from topology optimization to robust design - dynardo gmbh
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From Topology Optimization to Robust Design Optimization
Dipl.-Ing. Markus Kellermeyer, CADFEM GmbH
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Outline
1. Overview for Optimization in ANSYS Workbench
2. Project Description
3. Topology Optimization insideANSYS Workbench
4. Robust Design Optimization with „optiSLanginside Workbench“
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Overview for Optimization in ANSYS Workbench
TopologyOptimization
optiSLanginsideWorkbench
optiSLangwith optiPlug
Easy-to-usetool for difficult& nonlinearoptimizationtasks, robustnessevaluation and robust designoptimization
Advancedtool for alltasks
Parameterfreeoptimization
Parameter optimization
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Example for Topology Optimization: PowerWind GmbH
6 different loadcases were considered
by courtesy of PowerWind GmbH
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Project Description
Create a design within a predefined space, that
- consists of beams with predefined cross section profiles- where the beams do not exceed a predefined stress- where the 1st frequency will be as large as possible- where the structure will be a 2-σ design or higher due to appearingstresses
???
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Topology Optimization
Steps to do topology optimization with several load cases:
loadcase1
loadcase2
Define several load steps…
These will represent theloadcases
Run Macro… Solve…
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Topology Optimization
� Use Topology Optimization in Workbench� Several load cases can be considered:� a „one-click-solution“
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Topology Optimization
Use topology idea, to create a manufacturable concept:
Parameterize the beam structureto allow different design constellations:
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Topology Optimization
What‘s been done so far:
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Robust Design Optimization with „optiSLang inside Workbench“
General Information:Dynardo integrated „optiSLang“ in ANSYS Workbench as an easy-to-use tool.It‘s called „optiSLang inside Workbench“
� It will be used for the „Robust Design Optimization“ Workflow
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� 1-sigma level
� 3-sigma level
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Robust Design Optimization with „optiSLang inside Workbench“
Sensitivity Analysis:
Input1 Input2Input3 Input4 Input5 Input6Input7 …
Robustness Eva.:
Input1‘ Input2Input3 Input4‘Input5 Input6Input7 …
Constraints
Robustness Eva. 2:
Input1‘‘ Input2Input3 Input4‘‘Input5 Input6 …
Constraints
Optimization:
Input1 Input4
ObjectivesConstraints
� Input1‘ Input4‘
Optimization 2:
Input1‘ Input4‘
ObjectivesConstraints‘
� Input1‘‘ Input4‘‘
Modify Constraintsfor a new
Optimization
General Workflow:
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Robust Design Optimization with „optiSLang inside Workbench“
General Workflow in ANSYS Workbench:
Step1 Step2 Step3 Step4 Step5
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Robust Design Optimization with „optiSLang inside Workbench“
Step 1: Sensitivity Analysis - Setup
1. Definelower & upper bounds
2. Define numberof samples
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Robust Design Optimization with „optiSLang inside Workbench“
Step 1: Sensitivity Analysis - Results
� Important parameters: split2, split3, split6
Stress:Deformation:Frequency:
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Robust Design Optimization with „optiSLang inside Workbench“
Step 2: First Optimization
Just choose an algorithm.The ‚decision tree‘ helps!
Define constraints & objectives: σ < 43.5d < 0.17frequency � max
Parameter setting
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Robust Design Optimization with „optiSLang inside Workbench“
Step 2: First Optimization - Results
Stress = 40.87 < 41.5 (limit)Deformation = 0.169 < 0.17 (limit)1st Frequency = 27.9
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Robust Design Optimization with „optiSLang inside Workbench“
Step 3: Robustness Evaluation with optimized design
The current sigma level for this design is: (41.5-41.16)/0.242 = 1.4
� not good enough
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Robust Design Optimization with „optiSLang inside Workbench“
Step 4: Second Optimization with changed constraint
Define new stress constraint: σ < 41.2d < 0.17frequency � max
Stress = 39.0 < 41.5Deformation = 0.168 < 0.171st Frequency = 27.8
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Robust Design Optimization with „optiSLang inside Workbench“
Step 5: Robustness evaluation with second optimized design
Now, the sigma level is > 2σ
� ok! optional: 3rd run withinterpolated stress-
constraint
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Conclusion
� Topology Optimization good for finding a concept
90 min
20 min
5 min
10 min30 min
5 min 5 min 5 min 5 min
� Parametric Optimization good to work with manufacturableparameters and in more than 1 physics domain
� Robust Design Optimization can now be done inside Workbench in a very quick way: „optiSLang inside Workbench“
� easy-to-use tool, that safes time for the user:
setup-time
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Thanks for your attention!