE
S
= YES
= NO
Output parameters
CONSTRAINT_
OUTPUT
SIMULIA
Tosca Structure
REPORT_
FILE
= DEFAULT
= STANDARD
Constraint value is
normed with the constraint value
= NONORM
= STANDARD
= ALL
= NONE
Descriptors of what is
printed to the file
"optimization_report.csv".
See Remark.
= D,F,W,R,C
PLOT_CTRL_
INP_MINUS_
REF
= YES
= NO
DEFAULT_
SMOOTH
= ON
= OFF
DEFAULT_
REPORT
= ON
= OFF
DEFAULT_
SMOOTH_
ADD_TO_
REPORT
= ON
= OFF
DEFAULT_
SMOOTH_
ISOVALUE
= <value>
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Table 1)
SIMULIA
Tosca Structure
OPTIONS
DEFAULT_
SMOOTH_
VOLUME
= <value>
= __final_iteration_value__
DEFAULT_
SMOOTH_
GROUP
= __MODEL__
= <GROUP_NAME>
= __DESIGN__
DEFAULT_
REPORT_
GROUP
= __MODEL__
= <GROUP_NAME>
= __DESIGN__
Remarks
1. The REPORT_FILE item may be used to change the output in the file
optimization_report.csv:
Iteration number and value of the objective function (OBJ_FUNC) is always
written to optimization_report.csv. This is the only output by option
"NONE".
The default is ("STANDARD") output is:
DRESP, OBJ_FUNC:DRESP and CONSTRAINT values.
All outputs in following table are active by option "ALL".
2. Using the letter codes in the REPORT_FILE item the output may be
customized.
www.3ds.com/tosca
Output name
Description
Code
DRESP
OBJ_FUNC:DRESP
OBJ_FUNC:DRESP:
Weight
OBJ_FUNC:DRESP:
Ref
CONSTRAINT
SIMULIA
Tosca Structure
Table 1
3. Default result reports and smooth runs can be activated in the parameterfile to be created after the optimization (an example can be found in the
macro tosca_def_smooth_report_template.mac). To get a report with your
topology optimization results including the smoothed model with the
volume of the final optimization step, you could add the following to your
parameter file:
OPTIONS
DEFAULT_SMOOTH
DEFAULT_REPORT
DEFAULT_SMOOTH_ADD_TO_REPORT
DEFAULT_SMOOTH_VOLUME
DEFAULT_SMOOTH_GROUP
DEFAULT_REPORT_GROUP
=
=
=
=
=
=
ON
ON
ON
__final_iteration_value__
__MODEL__
__MODEL__
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
END_
SIMULIA
Tosca Structure
OPT_PARAM
OPT_PARAM
Defines parameters to control optimization. For more detailed information see
vol.2 chapter 5.8, Settings(toplogy optimization), vol.2 chapter 6.8, Settings
(shape optimization), vol.2 chapter 7.8, Settings (bead optimization) and
vol.2 chapter 8.8, Settings (sizing optimizataion) in the Tosca Structure 8.1.0
user manual.
ID_NAME
= <Id_name_of_OPT_PARAM>
Name of the
OPT_PARAM definition
OPTIMIZE
= <Name_of_OPTIMIZE>
<option>
= OFF
Modetracking is deactivated
= ON
Modetracking is activated
= ON, <node_group>
Modetracking is activated
for specified nodegroup
MODETRAC
K_REFEREN
CE
Number of modes
included in the modetracking.
Default: 5
= INITIAL
= PREVIOUS
www.3ds.com/tosca
MODENUMBERS
SIMULIA
Tosca Structure
= <real_value>
DAMP_
STRUCTURAL_
STIFF
= <real_value>
DAMP_
VISCOUS_
MASS
= <real_value>
DAMP_
VISCOUS_
STIFF
= <real_value>
SUM_Q_
FACTOR
= <real_value>
SCALE
= <real_value>
= <r_grow>,<r_shrink>
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
www.3ds.com/tosca
OPT_PARAM
MID_NODES
= LINEAR
= INTERPOLATE
CURV_
SMOOTH
= <elem_edge_length>
FILTER
VECTOR
= EVER
= FIRST
SIMULIA
Tosca Structure
DISP
= MINIMUM
= AVERAGE
TOL_VALUE
= <real_value>
= SLOW
Small stepsize
= MODERATE
Moderate stepsize
= MEDIUM
Medium stepsize
= FAST
= ITER,15
START_
DELETE
= <operator>, <value>
<operator>
= PERC
= ABS
<value>
AUTO_
FROZEN
<option>
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SPEED
SIMULIA
Tosca Structure
OPT_PARAM
= LOAD
(default for all algorithms)
= OFF
= SPC
= BOTH
www.3ds.com/tosca
DENSITY_
UPDATE
<option>
= NORMAL
Normal strategy
= CONSERVATIVE
Conservative strategy
= AGGRESSIVE
Aggressive strategy
DENSITY_
INITIAL
= <real_value>
DENSITY_
UPPER
= <real_value>
DENSITY_
LOWER
= <real_value>
DENSITY_
MOVE
= <real_value>
FILTER_
RADIUS
= <radius>
FILTER_TYPE
= STANDARD
= LOW
<option>
Material interpolation
scheme (Relation
between relative density
and relative element stiffness).
= SIMP
= RAMP
Rational Approximation
of Material Properties
MAT_
PENALTY
= <real_value>
PROCESSORS
<option>
= SINGLE
= MULTI
MAT_INTERPOLATION
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
SIMULIA
Tosca Structure
OPT_PARAM
www.3ds.com/tosca
STOP_
CRITERION_
LEVEL
<option>
= BOTH
= SINGLE
STOP_
CRITERION_
OBJ
= <real_value>
STOP_
CRITERION_
DENSITY
= <real_value>
STOP_
CRITERION_
ITER
= <real_value>
SOFT_
DELETE_
METHOD
= <method>,
<soft_delete_threshold_
value>
<method>
= STANDARD
(default for all algorithms)
Removal of elements is
done when component
check was sucessful
(check for disconnected
parts of the component)
= AGGRESSIVE
Removal of elements is
done on base of the rel.
density without any further checks.
= MAX_SHEAR_STRAIN
Removal of elements is
based upon maximum
elemental shear strain
(with positive shear
threshold)
= MIN_PRINCIPAL_STRAIN
Removal of elements
based upon minimal elemental principal strain
(with negative minimum
principal threshold)
= PLASTICITY
Removal of elements
based upon maximum
effective elastoplastic
strain (only to use for
elastoplastic constitutive
material law)
= VOLUME_CHANGE
Removal of elements
based upon the minimum
relative deformed elemental volume ((Vdeform Vorg) / Vorg) with negative threshold value
<soft_delete_threshold_v
alue>
Method = STANDARD or
AGGRESSIVE:
relative material density
value for indentification of
elements to be removed
(element with a value
below will be removed
from the finite element
calculation file), default
0.05
other methods: corresponding thresholds
must be defined (no
default value available,
for details see vol.2
chapter 5.8.2.3,
Removing soft elements for increasing
performance).
SOFT_
DELETE
= <el_group>, <radius>
<el_group>
<radius>
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
SIMULIA
Tosca Structure
OPT_PARAM
AUTO_
FROZEN
<option>
= LOAD
(default for all algorithms)
= OFF
= SPC
= BOTH
www.3ds.com/tosca
THICKNESS_
UPDATE
<option>
= NORMAL
Normal strategy
= CONSERVATIVE
Conservative strategy
= AGGRESSIVE
Aggressive strategy
THICKNESS_
MOVE
= <real_value>
FILTER_
RADIUS
= <radius>
FILTER_TYPE
= STANDARD
SIMULIA
Tosca Structure
= LOW
<option>
= BOTH
= SINGLE
STOP_
CRITERION_
OBJ
= <real_value>
STOP_
CRITERION_
THICKNESS
= <real_value>
STOP_
CRITERION_
ITER
= <real_value>
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
STOP_
CRITERION_
LEVEL
SIMULIA
Tosca Structure
OPT_PARAM
AUTO_
FROZEN
<option>
= OFF
(default for sizing)
No AUTO_FROZEN
applied, loaded elements
are treated normally (are
optimizable)
= LOAD
= SPC
= BOTH
www.3ds.com/tosca
VECTOR
=FIRST
=EVER
SCALE
= <real_value>
BEAD_
WIDTH
= <real_value>
Bead wide
BEAD_ITER
= <int_value>
SIMULIA
Tosca Structure
BEAD_
MIN_
STRESS
= <real_value>
BEAD_
MAX_
MEMBRANE
= <real_value>
CURV_
SMOOTH
= <elem_edge_length>
Default 5.0
BEAD_
NODE_
SMOOTH
= <real_value>
FILTER_
RADIUS
= <real_value>,
<ABS/REL-switch>
Default: 4.0, REL
FILTER_RADIUS is the
radius with which the
sensitivties are filtered.
REL is RELative to
medium edge length of
elements in the design
area. Values may also be
set ABSolute, fx. :
FILTER_RADIUS = 5.0,
ABS
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
OPT_PARAM
ONLY_DES_
NODES
= YES / NO
Default: YES
NODAL_
MOVE
= <real_value>
Default: 0.1
NODAL_
UPDATE
= CONSERVATIVE
PERTURBATION
= <real_value>
Deafult: 0.0001
= NORMAL
= AGGRESSIVE
Remarks
1. As the form of the component changes during optimization the shape
basis vector must be continually adjusted. The settings VECTOR=FIRST is
only to be used when a node displacement along the initial vector is explicitly required.
www.3ds.com/tosca
2. SCALE is the direction of the optimization displacement. 1.0 for the same
direction as the surface normals, -1 for the opposite.
3. MODETRACKING can be activated for a specific nodegroup (e.g. every
fifth node on the surface). This results in a significant gain of performance.
4. Setting FILTER_TYPE = LOW can be recommend for optimizations having
no casting constraints, a low mass constraint (<5%) and/or a coarse mesh.
This will lead to less optimization iterations and more clear designs.
5. Generally, setting FILTER_TYPE = LOW gives raise more to clear solidvoid designs compared to FILTER_TYPE =STANDARD.
6. The main disadvantage of setting FILTER_TYPE = LOW is that the optimization result can contain checkerboard.
SIMULIA
Tosca Structure
optimization_control
bead_optimization
- 1.0
0.01
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
END_
SIMULIA
Tosca Structure
REPORT
REPORT
www.3ds.com/tosca
Combines optimization results to postprocessing reports. These contain animation sequences of fringe plots of optimization results as well as result plots.
For more detailed information see vol.2 chapter 10.1, Generation of Postprocessing Data.
ID_NAME
= <Id_name_of_report>
MODEL
RESULT
OUTPUT_
FILE
= <name_of_VTFx_file>
CONTOURPLOT
PLOT
SIMULIA
Tosca Structure
DEFAULT_G
ROUP
APPEND_
TO_VTFX
=YES
=NO
Remarks
1. Note that MODEL, RESULT and OUTPUT_FILE should be specified using
absolute paths or relative paths starting from the job directory (more
precisely, from the directory where tosca_report is started)
2. To add sensitivity plots to your report file, you must first write the sensitivity
information to ONF using a USER_FILE command. Then use the following
command contained in your original parameter file (because Tosca Structure control must know all objective functions and constraint definitions):
REPORT
ID_NAME = sens_plots
SENSITIVITY_PLOT = YES
END_
The procedure in detail is described in vol.2 chapter 10.1.5.6, Sensitivity
plots.
=
=
=
=
=
=
=
default_shape
"SAVE.onf/SHAPE"
"SAVE.onf/MODEL_fem.onf"
MODEL
SHAPE_CTRL
SHAPE_DISP
"TOSCA_POST/default_shape"
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
REPORT
DEFAULT_GROUP
= MESHSMOOTH
www.3ds.com/tosca
END_
SIMULIA
Tosca Structure
SELECT
Selects subsets of different types of objects (solids, nodes, elements etc).
These subsets can be combined to a group with the command GROUP_DEF.
All commands have only reference to the selected (active) objects. For more
detailed information see vol.2 chapter 3.7, Selection of Objects in Tosca
Structure.gui in the Tosca Structure 8.1.0 user manual.
SELECT, object, type, item, lab1, lab2, lab3
type
CS
Coordinate systems
ELEM
Elements
ELGR
Element groups
EPROP
Element properties
ETYPE
Element types
MAT
Material types
NDGR
Node groups
NODE
Nodes
NONE
SOLID
Solids (primitives)
Selection type
S
ALL
NONE
INV
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
object
SIMULIA
Tosca Structure
SELECT
object=ALL
No further specification is possible.
object=CS
SELECT, CS, type, item, lab1
item
CS
Coordinate system
lab1
<cs_name>
object=ELEM
SELECT, ELEM, type, item, lab1, lab2, lab3
item
ELEM
increment
lab1
<min_value>
lowest element ID
lab2
<max_value>
highest element ID
lab3
<increment>
increment
www.3ds.com/tosca
LAYER
lab1
<layer_number>
lab2
Common nodes
LINE
AREA
ELGR
EPROP
ETYPE
SIMULIA
Tosca Structure
MAT
ND_ALL
ND_ANY
object=ELGR
SELECT, ELGR, type, item, lab1
item
ELGR
lab1
<el_group>
object=EPROP
SELECT, EPROP, type, item, lab1
ITEM
EPROP
lab1
<value>
EPROP_NAME
lab1
<name_of_Eprop>
ETYPE
lab1
<name_of_etype>
object=MAT
SELECT, MAT, type, item, lab1
item
MAT
lab1
<value>
Number of material
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
object=ETYPE
SIMULIA
Tosca Structure
SELECT
MAT_NAME
Selection of materials by
name
lab1
<name_of_mat>
Name of material
object=NDGR
SELECT, NDGR, type, item, lab1
item
NDGR
lab1
<name_of_nd_group>
object=NODE
SELECT, NODE, type, item
www.3ds.com/tosca
item
ELEM
ELGR
FIX_ALL
FIX_ANY
FIX_UX
FIX_UY
FIX_UZ
CORNER_NODE
MIDSIDE_NODE
NDGR
ND_ESF
SIMULIA
Tosca Structure
ND_SF
SOLID
NODE
min_value and
max_value are selected by
increment.
lab1
<min_value>
lab2
<max_value>
lab3
<increment>
Increment
item
DISP_DX
max_value
DISP_DY
max_value
DISP_DZ
lab1
<min_value>
Minimum value
lab2
<max_value>
Maximum value
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
max_value
SIMULIA
Tosca Structure
SELECT
lab3
<cs_name>
object=SOLID
SELECT, SOLID, type, item, lab1, lab2, lab3
item
SOLID
lab1
<name_of_solid>
Examples
Select all surface nodes. Very useful for shape optimization. See also volume
3: GROUP_DEF:
! Selecting all elements for surface identification
select,elgr,s,elgr,ALL_ELEMENTS
select,elem,s,elgr
SF_IDENT
! select surface nodes
select,node,s,ND_SF
Selection of all surface nodes of the elements in the design area. The elements in the design area have property 4.
SELECT, EPROP, S, EPROP, 4
www.3ds.com/tosca
Selection of all elements at least with one node of the node group
design_nodes and two layers of elements around that element group.
SELECT, NDGR, S, NDGR, DESIGN_NODES
SELECT, NODE, S, NDGR
SELECT, ELEM, S, ND_ANY
SELECT, ELEM, A, LAYER, 2, POINT
SIMULIA
Tosca Structure
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SELECT,NODE,U,NDGR
SIMULIA
Tosca Structure
SF_IDENT
SF_IDENT
Identification and marking of all surface nodes of the active nodes. The nodes
can be addressed with the command SELECT due to this marking. For example, if shells lie on the surface of solid elements, only the free boundary of the
shell is identified as being a surface. In this case the solid elements have to
be selected with the command SF_IDENT. The following commands may be
used to perform the identification of the surface nodes for 3D elementtypes
only after the finite element model was read in via FEM_INPUT
SELECT,ETYPE,S,ETYPE,SOLID_BRICK_8
SELECT,ETYPE,A,ETYPE,SOLID_TETRA_4
SELECT,ELEM,S,ETYPE
SF_IDENT
For more detailed information see vol.2 chapter 3.4.7.2, Identifying surface
nodes for shape optimization in the Tosca Structure 8.1.0 user manual.
Remarks
www.3ds.com/tosca
SIMULIA
Tosca Structure
SMOOTH
ID_NAME
= <ID>
TASK
= <option>
= ISO
= SURFACE
= ALL_ITERATIONS
MODEL
RESULT
OUTPUT_
FILE
ISO_VALUE
= <value>
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
SMOOTH_
CYCLES
= <value>
SHRINKAGE_CO
RRECTION
=YES
=NO
REDUCTION_
RATE
= <value>
REDUCTION_
ANGLE
= <value>
SELF_
INTERSECTION_
CHECK
= <option>
= OFF
No checks
= CHECK
Check once
= RUNTIME
Check always
= ITERATIVE
www.3ds.com/tosca
SMOOTH
MIN_ANGLE
= <value>
MIXED_MESH
= YES
= NO
If set to YES, then the quadrilaterals are formed from adjacent triangles; applies to
VTFX, ONF, IGES and WRL
output formats only. Default:
NO
FORMAT
OUTPUT_
SURFACE
= ORIGINAL
= NEW
= BOTH
VTF_
ORIGINAL_
MODEL
= YES
= NO
APPEND_TO_
VTFX
=YES
=NO
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
SIMULIA
Tosca Structure
IGES_UNIT
= IN (inches)
= MM (millimeters)
= FT (feet)
= MI (miles)
= M (meters)
= KM (kilometers)
= MIL (mils)
= UM (microns)
= CM (centimeters)
= UIN (microinches)
SLICE_
NUMBER
= <value>
SLICE_
NORMAL
= <x>,<y>,<z>
SLICE_
FORMAT
= IGS_POLYGON
= IGS_CURVES
= CLI
= ALL
www.3ds.com/tosca
SMOOTH
BORDER
= YES
= NO
GROUP_FILE
GROUP_
EXCLUDE
= <group name>
GROUP_
INCLUDE
= <group name>
GROUP_
SURFACE
= <group name>
TARGET_
VOLUME
= <value>
ISO_VALUE_
GROUP
= <group>,<value>
TARGET_
VOLUME_
GROUP
= <group>,<value>
ISO_
SEQUENCE
= CONST
TASK =
all_iterations. Default
= INCR
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
SIMULIA
Tosca Structure
EXCLUDE_
LOADED
= YES
= NO
ORIGINAL_
SURFACE_
SMOOTHING
= OFF
= SHRINK
= FULL
RESULT_
FILTERING
= OFF
= MODERATE
= FULL
KEEP_
CONNECTION_NODES
= YES
= NO
COMPONENT
_LIMITING_
SIZE
= <value>
Default: YES
Defines the minimal allowed
relative size of a connected
component (calculated using
its number of faces). All components with the relative size
below this value are removed.
Default: 0
www.3ds.com/tosca
SMOOTH
SIMULIA
Tosca Structure
FORMAT
Abaqus/CAE
inp
iges1
<name>.inp
<name>.igs (IGES using block 114)
ANSYS
cdb
<name>.cdb
<name>_3.igs (IGES using block 128)
iges3
CATIA
iges3
GLView
Inova
vtfx
<name>.vtfx
MEDINA
stl
<name>.stl
(using FEM formats is also possible)
MSC Nastran
bdf
<name>.bdf
Patran
out
Pro/E
iges1
stl
<name>.stl
Solid Works
iges2
Tosca Structure.view
vtfx
<name>.vtfx
NX
stl
<name>.stl
Graphic
(animation)
programs
obj
Other pre/
postprocessors
See above
Table 2
stl
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
parameter
SIMULIA
Tosca Structure
SMOOTH
Remarks
1. The parameter file may contain any number of SMOOTH blocks. In order to
avoid the output files to be overwritten, different values of OUTPUT_FILE
parameter for each SMOOTH block should be used, in case that this
parameter is defined. If OUTPUT_FILE parameter is omitted, the value of
ID_NAME parameter (that should be unique) is used and the files do not
get overwritten.
2. If TARGET_VOLUME parameter is set to a non-zero value, ISO_VALUE
parameter is ignored. In this case, the calculations will only result in an
isosurface if the relative volume can be attained for some isovalue between
0 and 1. Moreover, for some models, the dependence of the relative
volume on the isovalue has "jumps", therefore a certain target volume
cannot be attained even if it lies between the minimal and maximal relative
volumes. If this happens, it is recommended to choose another target relative volume, or run the calculation with a fixed isovalue instead.
