The Benefits of Topology Optimization

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The Benefits of Topology OptimizationHow to unlock the true potential of Additive Manufacturing

AM-DAGEN 2015 Lars Pursche

Copyright © 2013 solidThinking, Inc. Proprietary and Confidential. All rights reserved.

About Us

Founded ...

In 1985 as a product design consulting company

Today ...

A global software and technology company focused on simulation and

analytics, product development and advanced computing

solidThinking, Inc. is a wholly-owned subsidiary of Altair

We help businesses succeed

through the development and

application of simulation

technology to accelerate

innovation.


Agenda

Why?Topology / Design Optimization – Concept Design

How?Technology

Who?Industry applications


Two Simple Equations (I)

= min. f(x)

Time

Energy

Material

Waste…

Costs/Price

Weight

75% of the production/product costs

are defined at the design process.

Product Design:

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Two Simple Equations (II)

= min. f(x)

Energylimited

MovingParts

…

Functio-nality

Perfor-mance

Weight

Energycosts

Product in use:


Problem already solved…

Energy/Motion Weight Material/Performance

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Design & CAD

How can a designer come up with the best possible

shape?

Intuition, experience, trial & error,…

How can the engineer draw it in a CAD tool?

CAD tools rely on Boolean Operations of

simple geometric entities

Limited NURBS/freeform capabilities

„Drafting“ something like this can

take weeks with a conventional tool

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Problem

How do I develop extremely

efficient and lightweight

components?

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olfgang M

achnze,

EA

DS


Mechanotransduction

Julius Wolff

(1836-1902)

anatomist and surgeon

Wolff's law

Bone in a healthy person or animal

will adapt to the loads under which

it is placed.

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geometry loads

loads geometry

Solution

Def. Topology Optimization

mathematical approach/computer based algorithm

that optimizes material layout within a given

design space

for a given set of loads and boundary conditions

Method of Calculation

discretization of the 3D model

highly loaded areas density is increased

less congested areas density is reduced (line of

force)

stresses are distributed evenly

Topology Optimization

of Airbus A380 drop nose

leading edge ribs

Savings:

500 kg just on the leading edge

44% of the original design weight


geometry loads

loads geometry

Traditional Design Process

„Real“ Prototype

…ConceptDesign

Concept Design Software

EVOLVE, Rhino, …

DetailedDesign

CAD Software

SolidWorks, Creo, NX, Catia…

Validation(Simulation)

Simulation Tools

HyperWorks, Abaqus, Nastran,…


Start with the Solution

Mass = 9.15 Kg

Design Time:

3 Months

Conventional Design ProcessOptimization Driven Design

Process

Mass = 7.5 Kg

Design Time:

3 Weeks


Traditional Design Process vs. Topology Optimization

Traditional Design Process

Development

ConceptDetailed Design Production

Validation &

Prototyping

Documentation

Start with the solution and shorten time to market

Product

Definition

Concept

Design

Validation &

Prototyping

Documentation

Product-

Definition

With Topology Optimization

ProductionDet.

Design


Why we look at the Additive Manufacturing?

They are

cool

Elegant design

Structural freedom

Individual design

Democratic design

Complexity is for free

Functional integration

No tooling

Lot size 1

Custom made parts

Spare parts on demand

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3D Printing and Topology Optimization

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3D-Printing

Form freedom

Complexity made easy

Individual product

Accelerated production


Maximum

performance

Free-form

Individual design

Shortened process


Design / Redesign for AM

3D PrintingTopology

OptimizationPerfect

Symbiosis

Perform-ance

increase

Light-weightparts

Strongerparts

Part costreduction

Why should we design/redesign for AM?

