PRODUCT ENGINEERING OPTIMIZATION

USING CATIA V5

NARENDRA KOMARLA

M-CME

MENTOR

Prof. Dr Ing. H-B. Woyand

Fachgebiet Maschinenbau-Informatik
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CONTENTS

1. Basics of Optimization technique ------------------------- 3

2. Design of Experiments (Enumeration)

2.1. Introduction ------------------------- 3

2.2. Illustration using a Cantilever beam ------------------------- 4
2.2.1. FE Analysis of the beam ------------------------- 4
2.2.2. Computational resources ------------------------- 6
2.2.3. Defining the optimization parameters ------------------------- 7
2.2.4. A quick recap on creating parameters ------------------------- 8

3. Optimization

3.1. Optimization of the Cantilever beam ------------------------- 16

3.2. Optimization of a C-Hook ------------------------- 21

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1. Basics of Optimization Techniques

Optimization plays a prominent role in structural design. The importance of minimum

weight design of structures is recognized in most industries because the weight of the
system affects its performance or because of the depletion of our conventional energy
sources. However, optimization is not only a matter of weight; it can be used to optimize
any kind of data. In real world engineering problems, it is also common to minimize an
objective function describing data such as the total volume, the life-time or the cost of a
structure.

The Product Engineering Optimizer is the CATIA workbench for optimization. The
workbench offers iterative methods, which can be used to optimize any parameter. Using
the Product Engineering Optimizer is mainly a question of practice and methodology.

2. Design of Experiments (Enumeration)

2.1. Introduction

The Design of Experiments tool is designed to enable us to perform virtual experiments

taking into account as many parameters as needed. It enables us to:

Find interactions between parameters

Make predictions
Identify which parameter is the most influential

Figure 2.1 Influencing factors for a System

The system performs an analysis based on the computations done for each node of the
network and produces graphics showing the effects of each factor on each output and the
effects of each couple of parameters on each output. The results of the analysis are
stored in an output file (Excel file under windows and text file for all operating systems).

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2.2. Illustration using a Cantilever beam

2.2.1. FE Analysis of the beam

The structural analysis is carried out using parabolic tetrahedral elements of 5mm
length, with absolute sag of 1mm. It can be viewed from the analysis results that the
maximum stress occurs at the left end of the beam, which is fixed. The free end is loaded
with a force density of 1000N. For more details on Generative structural analysis, it is
advisable to go though the manual on this workbench, or CATIA V5 help. This is an
important pre-requisite for understanding this optimization task as the topic dealt
herewith is optimization of the geometry for an allowable value of stress.

Figure 2.2 - Cantilever Beam Geometry CATIA model

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Figure 2.3 - Cantilever Beam - Initial Stress distribution

It can be seen that the maximum stress corresponding to the initial geometry is 69,3MPa
at the fixed end.

After the FE calculation of the part has been carried out, a Global Sensor for the
maximum Von mises stress is added in the Static process. This sensor can be seen in the
model tree. A global sensor for the value of mass is also added.

Once the FE analysis is carried out, the part is ready to be optimized for stress.

The optimization Workbench in CATIA is entered through the following path from the
main menu:

Start Knowledgeware Product engineering optimizer

The workbench provides two new commands for product Optimization in the submenu,
Product engineering optimizer, which are:

1. Product Optimizer
2. Design of Experiments

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Figure 2.4 Product engineering optimizer toolbar

2.2.2. Computational resources

This method is extremely computationally intensive. After a change of the first

parameter, all values have to be passed through the second parameter, and so on. This
results in a large number of parameters, an exponential growth of expenses and thus the
computing time. Therefore this procedure should be applied only if relatively a few
parameters are considered. A fast PC/Workstation is preferred to carry out the
computation.

The procedure can be demonstrated using a cantilever beam, whose geometry is as seen
in the figure above.

The Design of Experiments form has the following options:

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Figure 2.5 Design of Experiments form

The input parameters can be entered/selected through the menu. The use of the design
of experiments for optimizing the cantilever beam discussed above is demonstrated.

In the form of the Design of experiments, the Select input parameters are the
parameters, which can be optimized (Generally the geometry parameters). Select
output parameters are the target parameters, like the stress and the deformation, which
have to be optimized.

2.2.3. Defining the Optimization parameters

The Optimization parameters can be defined through the Edit parameters button. Upon
clicking on this button, a new form opens, where the list of all available parameters can
be seen. The parameters required can be selected through the right arrow button seen in
Figure 2.6. Once these parameters are selected, the OK button takes the user back to

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the main form (along with these parameters). Please note that parameters have to be
created before optimization is started (After part modeling).