3. Group name "all" representing all elements of the model can be used
alongside actual group names loaded from an ONF group file. Group
names are case-insensitive.
www.3ds.com/tosca
SIMULIA
Tosca Structure
SOLID
Defines geometric SOLIDS For more detailed information see vol.2 chapter
3.9, Solids (Geometric Primitives) in the Tosca Structure 8.1.0 user manual.
ID_NAME
= <Id_name_of_solid>
SOLID_
PROP
= NEUTRAL
= VARIATION
= RESTRICTED
CS
= <name_of_coord_system>
VAL_1_MIN
= <lowest_value_coord_1>
VAL_1_MAX
= <highest_value_coord_1>
VAL_2_MIN
= <lowest_value_coord_2>
VAL_2_MAX
= <highest_value_coord_2>
VAL_3_MIN
= <lowest_value_coord_3>
VAL_3_MAX
= <highest_value_coord_3>
END_
Remarks
1. All coordinate axes must have: val_min < val_max.
2. It is necessary that all operators are entered.
SOLID
ID_NAME
SOLID_PROP
CS
VAL_1_MIN
VAL_1_MAX
VAL_2_MIN
VAL_2_MAX
VAL_3_MIN
VAL_3_MAX
END_
=
=
=
=
=
=
=
=
=
UNIT_CUBE
RESTRICTED
CS_0
0.0
1.0
0.0
1.0
0.0
1.0
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Examples
SIMULIA
Tosca Structure
STOP
STOP
Definition of STOP conditions. For more detailed information see vol.2 chapter 5.9.2, Global Stop Criterion (Number of iterations), vol.2 chapter 6.11,
Stop Condition and vol.2 chapter 7.10, Stop Condition in the Tosca Structure
8.1.0 user manual.
ID_NAME
= <Id_name_of_
stop_condition>
LOGICAL
= <name_of_
logical_variable>
ITER_MAX
= <value>
MOD_NDGR
= <name_of_node_group>
MOD_TYPE
MOVE
amount of optimization
displacement
... only positive
... only negative
optimization displacement referring to initial
model
... only positive
... only negative
controller input value
(equivalent stress)
ctrl_inp of design nodes
ctrl_inp of restricted
design nodes
ctrl_inp of free design
nodes
ctrl_inp of surface nodes
www.3ds.com/tosca
The following
parameters
are only available in combination
MOVE_GROWTH
MOVE_SHRINK
MOVE_TOTAL
MOVE_GROWTH_TOTAL
MOVE_SHRINK_TOTAL
CTRL_INP
CTRL_INP_SHAPE
CTRL_INP_SHAPE_FIX
CTRL_INP_SHAPE_FREE
CTRL_INP_SURFACE
SIMULIA
Tosca Structure
MOD_OPER
= [ LT | LE | EQ | GE | GT ]
comparison operater
(less than, less or
equal,...)
MOD_REF
MULT: <real>*Value of
MOD_TYPE in
PREV|FIRST iteration
ADD: <real>+ Value of
MOD_TYPE in
PREV|FIRST iteration
etc.
OPTIMIZE
= <name_of_
optimization_group>
Remarks
1. Using the parameter ITER_MAX a global stop condition can be set. In the
optimization system a number of 40 iterations is set by default.
2. If a global STOP condition is defined no other parameters can be defined in
the STOP command. If an additional logical STOP condition has to be
defined, another STOP definition has to be defined.
Examples
The optimization should stop, when the maximum equivalent stress of the
node group all_nodes is smaller than 1% of the maximum equivalent stress of
the first iteration:
ID_NAME
= STOP_COMMAND
MOD_NDGR
= ALL_NODES
MOD_TYPE
= MAX, CTRL_INP_SHAPE
MOD_OPER
= LE
MOD_REF
OPTIMIZE
= RUN
END_
The optimization should stop when the equivalent maximum von Mises stress
in the design area is smaller than 200 MPa.
VARIABLE
ID_NAME
DEF_TYPE
TYPE
= var_sig
= SYSTEM
= SIG_MISES
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
STOP
SIMULIA
Tosca Structure
STOP
ND_GROUP
GROUP_OPER
= design_nodes
= MAX
END_
LOGICAL
ID_NAME= logi_1
DEF_TYPE
OPER
VAR_A
FIX_VAL
=
=
=
=
BASE
LT
var_sig
200
END_
STOP
ID_NAME
LOGICAL
OPTIMIZE
= my_stop_condition
= logi_1
= my_optimization_problem
www.3ds.com/tosca
END_
SIMULIA
Tosca Structure
TEST_BEAD
Defines a test displacement for bead optimization. For more detailed information see vol.2 chapter 7.9, Check run (TEST_BEAD) in the Tosca Structure
8.1.0 user manual.
OPTIMIZE
= <Name_of_optimize>
FORMAT
= ONF
Output in optimization
neutral file (ONF) format
= USER_FILE
FILE_NAME
= <Name_of_output_file>
DIRECTION
= GROW
= SHRINK
= RANDOM
DISPLACEMENT
= <value_of_
max_displacement>
INCREMENT
= <Number_of_increments>
Number of increments
START_
MODEL
= NO
= YES
USER_FILE
= <id_of_userfile>
Remarks
1. TEST_BEAD is carried out immediately after entering the command as
long as the user entries are correct.
2. Test displacements are always carried out with reference to a defined optimization task (OPTIMIZE).
3. A given file name for naming the results file (Default = TEST_BEAD).
4. DIRECTION: There are three possibilities to define the direction of
displacement: standard growth out of the component (GROW) for all
3 - 166 Commands Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
TEST_BEAD
=
=
=
=
=
=
MY_OPT_TASK
ONF
TEST_BEAD
GROW
3.67
5
www.3ds.com/tosca
END_
SIMULIA
Tosca Structure
TEST_SHAPE
Defines a test displacement for shape optimization. For more detailed information see vol.2 chapter 6.9, Check run (TEST_SHAPE) in the Tosca Structure 8.1.0 user manual.
OPTIMIZE
= <Name_of_optimize>
FORMAT
= ONF
Output in optimization
neutral file (ONF) format
= USER_FILE
FILE_NAME
= <Name_of_output_file>
DIRECTION
= GROW
= SHRINK
= RANDOM
DISPLACEMENT
= <value_of_
max_displacement>
INCREMENT
= <Number_of_increments>
Number of increments
USER_FILE
= <id_of_userfile>
Remarks
1. TEST_SHAPE is carried out immediately after entering the command as
long as the user entries are correct.
2. Test displacements are always carried out with reference to a defined optimization task (OPTIMIZE).
3. A given file name for naming the results file (Default = TEST_SHAPE).
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
TEST_SHAPE
www.3ds.com/tosca
Examples
TEST_SHAPE
OPTIMIZE
FORMAT
FILE_NAME
DIRECTION
DISPLACEMENT
INCREMENT
=
=
=
=
=
=
MY_OPT_TASK
ONF
TEST_SHAPE
GROW
3.67
5
END_
SIMULIA
Tosca Structure
USER_FILE
Defines which data of the FE model, the FE calculation or the optimization
should be saved in a specified file. For more detailed information see vol.2
chapter 10.5.4, User defined output files (USER_FILE) in the Tosca Structure
8.1.0 user manual.
ID_NAME
<id_name_of_user_file>
FILE_NAME
<file_name>
FILE_
OPTION
EL_GROUP
= ADD
= VAR
= VAR2
File is created as an
ASCII file
= ONF
Output is in optimization
Neutral File (ONF) format.
= STL
Output is in Standard
Transformation Language (STL)
= VRML
= HTML
Output is in HTML
= <name_of_element_group>
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
FORMAT
= FIX
SIMULIA
Tosca Structure
USER_FILE
ND_GROUP
= <name_of_node_group>
TYPE
Output of variables in
tables
= CATIA_RSO
= DMIG
= DVGRID
= GROUPS
= SHAPE_DATA
= BEAD_DATA
= TOPO_DATA
= SIZING_DATA
= TEST_SHAPE_LEVEL
www.3ds.com/tosca
SIMULIA
Tosca Structure
= FINITE_MODEL,
<coordinate_system_option>
= SHAPE_NEXT_DATA
= BEAD_NEXT_DATA
= FINITE_MODEL
= TOPO_MAT_ALL
= TOPO_MAT_DES
= TOPO_MAT_NO
= TABULAR
SEPARATOR
Output of variables in
tables
Blank
= BLANK
Blank
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
USER_FILE
www.3ds.com/tosca
DATA_TAB
= TAB
Tabulator
= COMMA
Comma (default)
= EXCLAM
Exclamation mark
= <xx>
for TYPE=TABULAR
= <var_name>
TITLE_1
= <Title_1>
TITLE_2
= <Title_2>
ISO_VALUE
VRML_RES
= REL_DENS, <value>
Material distribution is
used as the basis for iso
surface calculations. The
given relative density
value must lie between 0
(minimum density) and 1
(maximum density).
= ABS_DENS, <value>
Material distribution is
used as the basis for iso
surface calculations. The
given density value is an
absolute density value.
= SIG, <value>
= CTRL_INP_EL
SIMULIA
Tosca Structure
VRML_
START
WRITE
= OPT_DISP
= MP_VALUE
<min_val>
Minimum user-defined
fringe value
<max_val>
Maximum user-defined
fringe value
NO
YES
= NOW
1. The data can be generated in different formats. The following entries are
necessary in order to obtain a complete definition of the file to be generated using the command USER_FILE:
- Name of the file in which the results are to be shown
- Type of file
- Output format
- Type of results
- When the file should be created
- Nodes and elements for which the data should be generated
Pre-settings already exist in the system for many of these settings. By
entering a relevant value, these are overwritten. The settings are done
using the command END_ and the active default values are checked for
consistency of entries, to check if the written command can be executed. If
the file cannot be generated due to entries cancelling each other (e.g. an
attempt to generate data referring to elements for a node group), the
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Remarks
SIMULIA
Tosca Structure
USER_FILE
system shows a warning and the write command is not activated. Only
when all entries are consistent, the file can be activated for writing.
2. A maximum of 20 columns can be defined in a table.
3. A total of maximum 200 columns can be defined.
4. One variable can be in several columns at the same time and different variables cannot exist in one column.
5. Columns not fully occupied and lying between the first column and the
highest occupied column, are filled with zeros.
6. The output of results done via a VRML mesh are automatically scaled
between the minimum and maximum result value of the start model when
no explicit minimum and maximum value is given.
7. When entering the file name, it is necessary to know that files can be
deleted or saved in sub-directories at the end of the optimization. This can
be controlled using "wildcards". Which files are to be moved or deleted can
be set in the initialization file (see Bd.1, Chapter 8.1.3). Using the system
settings, all files that end in ".txt" are moved to the directory TOSCA_POST
after optimization has been completed.
Examples
uf_shape_onf
USER_FILE
www.3ds.com/tosca
ID_NAME
FILE_NAME
FORMAT
EL_GROUP
DATA_TYPE
WRITE
=
=
=
=
=
=
uf_shape_onf
SHAPE
ONF
=
=
=
=
=
=
uf_seset
SESET.INP
ASCII
senas_nodes
SESET, 1
NOW
all_elements
SHAPE_DATA
EVER
END_
uf_seset
USER_FILE
ID_NAME
FILE_NAME
FORMAT
ND_GROUP
DATA_ TYPE
WRITE
END_
SIMULIA
Tosca Structure
=
=
=
=
=
=
=
=
=
=
=
tab1
freq_tab.dat
ADD
ASCII
EVER
TABULAR
EXCLAM
ITERATION
=
=
=
=
=
=
=
results_1
vrmlresults
VRML
=
=
=
=
=
=
=
UF_MODEL_ONF
MODEL_fem
FIX
ONF
freq_1
freq_2
freq_3
END_
VRML-Resultsfile
USER_FILE
ID_NAME
FILE_NAME
FORMAT
EL_GROUP
TYPE
VRML_RES
WRITE
all_elements
TOPO_MAT_ALL
CTRL_INP_ND
EVER
END_
uf_model_onf.mac
ID_NAME
FILE_NAME
FILE_OPTION
FORMAT
EL_GROUP
TYPE
WRITE
all_elements
FINITE_MODEL
NOW
END_
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
USER_FILE
SIMULIA
Tosca Structure
USER_FILE
USER_FILE
ID_NAME
FILE_NAME
FILE_OPTION
FORMAT
ND_GROUP
TYPE
WRITE
SEPARATOR
=
=
=
=
=
=
=
=
UF_RSO
RSO_OUTPUT.TXT
VAR
ASCII
TITLE_1
all_nodes
CATIA_RSO
EVER
TAB
www.3ds.com/tosca
END_
SIMULIA
Tosca Structure
VARIABLE
Defines numerical variables. The command VARIABLE defines fixed or
numerical variables that change from iteration to iteration. The following
parameters are used to define variables regardless of their type (For more
detailed information see vol.2 chapter 10.5.1, Numerical variables (VARIABLE) in the Tosca Structure 8.1.0 user manual):
ID_NAME
= <id_name_of_variable>
DEF_TYPE
= SYSTEM
Variable is determined
from a load case dependent or a loadcase independent value
= FIX
= OPER
LIST
UPDATE
No output of value
= LIST
Output of value
= EVER
VALUE
= <value>
EL_GROUP
= <name_of_element_group>
Name of an element
group in which the value
of the variable is to be
determined.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
VARIABLE
ND_GROUP
= <name_of_node_group>
GROUP_
OPER
= MAX
= AVERAGE
= MIN
= SUM
= COUNT
S: Scalar value
N E : Node with additional element information
www.3ds.com/tosca
AREA
BEAD_HEIGHT
Buckling frequency
CENTER_GRAVITY_X
CENTER_GRAVITY_Y
CENTER_GRAVITY_Z
DAMAGE
BUCK_FREQ
DAMAGE_LC
DISP_ABS
DISP_X
DISP_Y
DISP_Z
DISP_X_ABS
DISP_Y_ABS
DISP_Z_ABS
DYN_FREQ
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Description
Type of
variable
Loadcase
dependent
TYPE
SIMULIA
Tosca Structure
SIMULIA
Tosca Structure
Loadcase
dependent
Type of
variable
DYN_FREQ_KREISSEL
www.3ds.com/tosca
ELEMENT
Description
TYPE
VARIABLE
Eigenfrequency calculated
with Kreisselmaier-Steinhauser formula
Number of elements in a
group (only with operator
COUNT)
ENERGY_STIFF_MEASURE
FS_ACCEL_X
FS_ACCEL_Y
FS_ACCEL_Z
FS_DBA_PRESSURE
FS_DB_PRESSURE
FS_DISP_ABS
FS_DISP_X_ABS
FS_DISP_Y_ABS
FS_DISP_Z_ABS
FS_PHASE_X
FS_PHASE_Y
FS_PHASE_Z
Loadcase
dependent
Type of
variable
FS_PRESSURE
FS_RMS_PRESSURE
FS_VELOCITY_X
FS_VELOCITY_Y
FS_VELOCITY_Z
INERTIA_XX
INERTIA_XY
INERTIA_XZ
INERTIA_YY
INERTIA_YZ
INERTIA_ZZ
INTERNAL_FORCE_ABS
NE
INTERNAL_FORCE_X
NE
INTERNAL_FORCE_X_ABS
NE
INTERNAL_FORCE_Y
NE
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
TYPE
Description
SIMULIA
Tosca Structure
SIMULIA
Tosca Structure
Loadcase
dependent
Type of
variable
Description
TYPE
www.3ds.com/tosca
VARIABLE
INTERNAL_FORCE_Y_ABS
NE
INTERNAL_FORCE_Z
NE
INTERNAL_FORCE_Z_ABS
NE
INTERNAL_MOMENT_ABS
NE
INTERNAL_MOMENT_X
NE
INTERNAL_MOMENT_X_ABS
NE
INTERNAL_MOMENT_Y
NE
INTERNAL_MOMENT_Y_ABS
NE
Loadcase
dependent
Type of
variable
INTERNAL_MOMENT_Z
NE
INTERNAL_MOMENT_Z_ABS
NE
MOVE
MOVE_GROWTH
Deformation by addition of
material
MOVE_GROWTH_TOTAL
Deformation by addition of
material
MOVE_SHRINK
Deformation by removal of
material
MOVE_SHRINK_TOTAL
Deformation by reduction of
material
MOVE_TOTAL
NODE
REACTION_FORCE_ABS
REACTION_FORCE_X
REACTION_FORCE_Y
REACTION_FORCE_Z
REACTION_MOMENT_ABS
REACTION_MOMENT_X
REACTION_MOMENT_Y
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
TYPE
Description
SIMULIA
Tosca Structure
SIMULIA
Tosca Structure
www.3ds.com/tosca
Loadcase
dependent
Type of
variable
Description
TYPE
Version 8.1.0 Rev. 1 - 05.2014
VARIABLE
REACTION_MOMENT_Z
REACTION_FORCE_X_ABS
REACTION_FORCE_Y_ABS
REACTION_FORCE_Z_ABS
REACTION_MOMENT_X_ABS
REACTION_MOMENT_Y_ABS
REACTION_MOMENT_Z_ABS
RHO_DELTA_REL
RHO_DELTA
RHO_REL
RHO
ROT_X
ROT_X_ABS
ROT_Y
Loadcase
dependent
Type of
variable
ROT_Y_ABS
ROT_Z
ROT_Z_ABS
SF_LEN_FIX
SF_LEN_FREE
SF_LEN
CTRL_INP_SHAPE_FIX
CTRL_INP_SHAPE_FREE
CTRL_INP_SHAPE
CTRL_INP
E/N
Equivalent stress
CTRL_INP_SURFACE
SIG_1
E/N
SIG_2
E/N
SIG_3
E/N
SIG_ABS_123
E/N
SIG_ABS_3
E/N
SIG_CONTACT_PRESSURE
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
TYPE
Description
SIMULIA
Tosca Structure
SIMULIA
Tosca Structure
www.3ds.com/tosca
TYPE
Loadcase
dependent
Type of
variable
Description
VARIABLE
SIG_CONTACT_SHEAR
SIG_CONTACT_SHEAR_X
SIG_CONTACT_SHEAR_Y
SIG_CONTACT_TOTAL
SIG_KUHN
E/N
SIG_DRUCKER_PRAGER
E/N
Drucker-Prager stress
hypothesis
SIG_SANDEL
E/N
SIG_BELTRAMI
E/N
SIG_MARIOTTE
E/N
SIG_MISES
E/N
SIG_SAUTER
E/N
SIG_GALILEI
E/N
SIG_TRESCA
E/N
SIG_TOPO_MISES
E/N
STRAIN_ELASTIC
elastic Strain
STRAIN_PLASTIC
plastic Strain
STRAIN_TOTAL
STRAIN_ENERGY_DENS
E/N
STRAIN_ENERGY
E/N
Strain energy
VOLUME
volume of element
WEIGHT
weight of element
SIMULIA
Tosca Structure
<approach>
STATIC
MODAL
Modal analysis
NONLINEAR
<loadcase>
ALL
<no_of_loadcase>
<substep>
ALL
<no_of_substep>
<shell_layer
>
TOP
MID
BOT
MAX
MIN
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
LC_SEL
Definition of position
where the shell stress
should be evaluated
SIMULIA
Tosca Structure
VARIABLE
= MIN
= SUM
= <name_of_element_group>
Name of an element
group in which the value
of the variable is to be
determined.
ND_GROUP
= <name_of_node_group>
ELEM
= <number of element>
Number of element to be
used for the design
response (alternative to
EL_GROUP)
NODE
= <number of node>
Number of node to be
used for the design
response (alternative to
ND_GROUP)
www.3ds.com/tosca
GROUP_OP
ER
= AVERAGE
= MIN
= SUM
SIMULIA
Tosca Structure
= COUNT
VAR_OPER
Addition
A+B+C+D
= MULT
Multiplication
A*B*C*D
= MIN
Minimun
min(A,B,C,D)
= MAX
Maximum
max(A,B,C,D
)
= SUB
Subtraction
A-B
= DIV
Division
A/B
= ABS
absolute value
abs(A)
= SIN
Sinus
sin(A)
= COS
Cosinus
cos(A)
= CUT_OFF
Cutoff Operator to
remove peaks
(parameters are
specified with additional settings)
max(CUT_O
FF_LOW,mi
n(A,CUT_O
FF_HIGH))
= TAN
Tangens
tan(A)
= LOG
Common logarithm
log(A)
= EXP
Exponential function
exp(A)
= FILTER
filter(A)
= LN
Nat. Logarithm
ln(A)
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
www.3ds.com/tosca
VARIABLE
= NORM
= NPOWER
N-th power to A
(parameter is specified with EXPONENT
Item)
= NROOT
= SQRT
Square root
sqrt(A)
= INT
Integer
int(A)
= NINT
nint(A)
= SIGN
Sign function
sign(A)
= DELTA_1
Difference between 2
iterations A(i) - A(i-1)
= DELTA_2
Difference between 2
iterations A(i) - A(i-2)
= DELTA_3
Difference between 2
iterations A(i) - A(i-3)
= DELTA_4
Difference between 2
iterations A(i) - A(i-4)
= DELTA_5
Difference between 2
iterations A(i) - A(i-5)
= DELTA_6
Difference between 2
iterations A(i) - A(i-6)
operands defined by
item VARIABLE
= COMBINE
weighted addition
w1*VAR1 +
w2*VAR2 ...
