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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the optimization company
„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
03.12.2012
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FE-DESIGN Fields of application
03.12.2012
Automotive Machine construction Aerospace
Wind power generation Marine technology Medical devices
Engines & turbo machinery Home appliances Consumer products
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Topology optimization of a main frame
03.12.2012
Optimization result Assembly
Series production Conventional design
Design space for topology optimization Series production
Courtesy of
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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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Topology optimization of a hub
03.12.2012
Topology optimization Verification of new conceptual design
CAD surfaces Applying loading
Design space model Verification of new conceptual design
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the optimization company
Topology Optimization Example Transverse Link at AUDI
With the friendly permission of
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Initial situation
Transverse link at Audi
03.12.2012
With the friendly permission of
► 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
03.12.2012
Existing design
Design space model
Topology optimization
Cutting splines
Redesign
Courtesy of
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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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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_VOL_TOPO
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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DRESP_VOL_TOPO
DRESP_MAX_DISPLACEME
► 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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Topology optimization of a bike stem
Design space
New design
Conventional design
Load cases
Smoothed results
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Customers of FE-DESIGN
3.12.2012 г.
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