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Copyright © 2018 by CIMdata, Inc. 1
www.CIMdata.com
Copyright © 2018 by CIMdata, Inc.
Global Leaders in PLM Consulting
TTopology Optimization:
A Long Way To Go
Topology Optimization Round TableWashington, DC20 February, 2018
Keith Meintjes, Ph.D., [email protected]+1.248.891.6434
Copyright © 2018 by CIMdata, Inc. 2
Our Mission...Strategic management consulting for competitive advantage in global markets
CIMdata is the leading independent global strategic management consulting
and research authority focused exclusively on the PLM market.
We are dedicated to maximizing our clients’ ability to design and deliverinnovative products and services through the application of PLM.
Copyright © 2018 by CIMdata, Inc. 3
Dr. Keith Meintjes, Simulation & Analysis Leader of the Simulation & Analysis Council and consulting at
CPDA & CIMdata since 2008 (CPDA acquired by CIMdata in 2011) 29 years at GM included numerous positions of technical
and strategic leadership Responsible for GM’s global strategy for high-performance computing Champion of GM’s CAE “Grand Challenge” initiative to improve simulation
capability for all aspects of vehicle development Engineering group manager for simulation at GM Powertrain Part of a team to apply simulation tools for powertrain product development Developed CFD tools for engine combustion Ph.D. thesis (Princeton) on CFD fluid flow simulations with combustion Born in South Africa, holds B.Sc. and M.Sc. from U. of the Witwatersrand
Dr. Keith Meintjes, Executive Consultant Professional background
Copyright © 2018 by CIMdata, Inc. 4
AbstractTopology Optimization: A Long Way To Go
Topology Optimization (TopOpt) was "invented" in the late 1980s, but the technology was not widely adopted: The software was too difficult to use, and it generated designs that were not manufacturable by conventional means. Now, we have the maturing of additive manufacturing, which has caused renewed interest (or even excitement) in TopOpt. But, in a sense, we have gone from parts we can design but not manufacture, to parts we can manufacture but not design.
Dr. Keith Meintjes was customer #001 for Altair Optistruct, the first commercial TopOpttool, back in the early 1990s. He will point out that, nearly 30 years later, there is a lot of work yet to be done. The path from idea to product is far from even. While many share a vision that Generative Design and Topology Optimization will revolutionize product development, the realities of data flow through the product development process make this seem like a mirage.
Keith will stress that while people are earnestly working within their silos, there needs to be more attention on the end-to-end process of making useful products, communication between the silos.
Copyright © 2018 by CIMdata, Inc. 5
A Short History Shape and Topology Optimization
Shape optimization Developed in the late 1980s Fairly successful for some applications like stiffening ribs for sheet metal
stampings, lightening holes in aircraft structures
Topology optimization Developed in the early 1990s Some success with almost-2D parts: Struts, brackets, suspension components Low adoption
Codes were very difficult to use Creating useful CAD geometry from TopOpt results was is very difficult 3D TopOpt parts are usually not manufacturable by traditional (subtractive) means
So, why are we here, in DC, today?
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Why The Enthusiasm and Excitement? (1)How is it different this time, than it was 25 years ago?
The rise of Additive Manufacturing (3D Printing)
Yes, but also:
New materials
Advances in computational geometry
The incredible rise in computing power Computing is now infinitely fast and vanishingly cheap (by
comparison) We can compute in one second what would have taken the
Apollo moon program engineers 1400 years!
Copyright © 2018 by CIMdata, Inc. 7
Why The Enthusiasm and Excitement? (2)How is it different this time, than it was 25 years ago?
Advances in IT Digital product definition Cloud Machine learning Big data and analytics
Statistical Optimization Stochastics, robust design
And, the synergies between all of these
Many of us believe this will cause a revolution in product development and manufacturing
Copyright © 2018 by CIMdata, Inc. 9
“Generative Design” is a collection of tools and techniques that help to create or modify feasible product designs, including geometry, from statements of requirements and constraints.
This is different than the usual paradigm, where CAD (product geometry) is created and then evaluated against product requirements.
GD tools include Topology optimization Shape optimization Rules-driven Parametric CAD Cost and manufacturing optimization …
Generative Design (GD)
Copyright © 2018 by CIMdata, Inc. 10
Is the use of algorithmic methods to transform requirements into product geometry and design
Often includes optimization within constraints
Is not necessarily based on physics (nor on natural organic processes)
Has long been an idea for architectural design
Generative DesignCIMdata’s Definition
Copyright © 2018 by CIMdata, Inc. 11
Generative Design
“Integrated performance-driven generative design systems are aimed at creating new design processes
that produce spatially novel yet efficient and buildable designs through exploitation of current
computing and manufacturing capabilities.”