VAR_A
= <var_id_a>
VAR_B
= <var_id_b>
SIMULIA
Tosca Structure
VAR_C
= <var_id_c>
VAR_D
= <var_id_d>
Additional settings for the operators
NPOWER, NROOT and FILTER
EXPONENT
= <exponent value>
real value
= <radius value>
real value
The radius
defines the
maximum
distance for
influencing
neighbour
nodes
SIGMA
= <value>
real value
Sigma
defines the
reduction of
the radius
depending
on the surface bending
(default: 0.2)
CUT_OFF_LOW
= <value>
real value
lower bound
of the vector
value. All values under
this value will
be treated as
zero.
CUT_OFF_HIGH
= <value>
real value
upper bound
of the vector
value. All values higher
than this
value will be
set to the cut
off value.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
VARIABLE
VARIABLE
= <var_id_1>, <weight1>
Remarks
1. Definition can be done by direct allocation of a number or a database entry
or by linking several numerical variables. Variables make different
commands (e.g. STOP, OBJ_FUNC) much more flexible.
A numerical variable can have the following status:
- NOT_CHECK: The variable is not yet determined
- UNSET: The variable cannot be determined
- SET: The value of the variable is determined and has been saved.
www.3ds.com/tosca
= var_01
= FIX
= 10.5
END_
SIMULIA
Tosca Structure
VARIABLE
ID_NAME
DEF_TYPE
TYPE
UPDATE
=
=
=
=
var_02
SYSTEM
ITER
EVER
=
=
=
=
=
=
var_03
SYSTEM
SIG_MISES
my_el_group
MAX
EVER
=
=
=
=
=
=
DISP_TIP_RIGHT
DISP_Z
SYSTEM
STATIC,1
MAX
517
=
=
=
=
=
=
=
MAX_VAL_11_14
OPER
MAX
var_11
var_12
var_13
var_14
=
=
=
=
=
MEAN_VALUE_11_12
OPER
COMBINE
var_11,0.5
var_12,0.5
END_
VARIABLE
ID_NAME
DEF_TYPE
TYPE
EL_GROUP
GROUP_OPER
UPDATE
END_
VARIABLE
ID_NAME
TYPE
DEF_TYPE
LC_SET
GROUP_OPER
NODE
END_
ID_NAME
DEF_TYPE
VAR_OPER
VAR_A
VAR_B
VAR_C
VAR_D
END_
VARIABLE
ID_NAME
DEF_TYPE
VAR_OPER
VARIABLE
VARIABLE
END_
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
VARIABLE
SIMULIA
Tosca Structure
www.3ds.com/tosca
VARIABLE
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Volume IV
Examples Manual
www.3ds.com/tosca
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
SIMULIA
Tosca Structure
Preface
Preface
This manual lists and describes examples of topology, shape, bead and sizing optimization using Tosca Structure. The description covers the initial
model with its boundary conditions and loads, as well as the most important
attributes of the optimization model.
www.3ds.com/tosca
The examples found in this manual are available in the example directory of
the Tosca Structure distribution and can be executed by the user at any time.
The shown models normally have a low number of elements and nodes so
the optimization of the examples is easily done and with little calculation
efforts.
The examples are found in the following directories:
$tosca/<fe_solver>/examples/bead
$tosca/<fe_solver>/examples/shape
$tosca/<fe_solver>/examples/topo
$tosca/<fe_solver>/examples/sizing
$tosca/<life_solver>/examples/<fe_solver>/
The parameter file of the optimization (*.par), the analysis model for the FE
analysis (*.bdf, *.inp, ...) and all other necessary files that are important for
defining the optimization problem can be found in each individual model
directory. Specific files used for vol.1 chapter 3, Getting Started with Tosca
Extension for ANSYS/WB can be found in
$tosca/ansys/TS_Ext_for_WB.
Examples Manual 4 - 3
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
4 - 4 Examples Manual
SIMULIA
Tosca Structure
Topology Optimization
Topology Optimization
Topology optimization is a tool to generate a new design proposal and is often
used within the concept phase for a determining a new conceptual design for
a component. In this section, typical topology optimization examples are
described.
Example overview
Steering arm
Cranehook
Picker Arm
Control Arm
Booster
Examples
Airbeam
Keywords
Airbeam symm.
1.1
Geometric Restrictions
Casting
X
Maximum
member size
Minimum
member size
Symmetry:
cyclic
Symmetry:
planar
Symmetry:
rotational
www.3ds.com/tosca
Frozen
Examples Manual 4 - 5
SIMULIA
Tosca Structure
Airbeam
1.2
Airbeam
Task
Keywords
Commands
The actual model shows the main parts of a topology optimization task: Definition of design variables, constraints and objective function. The standard
task will be defined using Tosca ANSA environment or Tosca Structure.gui.
1.2.1
Model
Fig. 1
1.2.2
Optimization Task
The topology optimization task is to maximize the stiffness using only 45% of
the initial volume. For manufacturing reasons the outer element layer should
remain unmodified during optimization. This means that only the internal elements are permitted to be used as changeable elements for the optimization
4 - 6 Examples Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
In this model, a bending beam is fixed on the left side with a corresponding
force on the right side. All nodes on the left side of the model are fixed in the
x-axis direction. The node on the bottom left side is also fixed in the y-axis
direction. A force of 40N is applied in the right side in a negative direction of
the y-axis.
SIMULIA
Tosca Structure
Topology Optimization
1.2.3
Procedure: Summary
Model: airbeam.ext from the examples directory for your optimization task
Design area: all elements
Design variable constraint: a layer of one element on the surface is frozen
(elements fixed during optimization)
Objective: maximize stiffness
Constraint: relative volume of 45 % (equality constraint)
1.2.4
www.3ds.com/tosca
The objective function is to maximize stiffness. This corresponds to minimizing the compliance (sum of strain energy, a measure of flexibility). Thus,
choose COMPLIANCE for the group ALL_ELEMENTS as term for optimization (OBJ_FUNC_ITEM_1 | NEW | COMPLIANCE) and set the target to
MINMAX (OBJ_FUNC_ITEM_1 | EDIT).
Next, a relative target volume of 45 % has to be defined. Choose CONSTRAINTS | NEW | VOLUME_CONSTRAINT and set a relative value of 0.45
in the dialogue window for the group ALL_ELEMENTS.
1.2.5
Examples Manual 4 - 7
SIMULIA
Tosca Structure
Airbeam
GROUP_DEF
ID_NAME
= frozen_elements
TYPE
= ELEM
FORMAT
= LIST
LIST_BEGIN
1-109, 218-3815:109, 3816-3924
END_
= design_variables
= ALL_ELEMENTS
END_
= dvcon_frozen
= frozen_elements
= FROZEN
END_
The objective function is to maximize stiffness. This corresponds to minimizing the compliance (sum of strain energy, a measure of flexibility). A design
response (DRESP) must therefore be defined for the compliance of the structure:
DRESP
ID_NAME
DEF_TYPE
TYPE
UPDATE
EL_GROUP
GROUP_OPER
=
=
=
=
=
=
DRESP_SUM_ENERGY
SYSTEM
STRAIN_ENERGY
EVER
ALL_ELEMENTS
SUM
END_
4 - 8 Examples Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Topology Optimization
OBJ_FUNC
ID_NAME
DRESP
TARGET
= maximize_stiffness
= DRESP_SUM_ENERGY
= MINMAX
END_
=
=
=
=
=
=
DRESP_VOL_TOPO
SYSTEM
VOLUME
EVER
ALL_ELEMENTS
SUM
END_
This value is afterwards referenced in the constraint that enforces the maximal volume usage.
CONSTRAINT
www.3ds.com/tosca
ID_NAME
DRESP
MAGNITUDE
EQ_VALUE
=
=
=
=
volume_constraint
DRESP_VOL_TOPO
REL
0.45
END_
At last the optimization task is compiled, i.e. the design variables are linked
with the objective function and the constraints. Furthermore, additional
parameters for the optimization can be entered which can improve the convergence of the controller.
OPTIMIZE
ID_NAME
DV
OBJ_FUNC
DVCON
CONSTRAINT
=
=
=
=
=
topology_optimization
design_variables
maximize_stiffness
dvcon_frozen
volume_constraint
Examples Manual 4 - 9
SIMULIA
Tosca Structure
Airbeam
END_
OPT_PARAM
ID_NAME
OPTIMIZE
SPEED
START_DELETE
=
=
=
=
optimization_parameters
topology_optimization
SLOW
PERC,0.2
END_
1.2.6
Results
The optimization results created after 15 design cycles is illustrated in Fig. 2.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Fig. 2
4 - 10 Examples Manual
SIMULIA
Tosca Structure
Topology Optimization
1.3
1.3.1
Picker_arm
Task
Keywords
Commands
SMOOTH, FROZEN
Model
The model in this example refers to a robotic picker arm. The functional surfaces of the picker arm are loaded with pressure. The picker arm is fixed radially in the middle cross-bored area.
Fig. 3
1.3.2
Optimization Task
Minimize compliance (maximize the stiffness) using only 50% of the initial volume. Because the optimization task is nearly identical to the example in vol.4
chapter 1.2, Airbeam only the group of frozen elements and the target volume
must be changed.
Postprocess your result regarding the material distribution during the optimization progress. Create an isosurface of the optimization result for further
processing in the design process.
1.3.3
Procedure: Summary
Model: picker_arm.ext from the examples directory for your optimization task
Design area: all elements
Examples Manual 4 - 11
SIMULIA
Tosca Structure
Picker_arm
1.3.4
Fig. 4
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
After the optimization has finished, the optimization progress can be visualized.
To create postprocessing data, choose POST-PROCESSING
|
GENERATE_REPORT_FILE | CONTOUR_PLOT | [EDIT] in the task manager. Choose the result sequence to be visualized (ELEMENT FILL FILTER
in this case to visualize material distribution). The FILTER MIN value
defines the limit for the soft elements (i.e. elements with a relative material
value lower than FILTER MIN are not shown). After creating the VTFX file
with the optimization sequence (UPDATE) it can be visualized using the following entry VTF_VISUALIZATION in the task manager tree (UPDATE).
SIMULIA
Tosca Structure
Topology Optimization
which cannot be easily used for further processing in the design process.
Thus, a smooth run (SMOOTH | SMOOTH_INSTANCE | RUN_SMOOTH |
[EDIT] to define the settings) is the next step to prepare the result for CAD
transfer or validation run (Fig. 5). Enter the relative value of your target volume (in this case 0,5). The default ISO_VALUE is ignored automatically when
a TARGET_VOLUME is specified. If you have asked for VTFX output in your
smooth run, the isosurface created by Tosca Structure.smooth can be shown
with Tosca Structure.view (SMOOTH
|
SMOOTH_INSTANCE
|
VTF_VISUALIZATION | [UPDATE]). How to set up a validation run is
described in detail in vol.1 chapter 1.2.9, Result Transfer and Validation Run
(Smooth).
Fig. 5
www.3ds.com/tosca
1.3.5
Examples Manual 4 - 13
SIMULIA
Tosca Structure
Picker_arm
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Fig. 6
4 - 14 Examples Manual
SIMULIA
Tosca Structure
Topology Optimization
1.3.6
Optimization results
Fig. 7
1.4
Crane Hook
Task
Keywords
Commands
www.3ds.com/tosca
This simple model of a crane hook clearly shows the difference of an optimization with and without manufacturing restrictions. The initial model of the
hook is stressed by the forces of a cable as shown in Fig. 8. The crane hook
is being supported by the upper bore hole. As the model here is to be kept
Examples Manual 4 - 15
SIMULIA
Tosca Structure
Crane Hook
very simple, no other contacts or swinging motions in the bore hole are to be
described or taken into account.
Fig. 8
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
The surface elements in the area of the tip of the crane hook are defined as
being FROZEN, in order for it to remain as such during optimization. In addi-
4 - 16 Examples Manual
SIMULIA
Tosca Structure
Topology Optimization
tion, a force is applied in a second load case which illustrates a load case of
misuse.
Fig. 9
www.3ds.com/tosca
If the part is optimized without manufacturing restrictions (Fig. 10), the resulting structure is one with inner hollows that can not be easily manufactured. In
many cases such optimization suggestions are modified depending on the
Examples Manual 4 - 17
SIMULIA
Tosca Structure
Crane Hook
designers experience. This can cause the final structure to become unreliable. Changes made manually seldom provide the best solutions.
Fig. 10
Procedure: Summary
Model: cranehook.ext from the examples directory for your optimization task
Design area: all elements
Design variable constraint: Fix elements of group frozen_elements
Design variable constraint: demold restriction on all elements with middle
plane
Objective: maximize stiffness (minimize compliance)
Constraint: relative volume of 40 % (equality constraint)
Settings: 15 iterations (default)
1.4.2
4 - 18 Examples Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
1.4.1
SIMULIA
Tosca Structure
Topology Optimization
Fig. 11
www.3ds.com/tosca
1.4.3
=
=
=
=
=
=
=
dvcon_cast
ALL_ELEMENTS
CAST
0, 0, 1
0.
ALL_ELEMENTS
POINT,0,0,-20
END_
Examples Manual 4 - 19
SIMULIA
Tosca Structure
Crane Hook
The element group to which the restrictions refer is to be entered along with
the direction of deformation (with a vector), the deformation angle, the control
group and the middle plane.
The control group is the group of elements that need to be considered for the
deformation. The group must contain at least the elements given in the element group with the command (EL_GROUP). Should more elements be contained here than in the optimization group, the elements outside the
optimization group are regarded as being a barrier, i.e. the elements in the
optimization may not be removed under these elements.
For example, an engine bracket is optimized and a part of the engine block is
still retained in the analysis model. The check group should be reduced to the
engine bracket because the manufacture of the engine block does not affect
the manufacturing of the engine bracket. If the engine bracket is connected to
the motor, the engine block has to be taken into the CHECK_GROUP. Otherwise, the elements from the optimization area will be removed by the optimization ("pulled" by the engine block).
This must be referenced in the command Optimize in order to activate the
restrictions.
OPTIMIZE
ID_NAME
DV
OBJ_FUNC
DVCON
=topology_optimization
= design_variables
= maximize_stiffness
= dvcon_frozen
DVCON
= dvcon_cast
CONSTRAINT
= volume_constraint
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
END_
4 - 20 Examples Manual
SIMULIA
Tosca Structure
Topology Optimization
Optimization results
Fig. 12
www.3ds.com/tosca
1.5
Keywords
Commands
LINK_TOPO, DVCON_TOPO
Examples Manual 4 - 21
SIMULIA
Tosca Structure
Beam with Symmetry Restrictions (airbeam_sym)
dinate system is defined in the model it can be imported. The origin of the
coordinate system is in the middle of the design area.
center_cs
center_cs
Fig. 13
1.5.1
Procedure: Summary
Model: airbeam_sym.ext from the examples directory for your optimization
task
Design area: all elements
Design variable constraint: Fix elements of group frozen_elements
Design variable constraint: symmetry restriction
Objective: maximize stiffness (minimize compliance)
Constraint: relative volume of 55 % (equality constraint)
Settings: 15 iterations (default)
4 - 22 Examples Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
1.5.2
SIMULIA
Tosca Structure
Topology Optimization
Fig. 14
Further you can define more different symmetry restrictions. For example,
rotation symmetry can be defined. Edit the SYMMETRY_CONTROL item and
change the symmetry type to ROTATION_SYM. Specify a 60 angle and the zaxis direction while leaving the origin unchanged.
To define cyclic symmetry choose CYCLIC_SYM in the SYMMETRY_CONTROL
item and specify a translation value of 21. The origin should be the same as
in the previous definitions. The new direction is the x-axis.
Point symmetry can be defined like the rotation symmetry with 180 angle.
www.3ds.com/tosca
1.5.3
=
=
=
=
=
=
center_cs
RECTANGULAR
LOCAL
CS_0
43.5,14.5,0
0,0,0
END_
Examples Manual 4 - 23
SIMULIA
Tosca Structure
Beam with Symmetry Restrictions (airbeam_sym)
ence to the applied coordinate system and the type of coupling. The masterelement group and the child-coordinate system are referenced. The
LINK_TOPO command is referenced in the DVCON_TOPO command which
completes the assignment of the element group.
For example, plane symmetry regarding the XZ-plane is defined with the
command:
!DEFINE PLANE SYMMETRY
!SYMMETRY PLANE: X-Z PLANE OF CENTER_CS
LINK_TOPO
ID_NAME
TYPE
CS
= link_topo2
= PLANE_SYM, AXIS_2
= center_cs
END_
=
=
=
=
dvcon_plane
ALL_ELEMENTS
LINK_TOPO
link_topo2
!
!
!
!
ID_NAME
= topology_optimization
DV
= design_variables
OBJ_FUNC
= maximize_stiffness
DVCON
= dvcon_frozen
CONSTRAINT
= volume_constraint
Link Topo Constraint
DVCON
= dvcon_link
Plane Symmetry
DVCON
= dvcon_plane
Point Symmetry
4 - 24 Examples Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
END_
SIMULIA
Tosca Structure
Topology Optimization
! DVCON
= dvcon_point
! Rotation Symmetry
! DVCON
= dvcon_rotation
! Cyclic Symmetry
! DVCON
= dvcon_cyclic
END_
Optimization results
www.3ds.com/tosca
Fig. 15
Examples Manual 4 - 25
SIMULIA
Tosca Structure
Minimum und Maximum Member Size (plate_min_max)
1.6
Keywords
Commands
MIN_MEMBER, MAX_MEMBER
The model of the plate used for this example has a u-shaped nut that is
stressed by two opposing forces on its edges. The aim of the optimization is
to maximize the stiffness.
Fig. 16
1.6.1
Procedure: Summary
Model: plate_min_max.ext from the examples directory for your optimization
task
Design area: all elements
Design variable constraint: minimal member size 6 mm or maximal member
size 5.1 mm
Objective: maximize stiffness (minimize compliance)
Constraint: relative volume of 40 % (equality constraint)
4 - 26 Examples Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Topology Optimization
1.6.2
Fig. 17
www.3ds.com/tosca
Additionally you can create another member size constraint for a maximum
thickness. Choose a maximal thickness of 5.1 mm (Fig. 18).
Fig. 18
Examples Manual 4 - 27
SIMULIA
Tosca Structure
Minimum und Maximum Member Size (plate_min_max)
In the optimization task only one of the member size restrictions can remain
active. Choose one of the member size restrictions, right click on the item and
select Disable. The item appears crossed out. Run the optimization with the
chosen restriction. Further rerun the optimization by activating the other
restriction and disable the primary active one.
1.6.3
=
=
=
=
dvcon_min
ALL_ELEMENTS
MIN_MEMBER
7.0
=
=
=
=
dvcon_max
ALL_ELEMENTS
MAX_MEMBER
5.1
END_
DVCON_TOPO
ID_NAME
EL_GROUP
CHECK_TYPE
THICKNESS
For the minimum and maximum member size control the thickness specified
by the user should be at least twice the average element edge length. Undesirable conditions may appear for smaller values.
The definition has to be referenced in the OPTIMIZE command:
OPTIMIZE
ID_NAME
DV
OBJ_FUNC
!insert this line
! DVCON
!insert this line
DVCON
CONSTRAINT
END_
4 - 28 Examples Manual
= MAXIMIZE_STIFFNESS
= DV_DESIGN_ELEM
= USER_OBJ_FUNC
for minimum member size constraint
= dvcon_min
for maximum member size constraint
= dvcon_max
= VOLUME_CONSTRAINT
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
END_
SIMULIA
Tosca Structure
Topology Optimization
minimum membersize
www.3ds.com/tosca
Fig. 19
maximum membersize
Examples Manual 4 - 29
SIMULIA
Tosca Structure
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
4 - 30 Examples Manual
SIMULIA
Tosca Structure
Sensitivity Based Topology Optimization
Example overview
Temperature load
Mechanism
Stress constraint
Internal forces
Crank shaft
Plate frequency
Cranehook stat
Cranehook sen
Examples
Bonnet
Keywords
Airbeam vol.