AM & TopOpt provides answer to optimal product design

Use the best technology available that leverage the most

out of the complexity for free

If you don’t build the best parts possible, your competition

will do

Replacing the manufacturing

process with 3D printing does not

add any value and/or justify the

costs

Lattice is not redesign


LEIBER Group – Air Suspension Bracket Design Study

https://lightmetalage.files.wordpress.com/2015/02/truck-suspension-beam-realised-in-a-special-aluminium-alloy-aluxtremc2ae-leiber-group-gmbh-co.jpg


Original Design vs. Optimized Design

55% Mass Reduction

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Some Of Our Customers

http://www.google.com/url?sa=i&rct=j&q=&esrc=s&frm=1&source=images&cd=&cad=rja&docid=x_L7VXwyKpFrBM&tbnid=yypgx0-XuY5c9M:&ved=0CAUQjRw&url=http://anypopti.blogspot.com/2013/02/ford-logo.html&ei=wGuoUqPvOYzqkQfu44Bo&bvm=bv.57799294,d.eW0&psig=AFQjCNHx922Qk1t3_yseqDF-4MwY_OsoMw&ust=1386855737186070

http://www.google.com/url?sa=i&rct=j&q=&esrc=s&frm=1&source=images&cd=&cad=rja&docid=x_L7VXwyKpFrBM&tbnid=yypgx0-XuY5c9M:&ved=0CAUQjRw&url=http://anypopti.blogspot.com/2013/02/ford-logo.html&ei=wGuoUqPvOYzqkQfu44Bo&bvm=bv.57799294,d.eW0&psig=AFQjCNHx922Qk1t3_yseqDF-4MwY_OsoMw&ust=1386855737186070

http://www.google.com/url?sa=i&rct=j&q=&esrc=s&frm=1&source=images&cd=&cad=rja&docid=2Y4iZ7RlZY0rAM&tbnid=VUuwv7l0Kl933M:&ved=0CAUQjRw&url=http://www.helivision.com/other-services/maintenance/bell/&ei=FThMUvLcLOONygGOyYCQAQ&bvm=bv.53371865,d.aWc&psig=AFQjCNF2yga1ixLMvf1mblRR-f1zqacwCw&ust=1380813199845854

http://www.google.com/url?sa=i&rct=j&q=&esrc=s&frm=1&source=images&cd=&cad=rja&docid=2Y4iZ7RlZY0rAM&tbnid=VUuwv7l0Kl933M:&ved=0CAUQjRw&url=http://www.helivision.com/other-services/maintenance/bell/&ei=FThMUvLcLOONygGOyYCQAQ&bvm=bv.53371865,d.aWc&psig=AFQjCNF2yga1ixLMvf1mblRR-f1zqacwCw&ust=1380813199845854

http://www.google.com/url?sa=i&rct=j&q=&esrc=s&frm=1&source=images&cd=&cad=rja&docid=yo-ROqgW90kF6M&tbnid=WXhCI_GuT6ykWM:&ved=0CAUQjRw&url=http://www.cbt.com.my/2013/06/21/jaguar-land-rover-aims-for-one-million-anuual-sales-with-the-help-of-the-new-x-type/&ei=QG-oUpjMMMylkQeZzYHwBw&psig=AFQjCNF9v2u8Slaw-6BCfxewcxKuODcNHw&ust=1386856611194885

http://www.google.com/url?sa=i&rct=j&q=&esrc=s&frm=1&source=images&cd=&cad=rja&docid=yo-ROqgW90kF6M&tbnid=WXhCI_GuT6ykWM:&ved=0CAUQjRw&url=http://www.cbt.com.my/2013/06/21/jaguar-land-rover-aims-for-one-million-anuual-sales-with-the-help-of-the-new-x-type/&ei=QG-oUpjMMMylkQeZzYHwBw&psig=AFQjCNF9v2u8Slaw-6BCfxewcxKuODcNHw&ust=1386856611194885