2.2.4. A quick recap on creating parameters

The button, formula in the knowledge toolbar is used to create parameters.

Figure 2.6 Knowledge toolbar

Click of the mouse button on the f(x) i.e. Formula button opens a new form where a new
parameter of type, for ex, length can be created

Figure 2.8 Defining a new parameter

In the above example, a new length parameter called Height, with a value 30mm is
created. Once all the required parameters are created, the geometry is sketched.

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Figure 2.9 Sketch without parameters

Once the sketch and formulae have been created, the parameters can be added to the
dimensions, as seen in Fig 2.10.

Right click on the dimension, for which the parameter has to be added and guide yourself
to edit formula as seen in Fig. 2.10. The formula created in the previous step is chosen
from the list, as seen in Fig. 2.11, which in this case is Height. Clicking on the OK
button after this will add the parameter to the dimension. The dimension with
parameters added to it would look like as seen in fig. 2.12.

In similar fashion, parameters are added to all the dimensions required, which are
Height and Breadth in this case.

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Figure 2.10 Adding parameters to dimensions

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Figure 2.11 Adding parameters

Figure 2.12 Sketch with parameters

If the parameters have been created and are not seen in the model tree, they can be
switched on through the following:

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Tools Options Infrastructure Part infrastructure Display tab Toggle on

Parameters

The parameters are now seen in the model tree as seen in Fig 2.13

Figure 2.13 Parameters in Model tree

Now, getting back to the design of experiments form (Fig. 2.5), the input parameters are
selected from the list of the available parameters as seen in Fig. 2.14.

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Figure 2.14 Selecting input parameters

Figure 2.15 Selecting output parameters

The mass and Von-mises stress are chosen as the output parameters i.e., the
parameters to be optimized. (Global sensors are created for both of these parameters)

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Figure 2.16 Range for output parameters

Figure 2.17 Design of Experiments

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The number of updates is automatically calculated depending on the input parameters

and the number of levels chosen. In this case, the number of updates is 64. These are
the combinations possible between a range of 10mm to 80mm using 8 levels i.e. steps of
10mm each.

The calculation time for this Optimization problem is usually 20-25 minutes depending on
the number of combinations. Here we have 8 levels of combinations and the calculation
time was approximately 30 minutes. The generated excel sheet gives details of all the
combinations possible with the geometry and the resulting stress. Here is a preview of
the results. (Not the complete list, the total number of evaluations are 64)

Analysis Manager\Finite
Analysis Manager\Finite Element
Nb Breadth Height
Element Model.1\Maximum Von
Eval (mm) (mm)
Model.1\Mass.3\Mass(kg) Mises.2\Maximum Von
Mises (MPa)
1 10 10 0,141 1087,332
2 20 10 0,283 531,756
3 30 10 0,424 348,806
4 40 10 0,566 260,673
5 50 10 0,707 214,812
6 60 10 0,849 180,404
7 70 10 0,99 156,116
8 80 10 1,132 137,345
9 10 20 0,283 278,122
10 20 20 0,566 140,151
Figure 2.18 Results Preview

The excel sheet has much more data including graphs. From the results, we can view the
many possibilities of breadth and height of the beam, the corresponding mass and the
Von mises stress corresponding to this geometry and mass.

23 70 30 2,971 20,277
24 80 30 3,396 17,597
25 10 40 0,566 75,931
26 20 40 1,132 40,096
27 30 40 1,698 28,48
Figure 2.19 Results Preview

It can be seen in Fig. 2.19 that for a value of breadth 10mm and a height of 40mm, the
mass is 0.566Kg and the stress is 75.93Mpa, which is well within the allowable limit for
steel. Thus, these values can be considered to be optimum. It can also be inferred that
the mass corresponding to this geometry is minimum.

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3. Optimization:

3.1. Optimization of the Cantilever beam

Once the design of experiments has been performed, the product is now ready to be
optimized. This is possible through the product Optimizer option available in the
workbench. On the click of this button, a form as seen in

The optimization is the process of searching for the minimum, maximum, or for a target
value of an Objective function of one or several variables while satisfying certain
restrictions or constraints.

A good example of optimization is the minimum weight design of structures in aerospace

industry where aircraft structural designs often prevail on cost considerations. The
notion of optimization pre-supposes that the operation to be improved or optimized is
described by a function whose variation can be expressed with respect to a group of
parameters, also called variables or free parameters.

On pressing the Optimization button found in the already familiar Product

Engineering Optimizer toolbar, a form as displayed in Fig. 3.1 opens up. The free
parameters are selected, which are Breadth and Height in our case. The range for the
free parameters is keyed in (Fig. 3.2). A value for the step is optional. When there is no
value specified explicitly, the system takes an automatic value, which can be for ex,
1mm.