Prof. Dr. Kristina Shea (ETH Zurich)
K. Shea et al, “Towards integrated performance-driven generative design tools”, Automation in Construction 14 (2005) 253–264.
Copyright © 2018 by CIMdata, Inc. 12
Traditional Component Design ProcessCharacterized by many evaluation iterations
Previous Designs(History)
Design Constraints
Performance Requirements
Design Space
(Context)
Create Design (CAD)
Evaluate Design (CAE)
Issues
Valid Design
Design Iterations
Build
Copyright © 2018 by CIMdata, Inc. 13
Generative Design ProcessOptimization should directly create feasible and buildable designs
Previous Designs(History)
Design Constraints
Performance Requirements
Design Space
(Context)
Topology Optimiza-
tionvia CAE
Valid Design
Document Design (CAD)
Build
Copyright © 2018 by CIMdata, Inc. 14
Autodesk Generative Design (Dreamcatcher)
• Such lattice structures can be designed for a specified center of gravity and moments of inertia
• They can be efficient heat exchangers and catalyst beds
• They can also be designed as “pseudo-materials”, with properties like a negative Poisson’s Ratio or zero thermal Coefficient of Expansion
• The innovation options are endless
http://damassets.autodesk.net/content/dam/autodesk/www/solutions/generative-design/lattice-and-surface-optimization-thumb.jpg
Copyright © 2018 by CIMdata, Inc. 16
Topology Optimization Must Generate “Useful CAD”This is a difficult and manual process – unacceptable in a practical workflow
Adapted from: US Federal Highway Administration:http://ops.fhwa.dot.gov/publications/seitsguide/“Systems Engineering for Intelligent Transportation Systems”
Implementation
Image courtesy of Dr. Andreas Vlahinos, Advanced Engineering Solutions:
“Here, the process is broken”
Copyright © 2018 by CIMdata, Inc. 17
I have had some negative and critical things to say
Most of the software providers get it, and they are working to fix the issues
There are a lot of bright and innovative people engaged
The issues will be addressed, over time
But
There is a lot of work to be done
Neither Topology Optimization nor Additive Manufacturing are silver bullets
It’s not just software: User organizations have their issues
Keith’s Disclaimer
Copyright © 2018 by CIMdata, Inc. 18
Software is too difficult to use, the process is too manual
Organizational problem: You need FEA expert Manufacturing expert CAD expert Product engineering specialist
Resources are not deployed where decisions are made (“If you have CAD, It’s too late” – Matthew Loew)
Translation into CAD is very difficult and time-consuming
Redesign is required, for constraints are missing in TopOpt
Resulting designs cannot be manufactured
Issues with Traditional Topology Optimization
Copyright © 2018 by CIMdata, Inc. 19
The design documentation(CAD) step is completely broken
Developers should be cognizant of the entire process: Product requirements → manufactured, documented, product
The overall process should not require human intervention
Much innovation is required for lattice structures in CAD and CAE systems
Some Closing Comments (1)
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We have to get beyond the issue of being able to design parts we cannot manufacture
We should not get stuck with parts we can manufacture but not design
Generative Design and Additive Manufacturing will prove to be incredible tools to enable innovation
End users should strive to understand these technologies and processes, and leverage them to maximum advantage at the earliest possible stage
Some Closing Comments (2)
Copyright © 2018 by CIMdata, Inc. 22
CIMdata workshops and conferences
ASSESS – Nov 1 - 3, 2017, Potomac, MD (near DC)
COFES – April 12 - 15, 2018, Phoenix (Scottsdale), AZ
Topology Optimization Round Table – February 10 - 11, 2018, Washington, DC
User conferences: Autodesk Siemens PLM Software Dassault Systèmes Simulia Altair …
Further Resources - Conferences
Copyright © 2018 by CIMdata, Inc. 23
"I firmly believe that Topology Optimization (TO) with additive manufacturing will revolutionize the way many products are developed and engineered. Not only are the TO design geometries beyond the capability of a human designer to produce, but the design effectiveness is almost always superior. And it’s not just a point design. The explorable design space starts exploding. Adjusting prioritization of different load cases, different physics, including uncertainties, adjusting for manufacturing constraints on various machines and even creating and using custom materials via lattice-type metamaterials – this all becomes part of a viable design exercise. And frankly, we are just beginning to understand the power of this transformation."
Ted Blacker Says
Copyright © 2018 by CIMdata, Inc. 24
"Some, like me, believe that this move to Generative Design will revolutionize product design and development. In a relative sense, computing has become infinitely fast and vanishingly cheap, so we can now easily use heuristic brute-force methods to search for optimums. Also, Additive Manufacturing (3D Printing) promises the capability to make parts that were previously infeasible to produce."
Keith Meintjes Says
Copyright © 2018 by CIMdata, Inc. 26
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