2.1
Analysis Type
STATIC
FREQUENCY
www.3ds.com/tosca
Objective
Displacement
Frequency
(KreisselmaierSteinhauser)
Compliance
Volume
X
X
X
X
Target
MAX
MIN
MINMAX
X
X
X
X
Examples Manual 4 - 31
SIMULIA
Tosca Structure
Crane hook
Temperature load
Stress constraint
Plate frequency
Mechanism
Internal forces
Crank shaft
Cranehook stat
Cranehook sen
Bonnet
Examples
Airbeam vol.
Keywords
Constraints
Center of
gravity
Displacement
X
X
Frequency
Internal force
Rotation
von Mises
stress
Volume
Geometric Restriction
Casting
Frozen
X
X
Minimum
member size
2.2
Crane hook
Task
Minimize the volume of the structure with 2 displacement constraints and 2 frequency constraints
Keywords
Commands
4 - 32 Examples Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Maximum
member size
SIMULIA
Tosca Structure
Sensitivity Based Topology Optimization
The initial model of the hook is stressed by the forces of a cable as shown in
Fig. 20 a). In addition, a force is applied in a second load case which illustrates a load case of misuse Fig. 20 b). The crane hook is being supported by
the upper bore hole. As the model here is to be kept very simple, no other
contacts or swinging motions in the bore hole are to be described or taken
into account.
Fig. 20
www.3ds.com/tosca
The surface elements in the area of the tip of the crane hook are defined as
being FROZEN, in order for it to remain as such during optimization. Target of
Examples Manual 4 - 33
SIMULIA
Tosca Structure
Crane hook
the optimization is the minimization of the volume of the cranehook for given
constraints of displacements and frequencies.
Fig. 21
2.2.1
Procedure: Summary
Model: cranehook_dyn_stat.ext from the examples directory for your optimization task
Design area: all elements
Design variable constraint: Fix elements of group frozen_elements
Design variable constraint: demold restriction on all elements using a middle
plane
Objective: minimize volume
Constraint: maximal absolute displacement of node 7166 (Fig. 22) in both
static loadcases should be 1.3 mm (two less or equal constraints)
4 - 34 Examples Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Depending on the used solver the analysis can be performed in one or two
solver runs. If the solver supports the combined modal and static analysis the
static loadcases are the loadcases with number 1 and 2. The frequency loadcase is then number 3. For the case that two analysis files are used, the referenced loadcase numbers of the second file are shifted by 10.000. Therefore
the modal analysis has to be referenced with the loadcase number (boundary
conditions set number) 10.001.
SIMULIA
Tosca Structure
Sensitivity Based Topology Optimization
Constraint: first eigenfrequency from the modal loadcase should not be less
than 200 Hz, the second eigenfrequency should be minimum 500 Hz (two
greater or equal constraints)
Settings: 50 iterations (default).
Fig. 22
www.3ds.com/tosca
2.2.2
Examples Manual 4 - 35
SIMULIA
Tosca Structure
Crane hook
specify the node number 7166. Specify the loadcase number 1 for this constraint as shown in Fig. 23.
Fig. 23
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
4 - 36 Examples Manual
SIMULIA
Tosca Structure
Sensitivity Based Topology Optimization
constraint as shown in Fig. 24. In this case the selected substep number will
refer to the eigenfrequency with the same order number.
Fig. 24
2.2.3
www.3ds.com/tosca
If the solver does not support the combined analysis the FEM_INPUT command contains two entries for the FILE item.
FEM_INPUT
ID_NAME = READ_BLOCK
FILE=CRANEHOOK_SEN.CDB
FILE=CRANEHOOK_SEN_DYN.CDB
END_
For the following definition, the number of analysis files within the
FEM_INPUT command influences the definition of the design responses
because the referenced loadcase numbers of the second file are shifted by
Examples Manual 4 - 37
SIMULIA
Tosca Structure
Crane hook
10.000. Therefore the modal analysis has to be referenced with the loadcase
number (boundary conditions set number) 10.001.
Fig. 25
The design response for the volume design response and the objective function are defined via the following commands:
DRESP
ID_NAME
DEF_TYPE
TYPE
UPDATE
EL_GROUP
GROUP_OPER
=
=
=
=
=
=
DRESP_VOL_TOPO
SYSTEM
VOL_FILL
EVER
ALL_ELEMENTS
SUM
OBJ_FUNC
ID_NAME
DRESP
TARGET
= min_vol
= DRESP_VOL_TOPO
= MIN
END_
The design response for the second frequency constraint is (for the
FEM_INPUT with two files):
DRESP
4 - 38 Examples Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
END_
SIMULIA
Tosca Structure
Sensitivity Based Topology Optimization
ID_NAME
TYPE
DEF_TYPE
LC_SET
=
=
=
=
DRESP_FREQ_2
DYN_FREQ
SYSTEM
Modal,10001,2
END_
The constraint definitions limit the frequencies to be greater than 200 Hz for
the first mode and the greater than 500 Hz for the second mode. As example
the definition of the constraint for the second mode is shown below.
CONSTRAINT
ID_NAME
DRESP
MAGNITUDE
GE_VALUE
=
=
=
=
DRESP_FREQ_2_CON
DRESP_FREQ_2
ABS
500.0
END_
= DISP_NODES
= NODE
= LIST
END_
www.3ds.com/tosca
The node is referenced in the design responses for the displacement of the
first static and the second static loadcase (here only the first static loadcase is
shown):
DRESP
ID_NAME
TYPE
DEF_TYPE
LC_SET
ND_GROUP
=
=
=
=
=
DRESP_DISP1_ABS_1
DISP_ABS
SYSTEM
STATIC,1,
DISP_NODES
END_
Now one of the two displacement constraint can be defined as absolute constraint:
CONSTRAINT
ID_NAME
DRESP
MAGNITUDE
LE_VALUE
=
=
=
=
DISP_constraint_1
DRESP_DISP1_ABS_1
ABS
1.3
END_
Examples Manual 4 - 39
SIMULIA
Tosca Structure
Crane hook
The last step is to combine all the definitions in the OPTMIZE command. Only
the objects (like constraints, objective function, design variables,...) referenced in the OPTIMIZE command are used for the optimization.
OPTIMIZE
ID_NAME
DV
OBJ_FUNC
DVCON
DVCON
CONSTRAINT
CONSTRAINT
CONSTRAINT
CONSTRAINT
=
=
=
=
=
=
=
=
=
topology_optimization
design_variables
min_vol
dvcon_frozen
dvcon_cast
DISP_constraint_1
DISP_constraint_2
DRESP_FREQ_1_CON
DRESP_FREQ_2_CON
END_
For avoiding checkerboard effects the smoothing filter can be activated with
the OPT_PARAM command.
OPT_PARAM
ID_NAME
= OPT_PARAMS
OPTIMIZE
= TOPOLOGY_OPTIMIZATION
FILTER_RADIUS = 9.0
END_
Optimization results
For getting an impression of the quality of the optimization it is necessary to
check the values of the constraints and the objective at the end of the optimization. If Tosca Structure stops the problem has converged or the maximum
number of iterations (by default 50) is reached. If no convergence is
achieved, it can be possible that the constraints are too strict meaning that
they can not be reached because of the mechanical boundary conditions of
the model. The model plot does not give any information about the quality of
the result.
A converged model shows the following characteristics:
The change of the objective function is very small so that the plot of the
value of the objective shows a nearly horizontal line
All the constraints are fulfilled or inactive (fulfilled but not near to the constraints value)
4 - 40 Examples Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
2.2.4
SIMULIA
Tosca Structure
Sensitivity Based Topology Optimization
The changes of the constraint are very small so that the plot of the constraint value shows a nearly horizontal line.
www.3ds.com/tosca
Fig. 26
Examples Manual 4 - 41
SIMULIA
Tosca Structure
Crane hook
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Fig. 27
4 - 42 Examples Manual
SIMULIA
Tosca Structure
Sensitivity Based Topology Optimization
www.3ds.com/tosca
Fig. 28
Examples Manual 4 - 43
SIMULIA
Tosca Structure
Symmetric Plate (plate_sym_freq)
Optimization results
2.3
Optimization result
Keywords
Frequency (Kreisselmaier-Steinhauser)
Commands
DYN_FREQ_KREISSEL
For the optimization of the first natural frequency a symmetric plate is generated in the FE-preprocessor. The plate is fixed at the corners and in the mid-
4 - 44 Examples Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Fig. 29
SIMULIA
Tosca Structure
Sensitivity Based Topology Optimization
500.0
800.0
Fig. 30
2.3.1
Procedure: Summary
2.3.2
Examples Manual 4 - 45
SIMULIA
Tosca Structure
Symmetric Plate (plate_sym_freq)
Fig. 31
2.3.3
4 - 46 Examples Manual
=
=
=
=
=
=
=
DRESP_FREQ
SYSTEM
DYN_FREQ_KREISSEL
MAX
Modal, 1, 1
Modal, 1, 2
Modal, 1, 3
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Sensitivity Based Topology Optimization
LC_SET
LC_SET
= Modal, 1, 4
= Modal, 1, 5
END_
OBJ_FUNC
ID_NAME
DRESP
TARGET
= maximize_first_eigenfrequency
= DRESP_FREQ
= MAX
END_
The volume constraint declaration is similar to the one in the static optimization problem.
DRESP
ID_NAME
DEF_TYPE
TYPE
UPDATE
EL_GROUP
GROUP_OPER
=
=
=
=
=
=
DRESP_VOL_TOPO
SYSTEM
VOL_FILL
EVER
ALL_ELEMENTS
SUM
=
=
=
=
volume_constraint
DRESP_VOL_TOPO
REL
0.3
END_
CONSTRAINT
ID_NAME
DRESP
MAGNITUDE
LE_VALUE
END_
www.3ds.com/tosca
The FILTER_RADIUS item is the filter radius of the smoothing filter which
eliminates the checkerboard effects. The radius has to be chosen in such a
Examples Manual 4 - 47
SIMULIA
Tosca Structure
Symmetric Plate (plate_sym_freq)
way that the value is about twice the average element edge length in the
model (approx. 12.5). A value of 25 has been used in this example.
Fig. 32
= KREISSELMEIER_FREQ_SETTINGS
OPTIMIZE
= TOPOLOGY_OPTIMIZATION
END_
4 - 48 Examples Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
FILTER_RADIUS = 25.
SIMULIA
Tosca Structure
Sensitivity Based Topology Optimization
Optimization results
Fig. 33
Fig. 34
www.3ds.com/tosca
2.3.4
Examples Manual 4 - 49
SIMULIA
Tosca Structure
Bonnet with Minmax Formulation
2.4
Keywords
Volume constraint
Commands
MINMAX
With this example the difference between the MINMAX formulation and the
MIN formulation of an optimization problem is shown. A simple example of a
bonnet is used as finite element model. There are three different loadcases
applied to the model.
2.4.1
Procedure: Summary
Model: bonnet.ext from the examples directory for your optimization task
Design area: all elements
Objective: maximize stiffness (minimize compliance)
Constraint: relative volume of 40 % (less or equal constraint)
Settings: filter radius 0.8 mm
4 - 50 Examples Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Fig. 35
SIMULIA
Tosca Structure
Sensitivity Based Topology Optimization
2.4.2
2.4.3
www.3ds.com/tosca
DRESP
ID_NAME
TYPE
DEF_TYPE
LC_SET
EL_GROUP
GROUP_OPER
=
=
=
=
=
=
COMPL_1
STRAIN_ENERGY
SYS
STATIC,1,
ALL_ELEMENTS
SUM
=
=
=
=
=
=
COMPL_2
STRAIN_ENERGY
SYS
STATIC,2,
ALL_ELEMENTS
SUM
END_
DRESP
ID_NAME
TYPE
DEF_TYPE
LC_SET
EL_GROUP
GROUP_OPER
END_
Examples Manual 4 - 51
SIMULIA
Tosca Structure
Bonnet with Minmax Formulation
DRESP
ID_NAME
TYPE
DEF_TYPE
LC_SET
EL_GROUP
GROUP_OPER
=
=
=
=
=
=
COMPL_3
STRAIN_ENERGY
SYS
STATIC,3,
ALL_ELEMENTS
SUM
END_
As first variant the formulation of the optimization problem is done in the classic way, which means that the compliances of all three loadcases are added
and the the sum of the compliances of the three loadcases is minimized.
The formulation of the objective for this looks like:
OBJ_FUNC
ID_NAME
DRESP
DRESP
DRESP
TARGET
=
=
=
=
=
MIN_COMP
COMPL_1, 1.0, 0.0
COMPL_2, 1.0, 0.0
COMPL_3, 1.0, 0.0
MIN
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
END_
4 - 52 Examples Manual
SIMULIA
Tosca Structure
Sensitivity Based Topology Optimization
2.4.4
Optimization results
As result the following structure is determined:
Fig. 36
With the second formulation, the MINMAX formulation, the objective function
definition looks like:
ID_NAME
DRESP
DRESP
DRESP
TARGET
=
=
=
=
=
MIN_MAX_COMP
COMPL_1, 1.0, 0.0
COMPL_2, 1.0, 0.0
COMPL_3, 1.0, 0.0
MIN_MAX
END_
www.3ds.com/tosca
OBJ_FUNC
Examples Manual 4 - 53
SIMULIA
Tosca Structure
Bonnet with Minmax Formulation
In this case the sum of the compliance is not minimized. Instead the maximum compliance of the three defined design responses is minimized. As
result the optimization system ends up with the following structure:
The resulting structure looks totally different compared to the standard formulation. The reason for these differences becomes obvious if the compliances
of the different loadcases are compared.
The MIN formulation ends up with a lesser total compliance of the sum of all
loadcases but the loadcases with the smaller loads have a compliance which
is lesser (higher stiffness) than the loadcase with the doubled load in the middle of the structure (Fig. 38).
The result of the MINMAX formulation shows a higher total compliance but
the compliances of all loadcases are equal which means that the structure
can handle all loadcases in the same effective way. It is not possible to
reduce the compliance for one loadcase without increasing the compliance
4 - 54 Examples Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Fig. 37
SIMULIA
Tosca Structure
Sensitivity Based Topology Optimization
for another loadcase. This solution represents one point on a Pareto optimality front (Fig. 39).
Fig. 39
www.3ds.com/tosca
Fig. 38
Examples Manual 4 - 55
SIMULIA
Tosca Structure
Crankshaft
2.5
Crankshaft
Task
Keywords
Commands
CENTER_GRAVITY_Y
This example illustrates sensitivity based topology optimization of a crankshaft where following demands are considered: low weight, certain bending
and torsional stiffness as well as good behavior under centrifugal loading.
The latter can be achieved via optimized location of the gravity center (balanced design). In this example a constraint is set on the y-coordinate of the
center of gravity. Further constraints are used for the rotational displacements
of node 2. Both load cases are shown in Fig. 40
2.5.1
The model
The model is a simplified model of a crankshaft using shell elements for the
design area. The shafts are modeled with beam elements. The coupling
between shells and beams is done with RBE2. The coupling elements are
therefore defined as frozen elements and are not considered by the optimization. Boundary conditions are set to both outer nodes of the shaft beams
(nodes 1 and 2).
4 - 56 Examples Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Fig. 40
SIMULIA
Tosca Structure
Sensitivity Based Topology Optimization
2.5.2
Optimization task
The goal of the optimization is to reduce the weight of the crankshaft by minimizing the volume. Further two rotational displacement constraints are considered. An additional constraint is set on the location of the center of gravity.
For better convergence the initial volume of the structure is set to 90 percent.
2.5.3
www.3ds.com/tosca
Fig. 41
Examples Manual 4 - 57
SIMULIA
Tosca Structure
Crankshaft
the constraint type to ROT_Z and specify the first load case in the LC_SET
field below as shown in Fig. 42.
Fig. 42
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
8. Define a constraint for the y location of the center of gravity of the whole
model by selecting the item CENTER_OF_GRAVITY_CONSTRAINT. In the
CONSTRAINT_ITEM dialog, set the magnitude to ABS and specify a less or
4 - 58 Examples Manual
SIMULIA
Tosca Structure
Sensitivity Based Topology Optimization
Fig. 43
9. Define an initial density of 0.9 by adding the SETTINGS item to the optimization task.
10.Set up the generation of VTFX visualization and start the Tosca Structure
optimization.
www.3ds.com/tosca
2.5.4
Examples Manual 4 - 59
SIMULIA
Tosca Structure
Crankshaft
Fig. 44
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
4 - 60 Examples Manual
SIMULIA
Tosca Structure
Sensitivity Based Topology Optimization
7. Create a design response for the y location of the center of gravity of the
whole model as shown in Fig. 45. Make sure to switch the Group Oper to
Sum.
Fig. 45
www.3ds.com/tosca
Examples Manual 4 - 61
SIMULIA
Tosca Structure
Crankshaft
2.5.5
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Fig. 46
4 - 62 Examples Manual
SIMULIA
Tosca Structure
Sensitivity Based Topology Optimization
Fig. 47
www.3ds.com/tosca
Using Tosca ANSA environment you can generate a new mesh and apply the
initial boundary conditions on the new design model (Fig. 48). After that you
can perform a validation run.
Fig. 48
Examples Manual 4 - 63
SIMULIA
Tosca Structure
Mechanism
Check the analysis results. Are both rotation constraints still maintained?
Slight differences can occur due to the smoothing process. The results of the
validation run (here for the solver Abaqus) are shown in Fig. 49.
Fig. 49
Mechanism
Task
Keywords
Displacement
Commands
DISP
The present example shows that the topology optimization by Tosca Structure
is also capable of performing a mechanism design. The object function is now
different, actually opposite, from the classic compliance formulation. The
4 - 64 Examples Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
2.6
SIMULIA
Tosca Structure
Sensitivity Based Topology Optimization
Fig. 50
www.3ds.com/tosca
Fig. 50 displays the design problem. The symmetry of the structure and optimization problem is used in the input model; note that the input model as well
as the optimization results shows one half of the model (the upper rectangle)
only, however the complete model (the rectangle plus its reflection around the
lower side) are used in the finite element analysis and the optimization. In the
optimized model, the middle point of the right side (the point where the spring
is attached) is displaced towards the inside of the model, i.e., in negative x
direction, therefore the absolute value of the displacement is maximal if the
displacement itself (that is negative) is minimal. Thus, the objective function is
the minimization of the displacement of the node.
The upper left corner and the lower right corner of the half of the model (corresponding to the both left corners and the middle of the right side of the
Examples Manual 4 - 65
SIMULIA
Tosca Structure
Mechanism
entire model) are the frozen areas. The elements at these points constitute
the group support:
Fig. 51
2.6.1
Procedure: Summary
Model: mechanism.ext from the examples directory for your optimization task
Design area: all elements
Design variable constraint: the group support is marked as frozen
Objective: minimize the displacement in x direction of the node with ID = 2.
Constraint: relative volume is less than 25% (inequality constraint)
Settings: no more than 150 iterations, FILTER_RADIUS = 0.04.
4 - 66 Examples Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
2.6.2
SIMULIA
Tosca Structure
Sensitivity Based Topology Optimization
to set FILTER_RADIUS to 0.04, first create SETTINGS item using New ->
SETTINGS command of the context menu of TOPOLOGY_OPTIMIZATION_
SENSITIVITY item, then enter the value of the filter radius. Also,
AUTO_FROZEN should be set to LOAD in this dialog (this is the default value
in case that no SETTINGS item is present).
2.6.3
www.3ds.com/tosca
With the constraint that the volume is less or equal to 25% of the original
model (LE_VALUE = 0.25 with MAGNITUDE = REL) and the condition that
the elements at the supports are defined as frozen, the topology optimization
results in the structure shown in Fig. 52. In this figure, the complete model
(consisting of the model that has been actually optimized and its reflection
Examples Manual 4 - 67
SIMULIA
Tosca Structure
Internal Forces
Fig. 52
Internal Forces
Task
Keywords
Commands
INTERNAL_FORCE, REACTION_FORCE
The present example shows that the topology optimization by Tosca Structure
can also use the internal forces as the design response. See also vol.2 chapter 4.4.5, Internal force.
This example can be done using the CAE solvers Abaqus, ANSYS, MSC
Nastran and Msc Marc.
A model of a beam structure loaded with a single offset load and fully
clamped at the sides is shown in vol.4 chapter 2: First approach: a constraint
defined by internal forces. The beam structure should be optimized for stiffness but then at the same time each of the sides should only carry half of the
applied force P. That each of the clamped set of boundaries on the side
should be carrying P/2 can be ensured using two different approaches. In the
following, both approaches will be applied.
