Professional Documents
Culture Documents
What are you modeling? Why are you modeling it? How are you modeling it? How are you validating it?
2/14/2012
2/14/2012
2/14/2012
Modeling goals
Loading of current design has increased Will it survive its environment? Can we make it lighter?
Mechanical drawings
2/14/2012
Modeling assumptions
Plane stress assumption, Static equilibrium Small deformation assumption Linear elastic isotropic homogeneous material E = 70 GPa Failure mode: von Mises plasticity, MPa m
Modeling assumptions
Boundary conditions Zero displacement at wall Concentrated 1000N load at bolt center
1000 N
2/14/2012
Convergence study
Recommendations
Current design will not yield Make a more aggressive design
MPa
Recommended Reading
Morris, A and Rahman, A., A Practical Guide to Reliable Finite Element Modeling, John Wiley & Sons, West Sussex, 2008
Download FREE from UIUC library Minimally peruse chapter 10
Design Optimization
Can we improve our design? What should we change? Can we improve it even more? Optimization replaces trial-and-error Hyperworks/Optistruct
2/14/2012
Calculus example
Maximize the rectangle area subject to a perimeter constraint
NLP Algorithm
What we see
Make design a math problem Engineers are good at math problems Justify design choice in a sound manner Recipe Simulation to evaluate f and g Sensitivity analysis to evaluate and
no
Optimizer
Convergence
yes
2/14/2012
Optimize anything?
Matlab fmincon
Continuous design variables Differentiable cost and constraint functions Only requires three modules
Initialize d, dlower, dupper d= Fmincon(@costfunction, d,[],[],[],[], dlower, dupper, @constfunction Function f=costfun(d) Change input file reflect new value of d Call simulation program Read output file and retrieve cost-function value f Function g=constfunction(d) Change input file reflect new value of d Call simulation program Read output file and retrieve constraint function values g
Optimize anything?
Fit model parameters to experimental data
Inverse/identification study Loads Material properties Requires regularization term for stability
Cost function, e.g. mass Constraint function, e.g. maximum stress Design parameters, e.g. dimensions Each iteration requires FEA
Automated procedure eliminates model regeneration Automated procedure satisfies optimality criteria, e.g.
2/14/2012
In addition to FEM
Specify design parameters Specify cost and constrain functions Show optimized design
Denote values of Plot Deformed shape Plot contours of stress measures, etc. Compare to initial design
Computational design environment w/ S. Chen 1994 Pro/Engineer solid modeler Feature-based modeling OCTREE mesh generator Pro/Develop API MSC/Nastran DSA DOT SLP
2/14/2012
Analysis model
Quarter symmetry Initial mesh 2215 Tetrahedrons 4642 nodes Linear elastostatic FEA Steel Boundary conditions Big end: fixed Small end: distributed pressure Max von Mises stress 79 Mpa DOT SLP
Design model
Minimize mass 8 design variables Neck contour Wed radii Outer small end radius Web depth Stress constraint
Results
Discussion
Converges in 8 iterations 34% volume decrease Only initial user interaction Requires mesh generator Requires parameterization Applicable to other analyzes
10
2/14/2012
Topology Optimization
Specify length scale MINDIM (minimally thrice the larges element size)
?
Infinitesimal MINDIM
Large MINDIM
Smaller MINDIM
Hyperworks observations
Industry standard Surprising archaic,
but doable Many help/tutorial files
Shape optimization by
Morphing Free nodes
Define the objective (cost) function, i.e. choose a response Define constraint functions
Choose a response Specify an upper or lower limit
Topology optimization
Best to minimize compliance subject to a mass limit. Manually adjust mass limit until stress constraints are satisfied
11
2/14/2012
Hyperworks
Available on EWS machines Available from the webstore
Download both help11.0 and hw11.0 You will need to be on a network associated with the unversity (illinoisnet wireless for example) or connected through the vpn. (http://cites.illinois.edu/vpn/) You need to set the environmental variable LMX_LICENSE_PATH to 6200@altair.webstore.illinois.edu. Make sure to add a new one and not edit a previous one. For XP. http://support.microsoft.com/kb/310519 For windows 7. http://www.windows7hacker.com/index.php/2010/05/howto-addedit-environment-variables-in-windows-7/
View the How to Start the Process Manager Download 3D FEM Process Manager Download Cantilever_HM10.hm Download Clip_HM.hm View the Simplified 3D Process Guide View the What is Happening in the Background View the Basic Introduction into Topology Optimization
12
2/14/2012
13
2/14/2012
Recommended Reading
Christensen, P. and Klarbring, A., An Introduction to Structural Optimization, Springer, West Sussex, 2009
Download FREE from UIUC library
14