the optimization company - hamburg.de

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the optimization company Carsten Gerdes-Götz, FE-Design GmbH Dirk Pieper, pike-engineering & CAE- Forum.de

Transcript of the optimization company - hamburg.de

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the optimization company

Carsten Gerdes-Götz, FE-Design GmbH Dirk Pieper, pike-engineering & CAE-Forum.de

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the optimization company

Topologieoptimier-ung als Ansatz für Materialeinsparung und Ressourcen-schonung

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„Es ist das Gesetz aller organischen und anorganischen, aller physischen und metaphysischen, aller menschlichen und übermenschlichen Dinge, aller echten Manifestationen des Kopfes, des Herzens und der Seele, dass das Leben in seinem Ausdruck erkennbar ist, dass die Form immer der Funktion folgt.“ – aus Sullivans Aufsatz: „The tall office building artistically considered“, veröffentlicht 1896, in dem er den Ausspruch seines Partners Dankmar Adler zitiert, der ihn seinerseits sinngemäß von Henri Labrouste übernommen hatte. -Quelle: Wikipedia

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Structural optimization Design process

► Reduction of weight

► Enforcing desirable stiffness and dynamic process

► Maximize the maximum stresses of several loadcases

► Minimize damage and increase durability

► Include manufacturing constraints

► Design for displacements/forces/ eigenfrequences

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Topology optimization

Smoothing and generation of validation file

Validation run

Optimized design geometry

Initial design space geometry

Finite element model

Optimization model

Shape optimization

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FE-DESIGN Your partner for optimization

► FE-DESIGN combines development and application of optimization methods

► FE-DESIGN has the ability to deliver best solutions for our customers, benefiting from many years of experience

► Our customers continuously improve their optimization processes due to a steady know-how transfer through FE-DESIGN

► Customers leverage FE-DESIGN´s knowledge, with long-term business relationships

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ENGINEERING SERVICES

TRAINING, SUPPORT AND CONSULTING

SOFTWARE-DEVELOPMENT

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Product development values by using TOSCA

► Virtual prototypes accelerate the product development cycle

► Numerical simulation increases product quality ► Economy of energy and resources ► Higher efficiency through lower masses, higher

accelerations, shorter cycle times ► Lower stresses increase durability ► Savings of material at ensured product quality ► Earlier product launches due to shorter

development times

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FE-DESIGN Fields of application

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Automotive Machine construction Aerospace

Wind power generation Marine technology Medical devices

Engines & turbo machinery Home appliances Consumer products

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Main Frame Development

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Topology optimization of a main frame

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Optimization result Assembly

Series production Conventional design

Design space for topology optimization Series production

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Main frame - comparison

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40% savings on weight!!! (>1,0 Mio EUR in one year)

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Hub optimization

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Topology optimization of a hub

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Topology optimization Verification of new conceptual design

CAD surfaces Applying loading

Design space model Verification of new conceptual design

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Topology Optimization Example Transverse Link at AUDI

With the friendly permission of

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Initial situation

Transverse link at Audi

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► A modification of the component was necessary, because the load on the part became too high with the new engines. Topology optimization is used to derive a new structure.

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Topology optimization of a transverse link at AUDI

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Existing design

Design space model

Topology optimization

Cutting splines

Redesign

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Comparison Existing design – new design

► Speed-up of the development process ► 45% stress reduction, 10% weight reduction ► The 1st prototype passed all mechanical tests !

Result

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Weight Max. stress Max. displacement

Existing design New design

Admissible Stress

(Image ATZ MTZ extra)

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Structural Optimization of Washing Mashine Components

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Parts in FEA model

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H1

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H3 H4

H5 H6

H7

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Traverse (braces)

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Topology Optimization of a Washing Mashine Spider Arm

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Definition of the optimization task

► Minimize volume

► Displacement constraint on loaded nodes ► The maximum absolute displacement in z-direction for all nodes in the

displacement nodegroup is restricted to 4.5 mm

Objective

Constraints

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► Optimized design:

► Volume = 214208. (53%)

► MAX_DISP_1 = 4.44915

► MAX_DISP_2 = 4.46176

► MAX_DISP_3 =

0.619918E-01

► MAX_DISP_4 = 3.81158

► MAX_DISP_5 = 3.93099

► MAX_DISP_6 = 1.07937

Optimization I results (without cast constraint)

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DRESP_MAX_DISPLACEME

► Initial design:

► Volume = 398746. (100%)

► MAX_DISP_1 = 3.94601

► MAX_DISP_2 = 3.93227

► MAX_DISP_3 = 1.84903

► MAX_DISP_4 = 2.29052

► MAX_DISP_5 = 2.23707

► MAX_DISP_6 = 1.83949

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Optimization II results (considering cast constraint)

► Initial design:

► Volume = 398746. (100%)

► MAX_DISP_1 = 3.94601

► MAX_DISP_2 = 3.93227

► MAX_DISP_3 = 1.84903

► MAX_DISP_4 = 2.29052

► MAX_DISP_5 = 2.23707

► MAX_DISP_6 = 1.83949

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► Optimized design:

► Volume = 340751. (85%)

► MAX_DISP_1 = 4.46618

► MAX_DISP_2 = 4.40698

► MAX_DISP_3 = 1.72442

► MAX_DISP_4 = 4.32224

► MAX_DISP_5 = 4.52701

► MAX_DISP_6 = 0.731727

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Optimization of a bike stem

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Topology optimization of a bike stem

Design space

New design

Conventional design

Load cases

Smoothed results

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Thank you for your attention