PTIMISATION FOR PLASTIC - innovdays-plasturgie.com · OptiStruct 01 LINEAR Impact, Thermal, NON-LINEAR (IMPLICIT) NON-LINEAR (EXPLICIT) MULTI-BODY DYNAMICS OPTISTRUCT Statics, Dynamics,

Copyright © 2010 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

PEP, 30th June 2011

Emilien GOETZ

OPTIMISATION FOR PLASTIC PARTS


Agenda

Introduction

Optimisation for plastic parts

• Concept Optimisation

• Fine tuning Optimisation 02

01

01


Historique Altair 01

19 85

20 10

$175M

$100M


CONCEPT OPTMIZATION

FULL COMPOSITE OPTIMIZATION

OPTIMIZE RADIOSS BULK ANALYSIS

COMPATIBLE WITH NASTRAN

DESIGN OF EXPERIMENT

MULTIPLE OBJECTIF OPTIMIZATION

ROBUST OPTIMIZATION

LINK WITH ANY SOLVERS

Optimization with HyperWorks Introduction

01

HyperStudy Optistruct


DESIGN OF EXPERIMENTS

INPUT PARAMETERS

PROBABILITY DENSITY

ABAQUS

ADAMS

ANSYS

DADS

LS-DYNA

DIGIMAT

MARC

NASTRAN

PAM-CRASH

SIMPACK

RADIOSS

OptiStruct

MotionSolve

HyperForm

And More

COMPUTE

SIMULATION

RESPONSE SURFACE

OPTIMIZATION STOCHASTIC

ANALYZE

Optimization with HyperWorks ALTAIR HYPERSTUDY

01


Optimization with HyperWorks 01

Peak Stress

212 MPa

123 MPa

Volume

64420mm3

67087mm3

Gauge9 & 10

Gauge1, 2 & 3

Gauge4

Gauge5

Gauge6

Gauge7Gauge11, 12 & 13

Gauge14 &15


HY

PE

RS

TU

DY

+ S

OLV

ER

Optimization with HyperWorks OptiStruct

01

LINEAR

NON-LINEAR (IMPLICIT)

NON-LINEAR (EXPLICIT)

MULTI-BODY

DYNAMICS

OP

TIS

TR

UC

T

Statics, Dynamics, Buckling, Thermal, Plasticity, Normal

Modes, NVH, Contact

Quasi-static, Dynamics, Post-buckling, Materials,

Contact

Impact, Thermal, Materials, Contact

(Rigid & Flexible Bodies)

Kinematics, Static and

Dynamic, Quasi-static

Multi-physics, multi-disciplines


Agenda

Introduction

Optimisation for plastic parts

• Concept Optimisation

• Fine tuning Optimisation 02

01


€ € € €

€

Concept Design Virtual and

real tests

= Cost is a problem to solve

# Id

en

tifi

ed

pro

ble

ms

# Id

en

tifi

ed

pro

ble

ms

Altair’s Vision 02

Manufacturing Prototype

DMU

Simulation

CAE

Design

CAD

Concept

Phase


Optimization

The Traditional Design Process…

The Traditional Design Process…


Concept design + Design (CAD) Virtual Test

(CAE) Build Test

Concept Design

Optimization

Design (CAD)

Virtual Test (CAE)

Build Test

Redesign

Redesign


Positioning Concept Design...

Classic: Simulation as a

virtual test

What? Conceptual design, material substitution, weight loss, stress

reduction, increase in stiffness, natural frequencies, ...

Product Safety Design through early maturity!



DMU

Simulation

CAE

Design

CAD

Concept

Phase


Optimisation for plastic parts 02


DMU

Simulation

CAE

Design

CAD

Concept

Phase

First the concept then the fine Tuning!