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Figure 3.1 Optimizer form

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Figure 3.2 Range for parameters

It has to be noted that the algorithm type, chosen for this analysis is Simulated
Annealing Algorithm. This algorithm can be used as a general algorithm for Optimization.
It has the following characteristics*:

It is a global stochastic search algorithm hence two successive runs of this

method might not lead to the same result. It performs a global search that
evolves towards local searches as the time goes on.
It is usually used to explore non-linear, multimodal functions. These functions can
also be discontinuous.
If the shape of the objective function is unknown, it is recommended to start with
a Simulated Annealing then refine the results with a gradient descent**. This
approach is slow but works for a larger amount of functions.

*From CATIA V5 Help

**Another algorithm for Optimization (Gradient algorithm)

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Figure 3.3 Constraints for Optimization

In our case, the constraint is the condition where the Von mises stress is lesser or equal
to 100MPa. (Refer Fig. 3.3). Once the constraints are defined, the algorithm takes care of
this condition constantly. The Von mises stress can be chosen from the list displayed, or
by using a parameter, which is created by the user (See Fig. 3.4).

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Figure 3.4 Selecting the constraints from the list

Once the constraints are defined, the Run optimization button (Fig. 3.1) runs the
algorithm and displays the result, which is an optimized beam, in terms of its geometry
(Fig. 3.5). It can be clearly seen that the limit for the Von Mises stress is maintained at a
value of 100MPa, which is our requirement.

The optimized beam is the lightest beam possible of maintaining the specified condition.
This task would be very iterative and time consuming, if tried to be solved manually.

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Figure 3.5 Optimized beam Stress distribution and Geometry

3.2. Optimization of a C-Hook

The optimization technique is demonstrated using a C-Hook. A C-Hook is a lifting tool

which is supported at one end and loaded at the other. It is a device under very high
stress and therefore, structural analysis and optimization of this part is of very high
importance.

A C-Hook is used during transportation of huge steel structures. A crane hook engages
with the slot, seen above and a counter-mass keeps the C-Kook horizontal always. (The
counter-mass is not shown here). In our example, a force of 70,000N is applied at the
slot, where the crane hook would be engaged. This corresponds to a mass of about 7
tones.

The manufacturers of a C-Hook always aim to make the hook as light as possible, for a
specified load carrying capacity. Lighter the hook, lesser the cost for manufacturing the
same and it is easier to move the hook during operation too. Every gram saved, could be
used to transport more mass. The shape of the hook therefore has to be optimized for
minimum weight for a specified load carrying capacity.

The CATIA model for the C-Hook can be downloaded from the following path:

http://www.mbau.uni-wuppertal.de/index.php?id=175&L=0

The part to be downloaded here is C_Haken.CATpart. The parameters defined in the

part are the dimensions, that could be changed, i.e. are the dimensions, which can be
optimized. All these parameters correspond to the main sketch of the C-Hook. The

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download area also contains the FEM analysis of the C-Hook, under the name
C_Haken2.CATAnalysis.

Corresponding to the initial geometry of the part, the structural analysis will yield a value
for the maximum Von-Mises stress as 171MPa (Fig. 3.6). This hook measures 413Kgs,
when measured using CATIA V5.

The aim of the Optimization process is to minimize the mass and keep the maximum
stress to a limit of below 200MPa. (The yield stress of steel is around 210MPa). The
Optimization workbench is entered through the menu. Detailed steps regarding this
procedure are described as follows:

Figure 3.6 Structural analysis of a C-Hook

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Figure 3.7 Optimization form for C-Hook

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Constraints can be created with new option in the constraints tab. In our case, the
constraint is the condition where the Von mises stress is lesser or equal to 200MPa.
(Refer Fig. 3.9). Once the constraints are defined, the algorithm takes care of this
condition constantly. The Von mises stress can be chosen from the list displayed, or by
using a parameter, which is created by the user.

Figure 3.8 Defining the constraints

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Figure 3.9 Constraints and Precision

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Figure 3.10 Results - Preview

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Figure 3.11 Optimized C-Hook, Geometry and stress distribution

The process normally takes about 30 minutes on a Desktop PC. It can be seen that the
mass is reduced by 15.4%, and the stress is restrained below 200MPa. After the first run,
another FE calculation with an improved mesh should be carried out. The mesh can be
improved by local mesh refinement, or by using an adaptive mesh. It is important to
check if the results converge and there is no influence of the mesh over the final result.
The table below contains values of the C-hook parameters, before and after the
Optimization is carried out.

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