http://www.google.com/url?sa=i&rct=j&q=&esrc=s&frm=1&source=images&cd=&cad=rja&docid=pVVbCbdN5Ois-M&tbnid=m5tRo1s0EUWBSM:&ved=0CAUQjRw&url=http://www.successo.com.hk/Successo_2011/Container Handling Machines - Eng.htm&ei=zDhMUuX1JKKTyQGG9YCwBQ&bvm=bv.53371865,d.aWc&psig=AFQjCNFlJ59dbKW9u1-e_m287sMED1xlEA&ust=1380813364111351

http://www.google.com/url?sa=i&rct=j&q=&esrc=s&frm=1&source=images&cd=&cad=rja&docid=pVVbCbdN5Ois-M&tbnid=m5tRo1s0EUWBSM:&ved=0CAUQjRw&url=http://www.successo.com.hk/Successo_2011/Container Handling Machines - Eng.htm&ei=zDhMUuX1JKKTyQGG9YCwBQ&bvm=bv.53371865,d.aWc&psig=AFQjCNFlJ59dbKW9u1-e_m287sMED1xlEA&ust=1380813364111351


TopOpt

Workflow Topology Optimization (I)

Different Software Tools

Design Space FE Model

„STL Design“

Link to CAM

3D Printing

Link to FEA

Link to CAD

Smoothing Restore

features

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Workflow Topology Optimization (II)

Integrated Tool INSPIRE

Link to CAM

3D Printing

PolyNURBSDesign Space TopOpt

FEA

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INSPIRE - Workflow

Sketch or Import a

Part/AssemblyAssign Materials and Loads

Generate Ideal ShapeConfirm Performance

(optional)Refine Concept

Defeature the Part


Start with original CAD design

Export from CAD


INSPIRE - Example

Topology Optimization Tool


MTB Rocker Arm - Results

Creative Concept Driven

min S.F. = 1.125

mass = 578 gm

Standard Concept Driven

min S.F. = 1.213

mass = 586 gm

Original

min S.F. = 1.409

mass = 811 gm

Conservative Concept Driven

min S.F. = 1.274

mass = 653 gm


Original Design vs. Optimized Design

New Design: 25% Lighter


Topology Optimization Constrains

General shape (holes)

Design space, non-design space

Minimum & maximum thickness

Mass targets / maximize stiffness

Stress (Factor of Safety)

Frequency constrain

Displacement

Draw Direction (single draw, split draw, extrusion, stamping,…)

Symmetry (symmetric, cyclic, cyclic symmetric,…)

Pattern Repetition

… Sym

metr

y

5 Repetitions

No

Sym

metr

y

20 Repetitions

No symmetry XZ, YZ symmetry

YZ symmetry XZ symmetry

Hollow

sectio

n

Ribs

Without Draw Direction

With Draw Direction


Armrest and Race Car Air Duct

Example of „Customer Surface“


Design for the Freedom of Additive Manufacturing

-43 %


of an Aerospace Part to be productionised by

Additive Manufacturing

[64% weight reduction]


From the Printer into Space

3D Printed Antenna Bracket for

Sentinel-1 Satellite:

43% weight reduction

(from 1.626 kg to 0.936 kg)

Increased Eigen frequency

(70Hz 90 Hz)

Improved static behaviour, strength,

stiffness, stability

Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

From the Printer into Space

technology symbiosis:

“topology optimization and

additive manufacturing”

weight cut to half

increased stiffness

reduced stress

minimum design lead time

Source:

Joint project

RUAG, EOS

Antenna Bracket for

Sentinel Satellite


A simulation

driven design

process using

solidThinking

Inspire within the

development chain.

30% Mass Reduction

3x Faster Development


Unlock the

lightweight

potential with

concept

generation

and

organic

interpretation.

32% Weight Reduction


Steering Upright

Problem Statement

Original design has no structure to resist shear

Improve stiffness while maintaining the original mass and stress

levels

The result was, that the new design was close to 2x stiffer


Revolutionizing

the additive

manufacturing

design process for the

world’s first 3D

printed bike frame


Embark on

imaginative

Engineering

and architecture

projects.

Documents

The Benefits of Topology Optimization