DMU

Simulation

CAE

Design

CAD

Concept

Phase

Methods and examples of concept development


A preliminary design tool to generate optimal

design concepts

• An optimization tool for weight reduction

and performance tuning of concept and

existing designs

• A robust and accurate finite element solver

for linear structural analysis

02 Optimisation for plastic parts How to ensure the Plastic parts requirements?


METHOD TO FIND THE OPTIMUM MATERIAL DISTRIBUTION IN A GIVEN DESIGN SPACE

02 Optimisation for plastic parts Topology

2D ELEMENTS 3D ELEMENTS 1D ELEMENTS


• Min/Max Member Size

• Draw Direction

• Extrusion

• Symmetry

• Pattern Repetition

• Cyclic Repetition

02 Optimisation for plastic parts Manufacturing Constrains

Without Maximum Member Size

WITH Maximum Member Size

Material

Concentration

Eliminated

Hollow section

Ribs

Without Draw Direction

With Draw Direction

Without Extrusion

Design Space

With Extrusion

Without Pattern Repetition With Pattern Repetition

Without Pattern Repetition With Pattern Repetition

No symmetry XZ, YZ symmetry

YZ symmetry XZ symmetry S

ym

me

try

5 Repetitions

No

Sy

mm

etr

y

20 Repetitions


• Iso-surface extraction and remeshing

• NASTRAN, IGES, STL and H3D output formats

02 Optimisation for plastic parts Geometry Recovery through OSSmooth


TOPOLOGY 2D MATERIAL DOWNSCALING

• Time consuming because fine mesh needed to respect the rib thickness

• 1 or 2 Step of 3D topology

• Fast simulation

• good method for panel

• More conceptual : give path loads

Draw Z - No hole

• Approximate approach

• usefull for big design space

Draw Z

TOPOLOGY 3D



Draw Direction Constraints

MODEL OPTIMIZATION FINAL DESIGN

Optimisation for plastic parts CASE STUDIES: 3D TOPOLOGY

02


Is it permissible for an isotropic material model with linear and static load

cases, an interpretation of possibly dynamically loaded plastic components

to make?

“Optimization of Plastic Products” BPODevelopment; Oscar Brocades Zaalberg

“Optimization of Plastic Products” BPODevelopment; Oscar Brocades Zaalberg

„Not only allowed on, but

useful!“

Optimisation for plastic parts CASE STUDIES 02


Linearization of crash loading case : • Maximum 3 point harness forces

• Dummy contact forces

Design Space

Optimisation for plastic parts CASE STUDIES 02



02


TOTAL VOLUME

CU.UNITS

COMPLIANCE

EXISTING DESIGN

2.99 E-01

1.563

NEW OPTIMIZED DESIGN

2.99 E-01

1.384

MODEL OPTIMIZATION FINAL DESIGN


02




DMU

Simulation

CAE

Design

CAD

Concept

Phase


• AUTOMATED WAY TO MODIFY THE STRUCTURE PARAMETERS (THICKNESS, 1D

PROPERTIES, MATERIAL PROPERTIES, ETC…) TO FIND THE OPTIMAL SOLUTION

02 Optimisation for plastic parts Size


AUTOMATED WAY TO MODIFY THE STRUCTURE SHAPE BASED

ON A PREDEFINED SHAPE VARIABLES TO FIND THE OPTIMAL

SHAPE

Morphing Concept as Tool

Motivation: Reduce CAD Loops

Idea: FE-based Modification

Related changes make where the problem area has been identified!

Related changes directly on the simulation model

Concept development based on the predecessors FE-model!

02 Optimisation for plastic parts Shape


DESIGN PROBLEM

• Improve the stiffness

• Collapse load on top of the model

• Mass reduction

METHODS USED • DOE for identified most important parameters!

• Shape and size optimization

02 Optimisation for plastic parts CASE STUDIES : Fine tuning optimisation


Simulation

Parameterized

model

Results

Optimum? No

Yes

Update design

variables: geometry,

temperature,

pressure, ...

Optimisation for plastic parts CASE STUDIES : Fine tuning optimisation 02


• Improved collapse mechanism

• Increased Buckling +20%

• Mass reduction: 5%

Design sensitivities

Optimisation for plastic parts CASE STUDIES : Fine tuning optimisation 02


Combining the freeze contact between 2 shells elements and Morphing

allow you quick update and optimization with HyperStudy

+ FREEZE CONTACT

Optimisation for plastic parts Freeze contact and morphing in HW 11

02


Challenge

• Develop the design concept to meet the mass target within a three week process

development period

• A further four weeks was then allocated to optimizing the thirteen rib package

02 Optimisation for plastic parts Airbus Wing Rib


Optimisation for plastic parts 02 Airbus Wing Rib

Topology Optimization

Geometry Extraction

ICAD

Solid Geometry Extraction Size and Shape Optimization


Package Space Definition


Material Layout

Buckling and Stress


Results

• Mass Savings of 44% (500kg)

• Deadline met: Ribs developed in 13 weeks

02 Optimisation for plastic parts Airbus Wing Rib


02 Optimisation for plastic parts PLATFORM FOR THE VIRTUAL DEVELOPMENT PROCESS


DMU

Simulation

CAE

Design

CAD

Concept

Phase

Crash / Drop Test

Filling

Fatigue, …

Fiber orientation

+


Altair Engineering, Inc.

Innovation Intelligence™

MERCI

Documents

PTIMISATION FOR PLASTIC - innovdays-plasturgie.com · OptiStruct 01 LINEAR Impact, Thermal, NON-LINEAR (IMPLICIT) NON-LINEAR (EXPLICIT) MULTI-BODY DYNAMICS OPTISTRUCT Statics, Dynamics,