4 - 68 Examples Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
2.7
SIMULIA
Tosca Structure
Sensitivity Based Topology Optimization
In both approaches all the elements are defined as design elements and the
top layer of elements in the beam model at vol.4 chapter 2: First approach: a
constraint defined by internal forces is defined as frozen.
Fig. 53
www.3ds.com/tosca
In the first approach, a constraint is defined for the sum of internal forces
through a cut in the y-direction of the beam structure as shown in Fig. 54a.
For summing up the internal forces in the y-direction an element group
(EL_INTERNAL_GROUP) and a node group (ND_INTERNAL_GROUP) is
defined. In the second approach a constraint is defined for the sum of reaction forces in the y-direction for all the nodes on left side of the beam structure
Examples Manual 4 - 69
SIMULIA
Tosca Structure
Internal Forces
as shown in Fig. 54b. For summing up the reaction forces in the y-direction a
node group (ND_REACTION_GROUP) is defined.
2.7.1
Procedure: Summary
Model: internal_forces.ext from the examples directory for your optimization
task
Design area: all elements
Design variable constraint: Fix elements of group TOP_FROZEN
Objective: maximize stiffness (minimize compliance)
Constraint: In approach 1 the sum of the internal forces in y-direction in the
section cut is at least 0.0015 (greater or equal constraint)
Constraint: In approach 2 the sum of the reaction forces in y-direction on the
left side should not exceed 0.0015 (less or equal constraint)
Constraint: relative volume of 15 % (less or equal constraint)
Settings: DENSITY_UPDATE is set to CONSERVATIVE and a 0.1
DENSITY_MOVE value is specified for stabilizing the optimization
4 - 70 Examples Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Fig. 54
SIMULIA
Tosca Structure
Sensitivity Based Topology Optimization
2.7.2
www.3ds.com/tosca
Fig. 55
Examples Manual 4 - 71
SIMULIA
Tosca Structure
Internal Forces
Fig. 56
2.7.3
= DESIGN_VARIABLES
= ALL_ELEMENTS
and
GROUP_DEF
ID_NAME
TYPE
FORMAT
LIST_BEGIN
9801-10000
END_
DVCON_TOPO
ID_NAME
4 - 72 Examples Manual
= TOP_FROZEN
= ELEM
= LIST
= DVCON_FROZEN
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Sensitivity Based Topology Optimization
EL_GROUP
CHECK_TYPE
END_
= TOP_FROZEN
= FROZEN
www.3ds.com/tosca
In the first approach a constraint is defined for the sum of internal forces
through a cut in the y-direction of the beam structure as shown in Fig. 54a.
For summing up the internal forces in the y-direction an element group and a
node group is defined like the following:
GROUP_DEF
ID_NAME
= ND_INTERNAL_GROUP
TYPE
= NODE
FORMAT
= LIST
LIST_BEGIN
149,476,751,1078,1353,1680,1955,2282,2557,2884,3159,3486,
3761,4088,4363,4690,4965,5292,5567,5894,6169,6496,6771,
7098,7373,7700,7975,8302,8577,8904,9179,9506,9781,10108,
10383,10710,10985,11312,11587,11914,12189,12516,12791,
13118,13393,13720,13995,14322,14597,14924,15199,
15526-20551:201,
20826,21153,21428,21755,22030,22357,22632,22959,23234,
23561,23836,24163,24438,24765,25040,25367,25642,25969,
26244,26571,26846,27173,27448,27775,28050,28377,28652,
28979,29254,29581,29856,30183,30458,30785,31060,31387,
31662,31989,32264,32591,32866,33193,33468,33795,34070,
34397,34672,34999,35274,35601,35876,36604,36879,37206,
37481,37808,38083,38410,38685,39012,39287,39614,39889,
40216,40491,40818,41093,41420,41695,42022,42297,42624,
42899,43226,43501,43828,44103,44430,44705,45032,45307,
45634,45909,46236,46511,46838,47113,47440,47715,48042,
48317,48644,48919,49246,49521,49848,50123,50450,50725,
51052,51327
END_
GROUP_DEF
ID_NAME
TYPE
FORMAT
LIST_BEGIN
75-9875:200
END_
= EL_INTERNAL_GROUP
= ELEM
= LIST
In this approach the internal forces is summed up in the y-direction for the
previously defined node and element group yielding
Examples Manual 4 - 73
SIMULIA
Tosca Structure
Internal Forces
DRESP
ID_NAME
TYPE
DEF_TYPE
GROUP_OPER
ND_GROUP
EL_GROUP
END_
=
=
=
=
=
=
DRESP_INT_Y_SUM
INTERNAL_FORCE_Y
SYSTEM
SUM
ND_INTERNAL_GROUP
EL_INTERNAL_GROUP
=
=
=
=
CON_INT_Y_SUM
DRESP_INT_Y_SUM
ABS
0.0015
Afterwards, the sum of strain energy is minimized in the objective function for
obtaining a stiff structure in the following way
=
=
=
=
=
DRESP_SUM_ENERGY
SYSTEM
STRAIN_ENERGY
ALL_ELEMENTS
SUM
= MAXIMIZE_STIFFNESS
= DRESP_SUM_ENERGY
= MIN
4 - 74 Examples Manual
=
=
=
=
=
DRESP_VOL_TOPO
SYSTEM
VOL_TOPO_FILL
ALL_ELEMENTS
SUM
= VOLUME_CONSTRAINT
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
DRESP
ID_NAME
DEF_TYPE
TYPE
EL_GROUP
GROUP_OPER
END_
OBJ_FUNC
ID_NAME
DRESP
TARGET
END_
SIMULIA
Tosca Structure
Sensitivity Based Topology Optimization
DRESP
MAGNITUDE
LE_VALUE
END_
= DRESP_VOL_TOPO
= REL
= 0.15
Then all the design commands are added to the optimization in OPTIMIZE
commands yielding
OPTIMIZE
ID_NAME
DV
OBJ_FUNC
DVCON
CONSTRAINT
CONSTRAINT
END_
=
=
=
=
=
=
TOPOLOGY_OPTIMIZATION
DESIGN_VARIABLES
MAXIMIZE_STIFFNESS
DVCON_FROZEN
VOLUME_CONSTRAINT
CON_INT_Y_SUM
www.3ds.com/tosca
In the second approach a constraint is defined for the sum of reaction forces
in the y-direction for all the nodes on left side of the beam structure as shown
in Fig. 54b. For summing up the reaction forces in the y-direction a node
group for is defined like the following:
GROUP_DEF
ID_NAME
= ND_REACTION_GROUP
TYPE
= NODE
FORMAT
= LIST
LIST_BEGIN
1,402,603,1004,1205,1606,1807,2208,2409,2810,
3011,3412,3613,4014,4215,4616,4817,5218,5419,
5820,6021,6422,6623,7024,7225,7626,7827,8228,
8429,8830,9031,9432,9633,10034,10235,10636,
10837,11238,11439,11840,12041,12442,12643,13044,
13245,13646,13847,14248,14449,14850,15051,
15452-20678:201,
21079,21280,21681,21882,22283,22484,22885,23086,
23487,23688,24089,24290,24691,24892,25293,25494,
25895,26096,26497,26698,27099,27300,27701,27902,
28303,28504,28905,29106,29507,29708,30109,30310,
30711,30912,31313,31514,31915,32116,32517,32718,
Examples Manual 4 - 75
SIMULIA
Tosca Structure
Internal Forces
33119,33320,33721,33922,34323,34524,34925,35126,
35527,35728,36530,36731,37132,37333,37734,37935,
38336,38537,38938,39139,39540,39741,40142,40343,
40744,40945,41346,41547,41948,42149,42550,42751,
43152,43353,43754,43955,44356,44557,44958,45159,
45560,45761,46162,46363,46764,46965,47366,47567,
47968,48169,48570,48771,49172,49373,49774,49975,
50376,50577,50978,51179
END_
In this approach the reaction forces is summed up in the y-direction for the
previously defined node yielding
DRESP
ID_NAME
TYPE
DEF_TYPE
GROUP_OPER
ND_GROUP
END_
=
=
=
=
=
DRESP_REAC_Y_SUM
REACTION_FORCE_Y
SYSTEM
SUM
ND_REACTION_GROUP
CON_REAC_Y_SUM
DRESP_REAC_Y_SUM
ABS
0.0015
Then the OPTIMIZE command is modified to include the constraint for the
sum of reaction forces like the following instead of the constraint for internal
forces
OPTIMIZE
ID_NAME
DV
OBJ_FUNC
DVCON
CONSTRAINT
CONSTRAINT
END_
=
=
=
=
=
=
TOPOLOGY_OPTIMIZATION
DESIGN_VARIABLES
MAXIMIZE_STIFFNESS
DVCON_FROZEN
VOLUME_CONSTRAINT
CON_REAC_Y_SUM
4 - 76 Examples Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
CONSTRAINT
ID_NAME
DRESP
MAGNITUDE
LE_VALUE
END_
SIMULIA
Tosca Structure
Sensitivity Based Topology Optimization
2.7.4
www.3ds.com/tosca
The results of three different optimizations are shown in Fig. 57. Fig. 57a
shows the stiffness optimization including the internal force constraint define
in vol.4 chapter 2: First approach: a constraint defined by internal forces. Fig.
57b shows the result of the optimization when the reaction force constraint
given in vol.4 chapter 2: Second approach: a constraint defined by reaction
forces is applied instead of the internal force constraint. Fig. 57c shows the
stiffness optimization with only the volume constraint.
Fig. 57
Examples Manual 4 - 77
SIMULIA
Tosca Structure
Temperature Loading
2.8
Temperature Loading
Task
Keywords
Commands
Fig. 58
a) Load case 1 is combined of a static external force and a constant temperature loading. b) Load case 2 consists strictly of
external static forces. c) Load case 3 consists strictly of a constant temperature loading.
4 - 78 Examples Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
The present example shows that the topology optimization by Tosca Structure
is also able to consider the temperature loading.
This example can be done using the CAE solvers Abaqus and MSC Nastran.
Fig. 58 displays the design problem considering three load cases.
SIMULIA
Tosca Structure
Sensitivity Based Topology Optimization
Remark
1. STRAIN_ENERGY as DRESP when having temperature loading is not
allowed for Nastran because Nastran is calculating the strain energy using
a wrong principle.
2.8.1
Procedure: Summary
Model: temperature.ext from the examples directory for your optimization task
Design area: all elements
Objective: maximize stiffness (minimize compliance) in the first approach. In
the next approaches the objective function is to minimize the absolute displacement in y-axis direction of the load introduction nodes.
Constraint: relative volume of 40 % (less or equal constraint)
Settings: AUTO_FROZEN is set to OFF for the first approach, then to LOAD for
the next approaches.
2.8.2
www.3ds.com/tosca
Examples Manual 4 - 79
SIMULIA
Tosca Structure
Temperature Loading
2.8.3
SUM_ENERGY_LOADCASE_3
STRAIN_ENERGY
SYSTEM
STATIC,3,
ALL_ELEMENTS
SUM
and
OBJ_FUNC
ID_NAME
DRESP
TARGET
END_
= TEMP_OBJ
= SUM_ENERGY_LOADCASE_3
= MIN
Furthermore, the elements attached to the nodes where the static external
load is applied should not be frozen by default. Therefore, AUTO_FROZEN is
deactivated for the purely temperature load case 3 using the OPT_PARAM
command
OPT_PARAM
ID_NAME
4 - 80 Examples Manual
= MY_PARAMETERS
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
DRESP
ID_NAME
TYPE
DEF_TYPE
LC_SET
EL_GROUP
GROUP_OPER
END_
SIMULIA
Tosca Structure
Sensitivity Based Topology Optimization
OPTIMIZE
= TOPOLOGY_OPTIMIZATION
AUTO_FROZEN = OFF
END_
The result of the optimization is shown in Fig. 59a. One sees that basically all
material is removed from design domain. By removing all the material the
loading through the temperature loading is also removed. Thereby, the
STRAIN_ENERGY is also close to zero. Alternatively, one might maximize
the STRAIN_ENERGY like the following
OBJ_FUNC
ID_NAME
DRESP
TARGET
END_
= TEMP_OBJ
= STRAIN_ENERGY_LOAD_3
= MAX
The result of the optimization is shown in Fig. 59b. One sees that the structure is stiff in axial compression and thereby the solution leads to high reaction forces at the clamped boundary conditions and high stresses.
Remarks
1. STRAIN_ENERGY as DRESP when having temperature loading is not
allowed for Nastran because Nastran is calculating the strain energy using
a wrong principle.
www.3ds.com/tosca
Afterwards, the absolute displacements are defined for load case 2 and minimized in the objective,
DRESP
ID_NAME
TYPE
DEF_TYPE
LC_SET
=
=
=
=
DISP_LOADCASE_2
DISP_Y_ABS
SYSTEM
STATIC,2,
Examples Manual 4 - 81
SIMULIA
Tosca Structure
Temperature Loading
ND_GROUP
END_
OBJ_FUNC
ID_NAME
DRESP
TARGET
END_
= MY_GROUP
= TEMP_OBJ
= DISP_LOADCASE_2
= MIN
=
=
=
=
=
DISP_LOADCASE_1
DISP_Y_ABS
SYSTEM
STATIC,1,
MY_GROUP
= TEMP_OBJ
= DISP_LOADCASE_1
= MIN
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
4 - 82 Examples Manual
SIMULIA
Tosca Structure
Sensitivity Based Topology Optimization
Optimization results
Fig. 59
Minimizing (a) and maximizing (b) the sum of strain energy for
load case 3 in Fig. 57, respectively.
Fig. 60
Comparing the optimization results in Fig. 60 shows that the temperature field
has a significant impact on the designs.
www.3ds.com/tosca
2.8.4
Examples Manual 4 - 83
SIMULIA
Tosca Structure
Stress Constraint
2.9
Stress Constraint
Task
Keywords
Commands
SIG_TOPO_MISES_CONSTRAINT
This chapter shows the minimization of the volume with restrictions on the
maximum von Mises stress illustrated with the example of a beam as seen in
Fig. 61.
Maximizing the stiffness for a given target volume forms a standard optimization setup in topology optimization - applied, e.g., when a certain weight shall
not be exceeded. Initially a possible "target stiffness" can often not be determined, but the material parameters and thus the maximum admissible stress
for the structure is known. Thus, another optimization setup could be to minimize the volume for a specified stress constraint.
An example is seen in Fig. 62: The stiffness of the beam has been optimized
for a specified target volume. The result shows a stress concentration in the
upper horizontal bar. To reduce that stress it is helpful to specify a stress constraint and to minimize the volume.
Fig. 62
2.9.1
Stress concentration in the upper horizontal bar of a beam optimized for the stiffness and a volume constraint
Procedure: Summary
Model: stress_constraint.ext from the examples directory
4 - 84 Examples Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Fig. 61
SIMULIA
Tosca Structure
Sensitivity Based Topology Optimization
2.9.2
www.3ds.com/tosca
Fig. 63
Define an objective function to minimize the volume of your design area: Edit
your OBJ_FUNC_ITEM (right click on the item) and set the target to MIN.
Examples Manual 4 - 85
SIMULIA
Tosca Structure
Stress Constraint
Then OBJ_FUNC_ITEM | NEW | VOLUME (as shown in Fig. 66) and selection of your group.
Fig. 64
Remember
to
increase
the
number
(GLOBAL_STOP_CONDITION | ITER_MAX).
2.9.3
of
iterations
to
80
Fig. 65
4 - 86 Examples Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Sensitivity Based Topology Optimization
=
=
=
=
TOPO_STRESS_DESIGN_ELEMENTS
SIG_TOPO_MISES
SYSTEM
DESIGN_AREA
=
=
=
=
CON_STRESS
ABS
70000.
TOPO_STRESS_DESIGN_ELEMENTS
END_
CONSTRAINT
ID_NAME
MAGNITUDE
LE_VALUE
DRESP
END_
www.3ds.com/tosca
Define a design response (DRESP) for the objective function with Volume as
Type of Category Base. Then define an OBJECTIVE_FUNCTION with the
minimized DRESP as shown in Fig. 66
Fig. 66
=
=
=
=
=
DRESP_VOL_TOPO
VOLUME
SYSTEM
Sum
DESIGN_AREA
END_
Examples Manual 4 - 87
SIMULIA
Tosca Structure
Stress Constraint
OBJ_FUNC
ID_NAME
TARGET
DRESP
= MY_OBJ_FUNC
= MIN
= DRESP_VOL_TOPO
END_
2.9.4
Optimization results
Fig. 67 shows the result of two optimization setups: the upper beam with minimized volume and restricted stress, the lower one with minimized stress and
restricted volume. Both models have the same volume.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Fig. 67
4 - 88 Examples Manual
SIMULIA
Tosca Structure
Shape Optimization
Shape Optimization
Shape optimization allows specific detail improvements of existing designs.
Through shape optimization the surface geometry of a given model is modified automatically to avoid material failure and increase durability or comfort.
In this section, typical shape optimization examples are described.
Example overview
Clip
Conrod
Holeplate
Hub
Rim
Shaft
Shaft drill
Shaft turn
Threehole
Twohole
Cranehook morph
Examples
Carrier stamp
Keywords
Carrier
3.1
Strategy
Controller
Morph
Analysis Type
STATIC
www.3ds.com/tosca
FREQUENCY
Objective
von Mises
stress
v. Mises stress
on reference
nodes
Frequency
Target
MAX
MIN
X
X
Examples Manual 4 - 89
SIMULIA
Tosca Structure
Example overview
Cranehook morph
Twohole
Threehole
Shaft turn
Shaft drill
Shaft
Rim
Holeplate
Hub
MINMAX
Conrod
Clip
Carrier stamp
Examples
Carrier
Keywords
Constraints
Volume
Geometric Restrictions
Automatic
node selection
Displacement
direction (DOF)
X
X
Node fixation
Penetration
check (solid)
X
X
Symmetry:
rotational
Symmetry:
cyclic and
planar
Demolding
(casting)
Drilling
4 - 90 Examples Manual
X
X
X
X
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Turning
Displacement
amount
Stamping
Penetration
check (el.
group)
Symmetry:
planar
SIMULIA
Tosca Structure
Shape Optimization
3.2
Holeplate
Task
Keywords
Commands
100.0
Fig. 68
Model of "holeplate"
www.3ds.com/tosca
The goal of the optimization is to minimize the maximum stresses under the
constraint. Fig. 70 illustrates the von Mises stress and the FE displacement
for both load cases.
loadcase 1
Fig. 70
loadcase 2
Examples Manual 4 - 91
SIMULIA
Tosca Structure
Holeplate
The nodes on the surface of the drilled hole are to be kept free for modification in shape optimization. The nodes on the symmetry edges should not
move in relation to the symmetry plane. Design variable constraints
(DVCON_SHAPE) must be defined for the nodes on the symmetrical edges
for keeping them fixed during optimization. In this case, the nodes on the
symmetry edges are fixed with respect to the symmetrical planes.
3.2.1
Procedure: Summary
Model: holeplate.ext from the examples directory for your optimization task
Design area: node group design_nodes
Design variable constraint: apply boundary conditions for all nodes
Mesh smooth: mesh smoothing of all elements, while free surface nodes
remain fixed
Objective: minimize the von Mises stresses in the design area
Options: read boundary conditions for all nodes
Stop condition: the global stop condition is set to 5 iterations
3.2.2
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Choose a SHAPE_OPTIMIZATION_CONTROLLER task in Tosca ANSA environment and create the model link. Add the node group containing the design
nodes to the design area. The group design_nodes contains all surface
nodes on the quarter hole.
Choose the item PRE_PROCESSING | DESIGN_AREA | NEW |
MESH_SMOOTH in the task manager to set the mesh smoothing. In the
4 - 92 Examples Manual
SIMULIA
Tosca Structure
Shape Optimization
MESH_SMOOTH item, define a mesh smoothing area of all elements with fixation of all free surface nodes, LAYERS = 0 (Fig. 72).
Fig. 72
www.3ds.com/tosca
3.2.3
= ALL
END_
Examples Manual 4 - 93
SIMULIA
Tosca Structure
Two Hole (Relief Notch)
DVCON_SHAPE
ID_NAME
ND_GROUP
CHECK_BC
= dvcon_fix_spc
= ALL_NODES
= YES
END_
Optimization results
Fig. 73
3.3
Optimization results
Keywords
Commands
This example uses the principle of a relief notch and demonstrates how the
optimization task should be defined. High stresses are found in a notch (primary notch) of a component. A second notch (secondary notch) having a
4 - 94 Examples Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
3.2.4
SIMULIA
Tosca Structure
Shape Optimization
short distance to the primary notch should work to relieve the stresses on the
primary notch. The optimal shape of the secondary notch should be obtained
using shape optimization in order to achieve as low a stress factor as possible in the primary notch. Fig. 74 shows the stresses in the two hole model.
Fig. 74
www.3ds.com/tosca
The stress in the primary notch is only minimal when the maximum stresses
in the secondary notch and the primary notch are the same. A distribution of
the notch effect takes place at both positions. In order to optimize this effect,
a definition must be made using a variable reference value.
The definition of following groups is required for the optimization task (Fig.
75).
Fig. 75
3.3.1
Procedure: Summary
Model: twohole.ext from the examples directory for your optimization task
Design area: node group design_nodes
Design variable constraint: solid body boundaries for the design nodes
Examples Manual 4 - 95
SIMULIA
Tosca Structure
Two Hole (Relief Notch)
Design variable constraint: fixation of the displacement along the global yaxis for node group fix_y
Mesh smooth: mesh smoothing of element group ms_elgr, while free surface
nodes remain free
Objective: minimize the deviation of the maximal von Mises stresses in the
primary and secondary notch
Settings: average nodal displacement, nodal displacements are scaled by
factor 2 additionally
Stop condition: the global stop condition is set to 10 iterations
3.3.2
3.3.3
=
=
=
=
=
=
REF_NODE_STRESS
SYSTEM
EVER
SIG_MISES
REFERENCE_NODES
MAX
=
=
=
=
=
DRESP_VON_MISES
SYSTEM
SIG_MISES
design_nodes
Max
END_
4 - 96 Examples Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
END_
SIMULIA
Tosca Structure
Shape Optimization
is closer to the stress level found in the reference area (primary notch)
whereby the stress level in the primary notch is lowered.
OBJ_FUNC
ID_NAME
DRESP
TARGET
= minimize_deviation
= DRESP_VON_MISES, ,REF_NODE_STRESS
= MINMAX
END_
3.3.4
Optimization results
Fig. 76
www.3ds.com/tosca
The stresses at the reference nodes in the design area are drastically minimized through the optimized relief notch.
Fig. 77
Examples Manual 4 - 97
SIMULIA
Tosca Structure
Shaft
3.4
Shaft
Task
Keywords
Commands
During the optimization of rotary symmetrical components, the rotational symmetry is to be maintained. During restriction-free optimization a non-symmetrical stress distribution will create a non-rotational symmetrical structure.
Using the functionality LINK_SHAPE symmetrical requests are guaranteed. A
shaft that has been manufactured by turning is optimized in this example. The
rotational symmetry must be maintained during optimization. Fig. 78 represents the initial model with boundary conditions and the deformed structure.
In order to maintain the rotational symmetry the nodes on the surface of the
shaft must have the same z-coordinates as those in the global cylindrical
coordinate system. These nodes must be selected as a group and link conditions are arranged that couples the absolute displacement. The command
GROUP_AUTO_DEF is used in Tosca Structure to define the respective
node groups. This command allows a simple, automatic definition of these
node groups.
3.4.1
Procedure: Summary
Model: shaft.ext from the examples directory for your optimization task
Design area: node group surface_nodes
GROUP_AUTO_DEF: automatic definition of node group using the node
group parent (contains all nodes in the length of the shaft)
4 - 98 Examples Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Fig. 78
SIMULIA
Tosca Structure
Shape Optimization
Design variable constraint: left and right faces of the shaft (node groups
left_nodes and right_nodes) are fixed in global z-axis direction
Design variable constraint: nodal displacements of all surface nodes on one
diameter are the same in order to guarantee a turnable structure.
Mesh smooth: mesh smoothing of all elements, while free surface nodes
remain free
Objective: minimize the maximal von Mises stresses in the design area
Stop condition: the global stop condition is set to 5 iterations
3.4.2
3.4.3
www.3ds.com/tosca
direction of search
for link node group
Fig. 79
First, a parent node group is defined that contains all nodes in the length of
the shaft.
GROUP_DEF
ID_NAME
= parent
Examples Manual 4 - 99
SIMULIA
Tosca Structure
Shaft
TYPE
= NODE
FORMAT
= LIST
LIST_BEGIN
16, 177-1717:140
END_
From here, the command GROUP_AUTO_DEF is used for each node of the
parent group to find all nodes in a circumferential direction (360 of the global
cylindrical coordinate system CS_1) and to define new groups with the name
of the parent group as name prefix. For every node of the parent group a new
group is defined with indices (parent_1, paren_2,.., parent_13).
GROUP_AUTO_DEF
ND_GROUP
CS
TOL
SEARCH_TYPE
SEARCH_DIR
=
=
=
=
=
parent
CS_1
0.1,0.1,0.1
CONTINUOUS
+2
SEARCH_LEN
= 360
END_
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Shape Optimization
www.3ds.com/tosca
ID_NAME
MASTER
CLIENT
CS
TOL
=
=
=
=
=
link_length
MAX
LENGTH
CS_1
0.1,0.1,0.1
END_
SIMULIA
Tosca Structure
Shaft
END_
= DVCON_LINK_*
= PARENT_*
= LINK_LENGTH
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
END_
SIMULIA
Tosca Structure
Shape Optimization
ID_NAME
DV
OBJ_FUNC
DVCON
DVCON
DVCON
MESH_SMOOTH
=
=
=
=
=
=
=
shape_optimization
design_variables
minimize_max_mises
dvcon_left_fix_z
dvcon_right_fix_z
dvcon_link_*
mesh_smooth
END_
3.4.4
Optimization results
The results after optimization are shown below:
Fig. 80
www.3ds.com/tosca
3.5
Carrier
Task
Keywords
Commands
GROUP_AUTO_DEF, DVCON_AUTO_SHAPE,
LINK_PLANE_SYM
Both radii are to be optimized in this model. The component has been manufactured through punching and should not have any deflections in its depth.
Both radii should remain identical, i.e. the component should remain symmetrical. In free optimization, the nodes on the left radius will shrink and the
SIMULIA
Tosca Structure
Carrier
nodes on the right radius will grow due to the non-symmetrical stress distribution. Fig. 81 illustrates the initial model and relevant stresses.
Fig. 81
Procedure: Summary
Model: carrier.ext from the examples directory for your optimization task
Design area: node group surface
GROUP_AUTO_DEF: automatic definition of node group using the node
group parent (contains all outer nodes in the radius)
Design variable constraint: design nodes are fixed in global z-axis direction
Design variable constraint: plane symmetry restriction along the global x-axis
on the design nodes
Design variable constraint: nodal displacements of all surface nodes in a row
normal to the radius are the same in order to guarantee a stampable structure.
Mesh smooth: mesh smoothing of all elements, while free surface nodes
remain fixed up to the sixth layer
Objective: minimize the maximal von Mises stresses in the design area
Settings: average nodal displacement
Stop condition: the global stop condition is set to 5 iterations
3.5.2
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
3.5.1
Model "carrier"
SIMULIA
Tosca Structure
Shape Optimization
3.5.3
search
direction
parent node
group right
Fig. 82
Definition of LINK_LENGTH
First the parent group that contains the parent nodes on the right and left
radius is defined.
www.3ds.com/tosca
GROUP_DEF
ID_NAME
TYPE
FORMAT
LIST_BEGIN
1845-1865:2
853-873:2
= parent
= NODE
= LIST
END_
The link groups are defined from this group using the command for automatic
group definition:
GROUP_AUTO_DEF
ND_GROUP
CS
TOL
SEARCH_TYPE
SEARCH_DIR
SEARCH_LEN
=
=
=
=
=
=
parent
CS_0
0.01,0.01,0.01
CONTINUOUS
-3
40
END_
SIMULIA
Tosca Structure
Carrier
The link condition is defined for assigning the group at a later stage. The
nodes should all be assigned the same absolute optimization displacement
as the master node. The master node is determined using MAX (the largest
absolute displacement) from the relevant coupling group.
LINK_SHAPE
ID_NAME
MASTER
CLIENT
CS
TOL
=
=
=
=
=
link_length
MAX
LENGTH
CS_0
0.01,0.01,0.01
END_
Using DVCON_AUTO_SHAPE, all groups with the name prefix parent_ are
assigned the link condition as defined above.
DVCON_AUTO_SHAPE
ID_NAME
= dvcon_length_*
ND_GROUP_FAMILY = parent_*
CHECK_LINK
= link_length
END_
CS_0
Fig. 83
Definition of LINK_PLANE_SYM
LINK_SHAPE
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
symmetry plane
SIMULIA
Tosca Structure
Shape Optimization
ID_NAME
MASTER
CLIENT
CLIENT_DIR
CS
TOL
=
=
=
=
=
=
link_plane_sym
MAX
PLANE_SYM
1.0, 0.0, 0.0
CS_0
0.01,0.01,0.01
END_
This kind of LINK-coupling is only applicable for a symmetrical mesh. The link
conditions are assigned to the node groups using the command
DVCON_SHAPE. The node group 'surface' contains all nodes on the surface
of both radii that are to be optimized (all design nodes).
DVCON_SHAPE
ID_NAME
ND_GROUP
CHECK_SPC
CHECK_LINK
=
=
=
=
dvcon_plane_sym
surface
NO
link_plane_sym
END_
=
=
=
=
=
=
=
shape_optimization
design_variables
minimize_maximum_stress
dvcon_fix_z
dvcon_plane_sym
dvcon_length_*
mesh_smooth
www.3ds.com/tosca
END_
SIMULIA
Tosca Structure
Carrier_stamp
3.5.4
Optimization results
Fig. 84
3.6
Carrier_stamp
Task
Keywords
Commands
LINK_SHAPE, SURF_STAMP
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
This is the same model as the previous example and the objective function
and constraints are the same. In this case, the finite element model is built
using a tetrahedral mesh. Further, a constraint which enforces manufacturability by means of stamping (symmetry is also possible but not shown here)
is required.
SIMULIA
Tosca Structure
Shape Optimization
The standard coupling conditions may not be used, as the surface nodes of
the mesh are not lying exactly in the direction of stamping. Fig. 85 illustrates
the mesh, boundary conditions and the stress distribution of the initial model.
Fig. 85
Model carrier_stamp
www.3ds.com/tosca
For arbitrary meshes, the surface nodes may not be grouped using the standard link conditions. In this case, a geometric and mesh independent
approach has to be used. The user has to specify a surface node group
which describes the stamping surface. In addition, the stamping direction has
to be defined using a coordinate system.
The stamping surface is described by the stamping direction and the nodes
on this surface produce a manufacturing curve. When the manufacturing
curve is moved along the stamping direction, the stamping surface is
described. Tosca Structure automatically determines the producing curve for
a given link domain.
SIMULIA
Tosca Structure
Carrier_stamp
The definition of the following groups is required for the optimization task (Fig.
86).
Fig. 86
Procedure: Summary
Model: carrier_stamp.ext from the examples directory for your optimization
task
Design area: node group design_area
Design variable constraint: apply boundary conditions for all nodes
Design variable constraint: stamping restriction for node group geo_area in
direction of the global positive z-axis
Design variable constraint: fixation of the displacement along the global xaxis for node group fix_x
Design variable constraint: fixation of the displacement along the global yaxis for node group fix_y
Design variable constraint: fixation of the displacement along the global zaxis for node group fix_z
Mesh smooth: mesh smoothing of all elements, while free surface nodes
remain fixed up to the third layer
Objective: minimize the maximal von Mises stresses in the design area
Options: read boundary conditions for all nodes
Stop condition: the global stop condition is set to 5 iterations
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
3.6.1
SIMULIA
Tosca Structure
Shape Optimization
3.6.2
3.6.3
www.3ds.com/tosca
LINK_SHAPE
ID_NAME
MASTER
CLIENT
CLIENT_DIR
CS
=
=
=
=
=
geo
MAX
SURF_STAMP
0.0, 0.0, 1.0
cs_0
END_
= dvcon_geo
= geo_area
= geo
END_
SIMULIA
Tosca Structure
Shaft_turn
=
=
=
=
=
=
=
=
=
shape_optimization
design_variables
min_function
check_spc
dvcon_fix_x
dvcon_fix_y
dvcon_fix_z
dvcon_geo
mesh_smooth
END_
Optimization result
Fig. 87
3.7
Shaft_turn
Task
Keywords
Commands
LINK_SHAPE, SURF_TURN
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
3.6.4
SIMULIA
Tosca Structure
Shape Optimization
Fig. 88
www.3ds.com/tosca
Segmentation into link groups is not possible for arbitrary meshes. The
parameter SURF_TURN in the LINK_SHAPE command is used to define the
restriction. This geometric approach allows the definition of turning restrictions for any finite element mesh. The rotation curve is determined automatically by the optimization system. The user only has to define a surface node
group which specifies the turn surface and the rotation axis using a coordinate system.
SIMULIA
Tosca Structure
Shaft_turn
The definition of following groups is required for the optimization task (Fig.
89).
Fig. 89
Procedure: Summary
Model: shaft_turn.ext from the examples directory for your optimization task
Design area: node group design_area
CS_DEF: new cylindrical coordinate system, defined by rotating the global
CS by 270 around the global x-axis
Design variable constraint: apply boundary conditions for all nodes
Design variable constraint: turning restriction for node group geo_area1 in
direction of the global positive y-axis
Design variable constraint: fixation of the displacement along the global yaxis for node group fix_area
Design variable constraint: fixation of the first (radial) coordinate (in the new
cylindrical coordinate system) of the displacements for node group
cylinder_circle
Mesh smooth: mesh smoothing of all elements, while free surface nodes
remain free
Objective: minimize the maximal von Mises stresses in the design area
Options: read boundary conditions for all nodes
Stop condition: the global stop condition is set to 6 iterations
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
3.7.1
SIMULIA
Tosca Structure
Shape Optimization
3.7.2
www.3ds.com/tosca
the third point, e.g., on the border of the smaller circle (the location of the
third point makes no difference, it is only required that it does not lie on the
axis of the model).
In the dialog that opens after three points are chosen, it is possible to correct
the coordinates by editing the fields A1,..., C3, in case that better precision is
needed or if the selection of nodes has presented some difficulties:
A1 = 0, A2 = 0, A3 = 0, B1 = 0, B2 = 5, B3 = 0, C1 = 0.2, C2 = 0, C3 = 0.
Afterwards, this coordinate system should be mentioned in CS_DEF field of
DOF_CONTROL dialog (opened when New -> DOF_CONTROL command is
applied on the item DV_CONSTRAINTS), after CHECK_DOF is set to
CS_DEF in the dialog. Then, DOF_1 = FIXED sets the fixation of r coordinate
(i.e., the distance to the axis of the cylindrical coordinate system), so that all
nodes of the node group (cylinder_circle; choose it in ND_GROUP field) are
not allowed to be displaced radially.
SIMULIA
Tosca Structure
Shaft_turn
3.7.3
=
=
=
=
=
link_geo
MAX
SURF_TURN
0.0, 1.0, 0.0
CS_0
END_
= dvcon_geo
= geo_area
= link_geo
END_
=
=
=
=
=
=
=
=
shape_optimization
design_variables
min_function
check_spc
fix_y
fix_cylinder_circle
dvcon_geo
mesh_smooth
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
OPTIMIZE
SIMULIA
Tosca Structure
Shape Optimization
Optimization results
The optimization results for the model shaft_turn are illustrated in Fig. 90 :
Fig. 90
Shaft_drill
Task
Keywords
Commands
LINK_SHAPE, SURF_DRILL
The model is a shaft with a transverse drilling. Symmetrical aspects allow for
modeling of only a half model and symmetry boundary conditions are applied
to the symmetry plane. The drilling hole has to be maintained during the optimization procedure. Drilling combines a turning surface which has to be
demoldable against the feed direction of the die. If no restrictions are
enforced, an oval shaped hole would be the result of the optimization as the
stress distribution is not symmetrical.
www.3ds.com/tosca
3.8
SIMULIA
Tosca Structure
Shaft_drill
Fig. 91 illustrates the boundary conditions and the stress distribution of the
initial model.
Fig. 91
Fig. 92
3.8.1
Procedure: Summary
Model: shaft_drill.ext from the examples directory for your optimization task
Design area: node group drill
CS_DEF: new cylindrical coordinate system, defined by rotating the global
CS by 90 around the global y-axis and origin with coordinates (0,0,5)
Design variable constraint: apply boundary conditions for all nodes
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
The definition of following groups is required for the optimization task (Fig. 92)
SIMULIA
Tosca Structure
Shape Optimization
Design variable constraint: drilling restriction for the design nodes in direction
of the global positive z-axis
Design variable constraint: fixation of the displacement along the global xaxis for node group fix_x
Design variable constraint: fixation of the displacement along the global yaxis for node group fix_y
Design variable constraint: fixation of the displacement along the x-axis of the
new cylindrical CS for node group shell
Mesh smooth: mesh smoothing of all elements, while free surface nodes
remain fixed up to the fourth layer
Objective: minimize the maximal von Mises stresses in the design area
Options: read boundary conditions for all nodes
Stop condition: the global stop condition is set to 6 iterations
www.3ds.com/tosca
3.8.2
SIMULIA
Tosca Structure
Shaft_drill
3.8.3
=
=
=
=
=
GEO
MAX
SURF_DRILL
0.0, 0.0, 1.0
cs_0
END_
= dvcon_geo
= drill
= geo
END_
OPTIMIZE
ID_NAME
DV
OBJ_FUNC
DVCON
DVCON
DVCON
MESH_SMOOTH
DVCON
DVCON
END_
=
=
=
=
=
=
=
=
=
optimize
design_variables
min_function
dvcon_spc
dvcon_fix_x
dvcon_fix_y
mesh_smooth
dvcon_geo
dvcon_fix_shell
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Shape Optimization
www.3ds.com/tosca
Fig. 93
SIMULIA
Tosca Structure
Clip
3.9
Clip
Task
Keywords
Commands
CHECK_GROW_SHRINK, CHECK_DOF,
CHECK_SOLID
This example illustrates a plastic clip that is used to fix a variety of objects.
The maximum stress is found on the inner side of the clip
The aim of optimization is to reduce the stresses without changing the contour of the inner side. Only nodes on the outer side are to be designed.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Fig. 94
SIMULIA
Tosca Structure
Shape Optimization
The stress level is very low at the tips. Therefore, an optimization without
restrictions would result in these low-stressed areas shrinking. Thus, two
cylindrical frozen areas are defined at the tips.
Fig. 95
www.3ds.com/tosca
3.9.1
Procedure: Summary
Model: clip.ext from the examples directory for your optimization task
Design area: node group DV_NODES
CS_DEF: new rectangular coordinate system, defined by rotating the global
CS by 45 around the global z-axis
CS_DEF: new cylindrical coordinate system, defined by translating the previously defined rectangular CS to origin with coordinates (23,23,0)
CS_DEF: new cylindrical coordinate system, defined by translating the previously defined rectangular CS to origin with coordinates (23,-23,0)
Design variable constraint: two solid body boundaries for the design nodes
Design variable constraint: fixation of all displacements for node group
NODES_FIX_ALL
Design variable constraint: fixation of the displacement along the global zaxis for node group nodes_fix_z
Design variable constraint: maximal growth and shrinkage of 6 mm for the
design nodes
Mesh smooth: mesh smoothing of all elements, while free surface nodes
remain free
Objective: minimize the maximal von Mises stresses in the design area
Stop condition: the global stop condition is set to 5 iterations
SIMULIA
Tosca Structure
Clip
3.9.3
=
=
=
=
=
1
RECTANGULAR
LOCAL
CS_0
0,0,0
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
3.9.2
SIMULIA
Tosca Structure
Shape Optimization
ROTATION_321
= 45,0,0
END_
=
=
=
=
=
CS_CYL_LEFT
CYLINDRICAL
LOCAL
1
23,23,0
END_
=
=
=
=
=
CS_CYL_RIGHT
CYLINDRICAL
LOCAL
1
23,-23,0
END_
Definition of solids
The coordinate system is now used to define the cylindrical frozen areas in
the tips of the clip
www.3ds.com/tosca
SOLID
ID_NAME
SOLID_PROP
CS
VAL_1_MIN
VAL_1_MAX
VAL_2_MIN
VAL_2_MAX
VAL_3_MIN
VAL_3_MAX
=
=
=
=
=
=
=
=
=
SOLID_CYL_LEFT
RESTRICTED
CS_CYL_LEFT
0
7
0
360
-100
100
=
=
=
=
=
=
=
SOLID_CYL_RIGHT
RESTRICTED
CS_CYL_RIGHT
0
7
0
360
END_
SOLID
ID_NAME
SOLID_PROP
CS
VAL_1_MIN
VAL_1_MAX
VAL_2_MIN
VAL_2_MAX
SIMULIA
Tosca Structure
Clip
VAL_3_MIN
VAL_3_MAX
= -100
= 100
END_
Fig. 96
Defining DVCON_SHAPE
Both solids must now be defined as being frozen areas using a
DVCON_SHAPE definition. During the actual solid definition the solids were
assigned the attribute "RESTRICTED" which function as restricted bodies.
DVCON_SHAPE
=
=
=
=
=
=
dvcon_solid
DV_NODES
SOLID_CYL_LEFT
SOLID_CYL_RIGHT
NO
CS_0,FREE,FREE,FIX
END_
=
=
=
=
=
=
DRESP_MAX_MISES
SYSTEM
SIG_MISES
EVER
ALL_NODES
MAX
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
ID_NAME
ND_GROUP
CHECK_SOLID
CHECK_SOLID
CHECK_SPC
CHECK_DOF
SIMULIA
Tosca Structure
Shape Optimization
END_
3.9.4
Optimization results
Fig. 97
Optimization results
Task
Keywords
Commands
www.3ds.com/tosca
3.10 Rim
SIMULIA
Tosca Structure
Rim
restriction is specified for the outer surfaces of the rim holes. The rim model is
shown in Fig. 98
Fig. 98
Model "rim"
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Shape Optimization
Fig. 99
www.3ds.com/tosca
Create six more node groups containing each hole separately (HOLE_1 ...
HOLE_6). This group definitions are needed for the stamp restrictions on the
holes. Create two node groups containig the nodes of the inner
(TURN_INNER) and the outer rim surface (TURN_OUTER), needed for the
CHECK_SLIDE restriction (Fig. 100).
SIMULIA
Tosca Structure
Rim
Further create two more node groups for the demold restriction on the outer
surface of the rim holes (first group DEMOLD). Extend the group by adding
the nodes of the inner turn surface of the rim to create the check group for the
demold restriction (CHECK_DEMOLD).
Fig. 101 Demold group and check group for the demold restriction
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Shape Optimization
www.3ds.com/tosca
8. Create a DOF_CONTROL item and fix the nodes of the group FIX_NODES
in every direction of the global coordinate system CS_0
9. Create a DEMOLD_CONTROL restriction for the outer surfaces of the rim
holes (node group DEMOLD). Specify the positive global y axis as demold
direction and select the group CHECK_DEMOLD as check group.
10.Specify the MESH_SMOOTH area using the MS_LAYER option and add 4
layers starting from the design nodes.
11.Define the objective function as a MINMAX function to minimize the
maximal von Mises stress in the design area from both load cases. For
more details please refer to the Tosca Structure Getting Started manual.
12.Define a volume constraint to keep the initial volume of the rim
unchanged.
13.Set up the generation of VTFX visualization and start the Tosca Structure
optimization.
SIMULIA
Tosca Structure
Rim
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Shape Optimization
repeat the whole definition for the inner rim surface (node group
TURN_INNER).
www.3ds.com/tosca
SIMULIA
Tosca Structure
Rim
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Generate both displacement and control plots. Notice the growth and the
shrink areas. How does the shape of the rim holes change? Are all manufacturing restrictions maintained? Depending on the solver the maximal stresses
are reduced by more than 20 percent.
SIMULIA
Tosca Structure
Shape Optimization
3.11 Threehole
Task
Keywords
Commands
CHECK_DOF
www.3ds.com/tosca
SIMULIA
Tosca Structure
Threehole
DRESP
ID_NAME
DEF_TYPE
TYPE
LC_SET
LC_SEL
UPDATE
END_
=
=
=
=
=
=
OBJ_FUNC
ID_NAME
DRESP
TARGET
END_
= MAXIMIZE_FREQ
= DRESP_FREQ
= MAX
DRESP_FREQ
SYSTEM
DYN_FREQ
MODAL,ALL,1
MIN
EVER
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
The first natural frequency must be defined in the design response and then
maximized as objective function.
SIMULIA
Tosca Structure
Shape Optimization
Definition of constraints
Optimization where natural frequencies are to be maximized generally
causes an increase of mass/volume and thus increasing the natural frequencies. To avoid this from happening a volume constraint needs to be defined:
DRESP
ID_NAME
DEF_TYPE
TYPE
UPDATE
EL_GROUP
GROUP_OPER
=
=
=
=
=
=
DRESP_VOL_SHAPE
SYSTEM
VOLUME
EVER
ALL_ELEMENTS
SUM
=
=
=
=
=
volume_constraint
DRESP_VOL_SHAPE
REL
1.0
0.01
END_
CONSTRAINT
ID_NAME
DRESP
MAGNITUDE
EQ_VALUE
TOL_VALUE
END_
www.3ds.com/tosca
SIMULIA
Tosca Structure
Hub
Hub
Task
Keywords
Conserve cyclic and plane symm. (non-symm. meshes), Displacement direction (DOF), Symmetry: planar
Commands
SURF_CYCLIC_PLANE_SYM, CHECK_DOF,
ROTATION_SYM
This example illustrates the shape optimization of a hub of a wind turbine system. The optimization task is to lower the maximum von Mises stresses. The
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
3.12
SIMULIA
Tosca Structure
Shape Optimization
new design must show rotational symmetry by 120 with plane symmetrical
segments. The assembly of the hub model is shown in Fig. 109:
www.3ds.com/tosca
fixed constraint
SIMULIA
Tosca Structure
Hub
design nodes
fixed nodes
Model: hub.ext from the examples directory for your optimization task
Design area: node group design_nodes
Design variable constraint: apply boundary conditions for all nodes
Design variable constraint: fixation of all displacements for node group FIX
Design variable constraint: SURF_CYCLIC_PLANE-symmetry condition with
start point (0,0,1),direction (1,0,0) and angle 120 in the global coordinate
system
Mesh smooth: mesh smoothing of all elements in design area, while free surface nodes remain free
Objective: minimize the maximal von Mises stresses in the design area
Stop condition: 10 iterations
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Shape Optimization
www.3ds.com/tosca
SIMULIA
Tosca Structure
Hub
END_
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
ID_NAME = LINK_SHAPE_1_SYMMETRY_CONTROL_3
MASTER = MAX
CLIENT = SURF_CYCLIC_PLANE_SYM
CYCLIC_SYM_START = 0., 0. , 1.
CLIENT_DIR = 1.,0.,0.
CS = CS_0
TOL = 0.1
ANGLE = 120.
SIMULIA
Tosca Structure
Shape Optimization
Fig. 115 Optimization results for the front view of hub: von Mises stress of
original (left) and optimized (right) mode
www.3ds.com/tosca
Fig. 114 Optimization results for hub: von Mises stress of original (left) and
optimized (right) model
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Hub
www.3ds.com/tosca
SIMULIA
Tosca Structure
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
SIMULIA
Tosca Structure
Bead Optimization
Bead Optimization
Tosca Structure.bead supports the engineer in finding the layout of bead stiffeners for sheet metal components. In this section, typical bead optimization
examples are described.
Example overview
Oil pan
Plate
Hood eig.
Examples
Hood
Keywords
Holder
4.1
Strategy
Controller
Sensitivity
Analysis Type
STATIC
FREQUENCY
X
X
www.3ds.com/tosca
Objective
Frequency
Frequency
(KreisselmaierSteinhauser)
Compliance
Target
MIN
MAX
Geometric Restrictions
Bead height
SIMULIA
Tosca Structure
Plate
Displacement
amount
Mesh
enhancing
Symmetry:
planar
4.2
Plate
Oil pan
Hood eig.
Hood
Examples
Holder
Keywords
X
X
X
Plate
Task
Minimize compliance
Keywords
Bead height
Commands
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Bead Optimization
compliance. In Fig. 116 the initial model is illustrated. The boundary is fixed
and the center is loaded with a pressure load
www.3ds.com/tosca
4.2.1
Procedure: Summary
Model: plate.ext from the examples directory for your optimization task
Design area: all nodes
Design variable constraint: apply boundary conditions for all nodes
Objective: maximize stiffness (minimize compliance)
Constraint: maximum bead height 20 mm
Options: read boundary conditions for all nodes
Settings: 60 mm bead width
4.2.2
SIMULIA
Tosca Structure
Plate
4.2.3
= ALL
END_
This setting has to be set before the FEM_INPUT-statement. All nodal boundary conditions of the finite element model are imported. The fixations may
then be activated via the DVCON_BEAD command.
DVCON_BEAD
ID_NAME
ND_GROUP
CHECK_BC
END_
= dvcon_fix_spc
= ALL_NODES
= YES
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
OPTIONS
SIMULIA
Tosca Structure
Bead Optimization
The parameter CHECK_BC = YES ensures that all nodes with a fixation in
the finite element model are also fixed in the corresponding DOFs during the
optimization procedure.
The height of the stiffeners is the constraint to the optimization problem.
Therefore, a design response containing the Type = BEAD_HEIGHT has to
be defined referenced in the CONSTRAINT command:
DRESP
ID_NAME
DEF_TYPE
ND_GROUP
TYPE
GROUP_OPER
UPDATE
END_
=
=
=
=
=
=
DRESP_BEAD_HEIGHT
SYSTEM
ALL_NODES
BEAD_HEIGHT
MAX
EVER
CONSTRAINT
ID_NAME
DRESP
MAGNITUDE
EQ_VALUE
=
=
=
=
bead_height_constraint
dresp_bead_height
ABS
20.0
END_
www.3ds.com/tosca
DRESP
ID_NAME
DEF_TYPE
EL_GROUP
TYPE
GROUP_OPER
UPDATE
LC_SET
END_
OBJ_FUNC
ID_NAME
DRESP
TARGET
END_
=
=
=
=
=
=
=
DRESP_COMPLIANCE
SYSTEM
ALL_ELEMENTS
STRAIN_ENERGY
SUM
EVER
STATIC,1,ALL
= MINIMIZE_COMPLIANCE
= DRESP_COMPLIANCE
= MIN
OPTIMIZE
SIMULIA
Tosca Structure
Hood
ID_NAME
DV
OBJ_FUNC
DVCON
CONSTRAINT
END_
=
=
=
=
=
BEAD_OPTIMIZATION
DESIGN_VARIABLES
MINIMIZE_COMPLIANCE
DVCON_BC
BEAD_HEIGHT_CONSTRAINT
=
=
=
=
=
MY_PARAMETERS
BEAD_OPTIMIZATION
FIRST
1.0
60
END
4.3
Hood
Task
Minimize compliance
Keywords
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Optimization results
SIMULIA
Tosca Structure
Bead Optimization
Fig. 120 Hood loaded in a vertical pull (left) and a shear force (right).
The hood, shown in Fig. 120 is loaded with a vertical pull and a shear force. It
is fixed in the two upper corners. Dimensions: Height 15.0, width 20.0 and
depth 15.0.
www.3ds.com/tosca
4.3.1
Procedure: Summary
Model: hood.ext from the examples directory for your optimization task
Design area: all nodes
Design variable constraint: apply boundary conditions for all nodes
Design variable constraint: plane symmetry restriction
Objective: maximize stiffness (minimize compliance) considering both loadcases
Constraint: maximum bead height 0.5
Options: read boundary conditions for all nodes
Settings:
BEAD_WIDTH
=
3,
BEAD_MIN_STRESS
=
0.005,
BEAD_MAX_MEMBRANE = 2
4.3.2
SIMULIA
Tosca Structure
Hood
4.3.3
=
=
=
=
=
=
dresp_compliance_1
SYSTEM
ALL_ELEMENTS
STRAIN_ENERGY
SUM
EVER
LC_SET
= STATIC,1,ALL
LC_SEL
= MAX
DRESP
ID_NAME
DEF_TYPE
EL_GROUP
TYPE
GROUP_OPER
UPDATE
=
=
=
=
=
=
dresp_compliance_2
SYSTEM
ALL_ELEMENTS
STRAIN_ENERGY
SUM
EVER
LC_SET
= STATIC,2,ALL
LC_SEL
= MAX
END_
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
END_
SIMULIA
Tosca Structure
Bead Optimization
ID_NAME
DRESP
DRESP
TARGET
=
=
=
=
minimize_compliance
dresp_compliance_1, 1.0
dresp_compliance_2, 1.0
MIN
END_
Here the weight fraction for both design responses is 1.0. The optimization
task then is:
OPTIMIZE
ID_NAME
DV
OBJ_FUNC
DVCON
CONSTRAINT
STRATEGY
=
=
=
=
=
=
BEAD_OPTIMIZATION
DESIGN_VARIABLES
minimize_compliance
dvcon_FIX_spc
bead_height_constraint
BEAD_CONTROLLER
END_
The optimization result is shown in Fig. 121. The optimization result is however not symmetric.
To enforce plane symmetry a link condition is created. But in order to create
this link condition, a coordinate system needs to be created somewhere on
the symmetry plane.
CS_DEF
ID_NAME
DEF_TYPE
CS_TYPE
CS_REF
ORIGIN_123
ROTATION_321
=
=
=
=
=
=
MY_CS
LOCAL
RECTANGULAR
CS_0
5.0, 0.0, 10.0
0.0, 0.0, 0.0
END_
www.3ds.com/tosca
The normal of the symmetry plane is the 3rd axis of the coordinate system.
The link condition is then:
LINK_BEAD
ID_NAME
TYPE
CS
= my_link_plane
= PLANE_SYM, AXIS_3
= MY_CS
END_
SIMULIA
Tosca Structure
Hood
ID_NAME
CHECK_LINK
ND_GROUP
= my_dvcon
= my_link_plane
= all_nodes
END_
OPTIMIZE
ID_NAME
DV
OBJ_FUNC
DVCON
=
=
=
=
BEAD_OPTIMIZATION
DESIGN_VARIABLES
minimize_compliance
dvcon_FIX_spc
DVCON
= MY_DVCON
CONSTRAINT
STRATEGY
= bead_height_constraint
= BEAD_CONTROLLER
END_
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Bead Optimization
4.3.4
Optimization results
4.4
4.4.1
Task
Maximize eigenvalue
Keywords
Commands
BEAD_HEIGHT, CHECK_GROW_SHRINK
www.3ds.com/tosca
Fig. 121 Optimization results without (left) and with symmetry restriction
(right)
SIMULIA
Tosca Structure
Hood_eig and Hood_eig_sens
4.4.2
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Procedure: Summary
SIMULIA
Tosca Structure
Bead Optimization
www.3ds.com/tosca
Optimization results
SIMULIA
Tosca Structure
Hood_eig and Hood_eig_sens
4.4.3
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
BEAD_SENSITIVITY
Using Tosca Structure.gui Bead-wizard the parameter file for optimizing first
eigenvalue is also easily achieved for the sensitivity based approach. Instead
SIMULIA
Tosca Structure
Bead Optimization
www.3ds.com/tosca
The default settings from Tosca Structure.gui Wizard only regard the first
eigenmode:
DRESP
ID_NAME
TYPE
DEF_TYPE
LC_SET
END_
=
=
=
=
DRESP_EIGENFREQUENCY
DYN_FREQ
SYSTEM
MODAL,ALL,1
For most applications you want to avoid that the modes switch during optimization. The easiest way to do this is to define a new design response based
on the Kreisselmaier-Steinhauser formulation. Here we assume that the first
mode will never get larger as the 5th mode.
DRESP
ID_NAME
TYPE
DEF_TYPE
LC_SET
END_
=
=
=
=
DRESP_KREIS
DYN_FREQ_KREISSEL
SYSTEM
ALL,ALL,1-5
SIMULIA
Tosca Structure
Hood_eig and Hood_eig_sens
Optimization results
Fig. 125 Bead pattern from eigenvalue optimization with sensitivity based
approach
4.4.4
Discussion of differences
The sensitivity based algorithm uses many more design cycles to get to a
much better result. This is a typical observation for dynamic problems. The
sensitivity algorithm requires a significantly higher calculation effort (120
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Result is a final eigenvalue of 0.3558 (15%), which may even become higher
if one lets the optimization continue for more than 20 iterations (see Fig. 126).
SIMULIA
Tosca Structure
Bead Optimization
www.3ds.com/tosca
=
=
=
=
dvcon_max_disp
NO
ALL_NODES
.5
SIMULIA
Tosca Structure
Holder
CHECK_SHRINK
= .0
END
Fig. 127 Bead pattern from eigenvalue optimization with sensitivity based
approach, but only allowing growth (CHECK_SHRINK=0.0)
4.5
Holder
Task
Minimize compliance
Keywords
Mesh enhancing
Commands
BEAD_NODE_SMOOTH
CURV_SMOOTH
This example illustrates the two mesh enhancing capabilities in Tosca Structure.bead. In most cases the default values should not be changed so this
example is only presented for the sake of completeness.
4 - 164 Examples Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
The result is seen in Fig. 127. Note that the bead in the middle of the top part
did not develop in this case (compare with Fig. 125). This may well be due to
the fact that the algorithm cannot push the surroundings down
(CHECK_SHRINK = 0.0). But it is interesting to see that the iteration history
of the two sensitivity based optimizations is nearly identical (Fig. 126).
SIMULIA
Tosca Structure
Bead Optimization
Fig. 128 displays the optimization problem, a curved sheet metal structure
with a hole in the middle. Around the hole is a non-design area plotted in
white.
In Fig. 129 is the optimized solution shown using BEAD_WIDTH = 50.0 and
BEAD_HEIGHT = 10.0, but otherwise the standard settings from Tosca Structure.gui. The two areas of interest are circled and marked with "1" and "2" and
will used in the following to explain the function of the two optional
OPT_PARAM: BEAD_NODE_SMOOTH (1) and CURV_SMOOTH(2).
Fig. 128 Holder with a vertical load and simple supported. The white area
is nondesign area
.
www.3ds.com/tosca
SIMULIA
Tosca Structure
Holder
a)
b)
c)
Fig. 130 BEAD_NODE_SMOOTH for values 1.0 (a), 12.5 (b) and 24.0 (c)
a)
b)
c)
Fig. 131 CURV_SMOOTH for values 1.0 (a), 5.0 (b) and 10.0 (c)
Fig. 131 shows the effect of CURV_SMOOTH for different values. It is important to notice the different element size in the bead onthe left picture. Fig. 131
(a) the curvature of the initial structure squeezes the nodes together so that
the elements become quite small. For even higher degrees of curvature and
large bead heights it is possible that the nodes "grow together", thus distorting the elements so much that the FE-analysis will fail. For Fig. 131 (c) the
smoothing radius is 10 times the average element edge length. The elements
in the curved area are almost the same size as the elements in the non-opti4 - 166 Examples Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
BEAD_NODE_SMOOTH defines a distance which is the lowest possible inplane distance where the optimization displacement is allowed to vary from
0.0 to the defined bead_height. Fig. 130 shows the effect of
BEAD_NODE_SMOOTH for different values. Fig. 130 a) the value 1.0 is
smaller than the element edge length and there no smoothing is enforced
from the non-design to design area (see Fig. 128). In Fig. 128 (b) and (c) the
values are higher and it is seen from the figure that more elements are forced
to be in the transition from non-design to design area. The default value in
Tosca Structure.bead is BEAD_NODE_SMOOTH = 0.25*BEAD_WIDTH and
that is in this case shown in Fig. 128 (b). If BEAD_NODE_SMOOTH >
0.5*BEAD_WIDTH the optimization will stop with an error.
CURV_SMOOTH defines the radius in which mesh effects of a curved surface can be reduced. The value depends on the average element edge
length in the design domain and is default set to 5.0 times this length (Fig.
131 b).
SIMULIA
Tosca Structure
Bead Optimization
www.3ds.com/tosca
mized areas and thereby keeping a valid mesh. It should be noted that high
values of CURV_SMOOTH will result in a large computational effort.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Holder
SIMULIA
Tosca Structure
Sizing
Sizing
Tosca Structure.sizing supports the engineer in finding optimal thicknesses
for sheet metal components. In this section, typical sizing examples are
described.
Examples overview
Holder
Examples
Beam symm.
Keywords
Beam 2D
5.1
Strategy
Sensitivity
Analysis Type
STATIC
Objective
Strain energy
Target
www.3ds.com/tosca
MIN
MINMAX
Constraints
Volume
Geometric Restrictions
Minimum
member size
Symmetry:
cyclic
Symmetry:
planar
SIMULIA
Tosca Structure
Beam2D
Symmetry:
rotational
Shell thickness
bounds
5.2
Holder
Beam symm.
Examples
Beam 2D
Keywords
X
X
Beam2D
Task
Keywords
Commands
5.2.1
Model
In this model, a bending beam is fixed on the left side with a corresponding
force on the right side. All nodes on the left side of the model are fixed in x-
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Sizing
and y-direction. A force of 10N is applied in the middle node of the right side
in a negative direction of the y-axis.
y
x
5.2.2
Optimization Task
The sizing optimization task is to maximize the stiffness using 50% of the initial volume. The shell thicknesses are to be changed during the optimization
and may vary between a lower bound of 0.1 and an upper bound of 2.0.
Two optimization tasks can be run - the first changing with a free change of
the shell sizes, the second clustering element areas with the same shell thickness.
www.3ds.com/tosca
5.2.3
Procedure: Summary
Model: beam2d.ext from the examples/sizing directory for your optimization
task
Design area: all elements
Design variable constraint: lower and upper bound for shell thicknesses (0.1
and 2.0, resprectively)
Objective: maximize stiffness
Constraint: relative volume of 50 % (inequality constraint)
5.2.4
SIMULIA
Tosca Structure
Beam2D
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
The objective function is to maximize stiffness. This corresponds to minimizing the compliance (sum of strain energy, a measure of flexibility). Define your
objective as follows: With OBJ_FUNC_ITEM | NEW | COMPLIANCE click
OK (check if ALL_ELEMENTS is selected as group). With OBJ_FUNC_ITEM
| EDIT set your target to MIN.
SIMULIA
Tosca Structure
Sizing
www.3ds.com/tosca
The optimization task above perform a free change of each single shell thickness. If you want to enforce certain areas to obtain the same shell thickness,
you can cluster the elements in these areas. Define an element group
(EL_SET_1, EL_SET_2,... (predefined in the example model)) for each of the
clustering areas and assign them to a cluster group design variable constraint
(one for each group) as follows:
5.2.5
= design_variables
SIMULIA
Tosca Structure
Beam2D
EL_GROUP
= ALL_ELEMENTS
END_
In order to define thickness bounds for the shell thicknesses, a design variable constraint must be activated. The lower and upper bounds for the shell
thicknesses are defined as absolute values (MAGNITUDE = ABS):
DVCON_SIZING
ID_NAME = DVCON_SIZING
EL_GROUP = P1
CHECK_TYPE = THICKNESS_BOUNDS
MAGNITUDE = ABS
LOWER_BOUND = 0.1
UPPER_BOUND = 2.0
END_
=
=
=
=
=
DRESP_SUM_ENERGY
SYSTEM
STRAIN_ENERGY
ALL_ELEMENTS
SUM
= maximize_stiffness
= DRESP_SUM_ENERGY
= MIN
END_
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
END_
SIMULIA
Tosca Structure
Sizing
DRESP
ID_NAME
DEF_TYPE
TYPE
EL_GROUP
GROUP_OPER
=
=
=
=
=
DRESP_VOL_SIZING
SYSTEM
VOLUME
ALL_ELEMENTS
SUM
END_
This value is afterwards referenced in the constraint that enforces the maximal volume usage.
CONSTRAINT
ID_NAME
DRESP
MAGNITUDE
LE_VALUE
=
=
=
=
volume_constraint
DRESP_VOL_SIZING
REL
0.5
END_
At last the optimization task is compiled, i.e. the design variables are linked
with the objective function and the constraints.
OPTIMIZE
ID_NAME
STRATEGY
DV
OBJ_FUNC
CONSTRAINT
DVCON
=
=
=
=
=
=
SIZING
SIZING
DESIGN_VARIABLES
MAXIMIZE_STIFFNESS
VOLUME_CONSTRAINT
DVCON_SIZING
www.3ds.com/tosca
END_
= CLUSTERING
= EL_SET_1
= EL_SET_2
SIMULIA
Tosca Structure
Beam2D
EL_GROUP
EL_GROUP
EL_GROUP
CHECK_TYPE
=
=
=
=
EL_SET_3
EL_SET_4
EL_SET_5
CLUSTER
END_
= SIZING
= CLUSTERING
END_
5.2.6
Results
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
The optimization result created with free shell modification shows a variying
shell thickness over the model. This can be used as a hint for clustering, i.e.
where to create borders between single sheets of same thickness.:
SIMULIA
Tosca Structure
Sizing
The optimization result created with clustering shows a very uniform thickness distribution:
www.3ds.com/tosca
5.3
Keywords
Commands
LINK_SIZING, DVCON_SIZING;
THICKNESS_BOUNDS
The beam in this example is more finely meshed than in the previous example. Symmetry conditions should be introduced as an addition to a standard
stiffness optimization. The definition of the symmetry plane, of the symmetry
point or of cyclic symmetry needs to include a reference coordinate system.
This definition can be made with the CS_DEF command. If the coordinate
system is defined in the model it can be imported. The origin of the coordinate
system is in the middle of the design area.
Origin
CS_local
Fig. 139 Coordinate system in the center of the beam
SIMULIA
Tosca Structure
Beam with Symmetry Restrictions (beam_sym)
5.3.1
Procedure: Summary
Model: beam_sym.ext from the examples directory for your optimization task
Design area: all elements
Design variable constraint: lower (0.1) and upper (2.0) bound for shell thicknesses
Design variable constraint: symmetry restriction
Objective: maximize stiffness (minimize compliance)
Constraint: relative volume of 120 % (inequality constraint)
5.3.2
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
This definition specifies the type of symmetry ( plane, rotation or cyclic), and
location of the symmetry plane (point and normal direction) or rotational axis
(point and direction).
For example, plane symmetry with respect to the XZ-plane is defined as follows:.
SIMULIA
Tosca Structure
Sizing
For rotational and cyclic symmetry we recommend the activation of a minimum cluster width (of 20 for this model) to get more discernible effects..
5.3.3
=
=
=
=
=
=
CS_local
RECTANGULAR
LOCAL
CS_0
125.0, 50.0,0
0,0,0
www.3ds.com/tosca
END_
= my_link_plane
= PLANE_SYM, AXIS_1
SIMULIA
Tosca Structure
Beam with Symmetry Restrictions (beam_sym)
CS
= CS_local
END_
=
=
=
=
dvcon_plane
ALL_ELEMENTS
LINK_SIZING
my_link_plane
END_
!
!
!
!
!
!
!
ID_NAME
= SIZING
DV
= design_variables
OBJ_FUNC
= maximize_stiffness
DVCON
= dvcon_sizing
CONSTRAINT
= volume_constraint
Link sizing Constraint
DVCON
= dvcon_sizing
Plane Symmetry
DVCON
= dvcon_plane
Rotation Symmetry
DVCON
= dvcon_rotation
Cyclic Symmetry
DVCON
= dvcon_cyclic
END_
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
OPTIMIZE
SIMULIA
Tosca Structure
Sizing
5.3.4
Optimization results
Fig. 143 Beam without symmetry (left) and with reflection symmetry (right)
www.3ds.com/tosca
SIMULIA
Tosca Structure
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Shape Optimization in Combination with
Shape Optimization in
Combination with Durability
Analysis
Shape optimization allows specific detail improvements of existing designs.
Through shape optimization the surface geometry of a given model is modified automatically to avoid material failure and increase durability or comfort.
Often stress reduction already leads to a significant increase in durability.
Nevertheless for realistic models, stress peaks as identified by static analysis
may differ largely from areas of maximum damage. In these cases stress
based shape optimization may even worsen the design performance.
If the location of maximum damage and maximum stress are not matching,
fatigue life simulation should always be included in the optimization loop. In
this section, a typical setup including fatigue analysis is described.
www.3ds.com/tosca
SIMULIA
Tosca Structure
Holeplate_dam: Femfat
6.1
Holeplate_dam: Femfat
Task
Keywords
Commands
In this simple model (realized as quarter model) two load cases are defined
as illustrated in the figure. The loads of load case two are twice as large as
the loads of the first load case.
loadcase 2
Fig. 146 Boundary conditions, cyclic loading and von Mises stress distribution for the 2 loadcases of the initial model.
The maximum von Mises stress in the initial model is located at the lower side
of the notch. Nevertheless, the maximum damage due to cyclic loading is
located at the upper side of the notch (see Fig. 149).
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
loadcase 1
SIMULIA
Tosca Structure
Shape Optimization in Combination with
=
=
=
=
=
=
DRESP_MAX_DAMAGE
SYSTEM
DAMAGE
EVER
design_nodes
MAX
END_
www.3ds.com/tosca
SIMULIA
Tosca Structure
Holeplate_dam: fe-safe
6.2
Holeplate_dam: fe-safe
Task
Keywords
Commands
In this simple model (realized as quarter model) two load cases are defined
as illustrated in the figure. The loads of load case two are twice as large as
the loads of the first load case.
loadcase 2
Fig. 148 Boundary conditions, cyclic loading and von Mises stress distribution for the 2 loadcases of the initial model.
The maximum von Mises stress in the initial model is located at the lower side
of the notch. Nevertheless, the maximum damage due to cyclic loading is
located at the upper side of the notch (see Fig. 151).
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
loadcase 1
SIMULIA
Tosca Structure
Shape Optimization in Combination with
=
=
=
=
=
=
DRESP_MAX_DAMAGE
SYSTEM
DAMAGE
EVER
design_nodes
MAX
END_
www.3ds.com/tosca
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Holeplate_dam: fe-safe
SIMULIA
Tosca Structure
Morphing
Morphing
Tosca Structure.morph allows the easy setup and analysis of model variants.
Thereby morphing areas are simply defined through groups of surface nodes.
7.1
Crane hook
Task
Keywords
Commands
MORPH_AREA
MORPH
www.3ds.com/tosca
In this crane hook example, the maximum stresses for both load cases (see
Fig. 151) are in an area (see Fig. 151) which cannot be modified, for example, by a shape optimization. On the other hand, the outer side of the crane
hook can be modified to reduce the stresses on the inner side..
SIMULIA
Tosca Structure
Crane hook
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Morphing
The morphing areas will then be modified, based on the user defined design
of experiment. In this experiment plan a constant displacement (positive, negative or zero) for each morphing area is defined. The modified model will be
analyzed by your FE solver.
7.1.1
Model: cranehook_morph.ext from the examples directory for your optimization task
Design area: DESIGN_NODES (combination of all MORPH_AREAs)
Mesh smooth: three layers based on DESIGN_NODES
Objective: minimize the stresses in the critical area
Morphing: morph the morphing area with the experiment plan
cranehook_morph.csv
Procedure: Summary
7.1.2
SIMULIA
Tosca Structure
Crane hook
maximum stress in the critical area. These definitions are required to get
results for evaluation of the quality of the model model variants.
Define your design area as area which contains all regions which are allowed
to be morphed. The objective is used only for post-processing and does not
influence the morphing results.
.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Add a new MORPHING folder to your optimization task within the Task Manager with right clicking on Tosca Structure Task -> New -> MORPHING
SIMULIA
Tosca Structure
Morphing
www.3ds.com/tosca
For each morphing area add a MORPH_AREA block via right-click on MORPHING folder
SIMULIA
Tosca Structure
Crane hook
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Morphing
Add a new MORPH command via right-click on MORPHING folder and adding New -> MORPH.
www.3ds.com/tosca
SIMULIA
Tosca Structure
Crane hook
Define an experiment plan. Save your morphing scheme in a *.csv -file, e.g.
cranehook_morph.csv (see, e.g. vol.2 Morphing parameter file), where the
first line refers to the morphing areas and each following line corresponds to
one model variant:
0,
1,
2,
3,
4,
5,
6,
7,
8,
9,
In this example, each morphing area will first be morphed with a displacement of 3 mm. Then we will morph all the design areas simultaneously to see
the effect of a large-scale geometric change. In the last experiment, a new
geometry of the crane hook will be created. For this experiment, some
MORPH_AREA will shrink, and others will grow. This is controlled by a negative/positive sign in the *.csv-File.
Remark
1. Displacement must be given as real values. So do not forget the dot. For
example, write 1.0 instead of 1.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Morphing
solver runs in parallel (as long as enough morphing variants are available for
calculation)
SMOOTHING switches surface smoothing of nodes in modified morphing
areas on/off.
www.3ds.com/tosca
After these settings you can run the morph task. Add a RUN_MORPH command via right-click on MORPHING folder.
SIMULIA
Tosca Structure
Crane hook
7.1.3
Morph1
MORPHING_1
NORMAL
= 1
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
END_
SIMULIA
Tosca Structure
Morphing
In this example, each morphing area will first be morphed with a displacement of 3 mm. Then we will morph all the design areas simultaneously to see
the effect of a large-scale geometric change. In the last experiment, a new
geometry of the crane hook will be created. For this experiment, some
MORPH_AREA will shrink, and others will grow. This is controlled by a negative/positive sign in the *.csv-File.
Remark
1. Displacement must be given as real values. So do not forget the dot. For
example, write 1.0 instead of 1.
Assign this experiment plan to your task using the MORPH command:
MORPH
ID_NAME
OPTIMIZE
MORPH_AREA
MORPH_AREA
MORPH_AREA
MORPH_AREA
MORPH_AREA
MORPH_AREA
MORPH_AREA
MORPH_PARAM_FILE
=
=
=
=
=
=
=
=
=
=
tosca_morph
<my_opt_task>
Morph1
Morph2
Morph3
Morph4
Morph5
Morph6
Morph7
cranehook_morph.csv
END_
www.3ds.com/tosca
Now save your definitions to a parameter file (e.g. my_morph_job) and start
your morphing task on the screen Start TOSCA Structure.
Fig. 178 Start of a morphing run for shape optimization in Tosca Structure.gui
Create your visualization sequence using Tosca Structure.report in the same
way like for shape optimization results: The only difference is that the report is
generated
from
the
files
TOSCA_MORPH_xxx.onf
instead
of
SHAPE_xxx.onf.
SIMULIA
Tosca Structure
Crane hook
7.1.4
Optimization results
In the *.vtfx-File, you can see the controller input (f.e. stresses) and the nodal
displacements for all experiments. Each frame corresponds to an experiment.
In this example, the experiment 8 with the large-scale modification of the
geometry gives the best results for the stresses. The experiment 9 which is a
combination of grow and shrink gives good results too, and the modified
geometry is significantly lighter than the geometry in the experiment 8. So the
experiment 9 can be a good compromise for further processing (e.g. a subsequent local shape optimization...).
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Fig. 179 Stress distribution and morphing displacements for the last
experiment
SIMULIA
Tosca Structure
INDEX
A
Abaqus
Optimization using an all-in-one file
ments 2-423
Displacement check against solids 22-
623
www.3ds.com/tosca
ADD_FILE 2-424
Advanced Modus 2-378
Analysis File 2-42
Analysis model 2-9
ANSYS
Groups 2-37
Input deck 2-35
Loadcases 2-36
Preprocessing 2-35
B
Band gap 2-267, 2-439
Bead height 2-142
Bead Optimization
Surface Calculation 2-519
Bead optimization 2-405
CHECK_ELGR 2-423
CHECK_GROW 2-420
CHECK_LINK 2-425
CHECK_SOLID 2-422
Controller based 2-407
Differential Stress Tensor (DST) 2-407
Displacement check against elements 2423
Restrictions
Design variable constraints 2-418
Displacement amount 2-420
Displacement check against ele-
422
4 - 201
SIMULIA
Tosca Structure
4 - 202
2-
2-
303
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. Rev.
1 - 05.2014
1 - 05.2014
DV_TOPO 3-70
FEM_INPUT 3-72
GROUP_AUTO_DEF 3-75
GROUP_DEF 3-78
GROUP_IMPORT 3-81
INCLUDE 3-82
LINK_BEAD 3-83
LINK_SHAPE 3-84
LINK_TOPO 3-97
LIST 3-100
LIST, info 3-106
LOGICAL 3-107
MESH_REFINE 3-109
MESH_SMOOTH 3-109
OBJ_FUNC 3-118
OPTIMIZE 3-120
OPTIONS 3-123
OPT_PARAM 3-129
SELECT 3-146
SF_IDENT 3-153
SMOOTH 3-154
SOFT_DELETE 3-135, 3-136
SOLID 3-162
STOP 3-163
TEST_BEAD 3-166
TEST_SHAPE 3-168
USER_FILE 3-170
VARIABLE 3-178
Compliance 2-87, 2-226, 2-432, 2-483
CONFIG 3-3
Configuration
Check actual settings 2-712
Configuration 2-712
Configuration files 2-712
CONSTRAINT 3-24
Constraints 2-79
Bead optimization 2-440
Displacement 2-250
Displacement difference 2-235
Eigenfrequency 2-270
Multiple materials 2-223
Shape optimization 2-362
Topology optimization 2-220, 2-481
www.3ds.com/simulia
SIMULIA
Tosca Structure
TOSCA.OUT 2-722
Forging 2-354
FREE_SF 2-309
G
Geometric Primitives 2-68
GROUP_AUTO_DEF 2-50, 3-75
GROUP_DEF 3-78
GROUP_IMPORT 3-81
Groups 2-47
Automatic node group definition 2-50
Default groups 2-48
Definition 2-47
Isosurfaces 2-536
Surface Calculation 2-536
TOSCA.smooth 2-536
Types of 2-48
I
Identifying surface nodes 2-47
INCLUDE 2-47, 3-82
Include Files 2-47
Interface
Internal 2-43
Internal force 2-105, 2-240, 2-486
Isosurfaces
Group Processing 2-536
Isovalue 2-521
Smoothing Parameters 2-520
Isovalue 2-521
L
LENGTH 2-351
LEVEL_CONV 2-313
Link conditions 2-336
Coupling displacement coordinates 2-349
Deformable surface 2-354
Displacement CS 2-352
Drilling surface 2-354
Forging surface 2-354
Link direction 2-350
Link length 2-351
Plane symmetrie 2-342
Point symmetry 2-347
Rotational symmetrie 2-348
Stamping surface 2-352
4 - 203
SIMULIA
Tosca Structure
4 - 204
2-
303
O
Objective function 2-72
Maximization 2-75
Band gap 2-267, 2-439
Eigenfrequency 2-433
Stiffness 2-430
Minimization 2-75
Compliance 2-226, 2-432, 2-483
Contact pressure 2-373
Displacement 2-228, 2-483
Internal force 2-240, 2-486
Maximum equivalent stress 2-364
Reaction force 2-240, 2-486
Relief notch 2-369
Rotation 2-228, 2-483
Volume 2-250
Minmax 2-76
Multidisciplinary optimization 2-76
OBJ_FUNC 3-118
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. Rev.
1 - 05.2014
1 - 05.2014
www.3ds.com/simulia
SIMULIA
Tosca Structure
Optimization
Controller based
Combined terms 2-176
Element types 2-33
Sensitivity based
Design responses 2-167
Optimization boundary conditions
Import 2-666
Reading 2-46
Subcase ID 2-667
Optimization database 2-719
Optimization Model 2-9
Optimization parameters
Bead optimization 2-441
Shape optimization 2-376
Topology optimization 2-273, 2-495
Optimization Postprocessing
VRML 2-616
Optimization Preprocessing 2-719
ANSYS 2-35
OPTIMIZE 3-120
OPTIONS 2-43, 2-46, 3-123
OPT_PARAM 3-129
CURV_SMOOTH 2-379
DISP 2-383
FILTER 2-380
SCALE 2-377, 2-417, 2-445
VECTOR 2-382
P
Parent group 2-50
Parts & Assemblies 2-35, 2-622
PLANE_SYM 2-342
Point symmetry 2-211, 2-474, 4-181
POINT_SYM 2-347
Postprocessing with FE postprocessors 1-186
R
Reaction force 2-240, 2-486
DRESP
Reaction force 2-102
Read Options 2-43
READ_ADD 2-44
Reading FE-Data
Additional nodes and elements 2-44
4 - 205
SIMULIA
Tosca Structure
326
Solids 2-326
Restrictions (design variable constraints)
2-320
4 - 206
2-455, 2-
614
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. Rev.
1 - 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
www.3ds.com/simulia
1-186
Start 2-580
Topology Optimization Results 2-591
TOSCA.OUT 2-722
TOSCA_POST 2-722
TOSCA_PREP 2-719
Troubleshooting
directories
DB_ERROR 2-723
protocol files 2-723
TOSCA Structure.smooth 2-540
U
UNDERCUT_TOL 2-354, 2-355
USER_FILE 3-170
V
VARIABLE 2-611, 3-178
Variable
Condition of logical variables 2-611
Logical 2-612
Combining logical variables 2-612
Comparing numerical variables 2-612
Status 2-612
Numerical
Database access 2-611
definition 2-611
Mathematical operators 2-611
VECTOR 2-349
Volume 2-135, 2-226, 2-250, 2-362, 2-483
VRML
Create data 2-616
W
Weight 2-137, 2-139
Wizard 1-182
4 - 207
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. Rev.
1 - 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
4 - 208