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Goal of this tutorial
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Open the Optimisation Tools and click on the Design Space Tool Tool
Choose the option Create Design Space enclosing parts and choose the three parts you want to consolidate
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You can choose the Alignment Type and an Offset Factor in the Advanced Properties. In this case an offset percentage of 5% was chosen to give the optimiser more room to operate.
The input is confirmed and the Tool creates a new part with the initial Design Space
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Create Access and Clearance Regions
Next some help geometries are created that will be subtracted from the initial Design Space. For these steps the Design Space is hidden.
Non-Design Spaces are created where the exact Geometry after the optimisation is needed
With the Offset-Method of the Non-Design Spaces Tool the six Non-Design Spaces are chosen as shown in the picture (offset of 2 mm)
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After this the Access Regions based on the Non-Design Spaces can be created.
Therefore, the Access Region Tool in the Optimisation Tools is activated
A sufficient extrude Distance is entered and the face of the Non-Design Space is chosen to create the according Access Region
It’s recommended to choose a scaling factor for the Access Regions to have a little bit extra space for the assembly work later on (like 1.1)
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The inner surface of the Access Region is defeatured to create one filled volume. To ensure that there is also some free space on the other side, the Push/Pull Tool can be used. Drag the surface 20 mm in the positive y-direction.
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The Bracket is subtracted from the Access Region to ensure that the Non-Design Space isn’t Part of the Access Region solid
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With the same technique all Access Regions can be created. The result looks like the picture below
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Next the Clearance Region for the Sensor and the force input and the Access Region for the Sensor are defined
For the Sensor the Clearance Region Tool is used with an offset of 0.3 2 mm. All faces except the one that faces towards the attachment point is chosen.
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For the force input the Clearance Region Tool is used with an offset of 3 mm to ensure that there is enough space around it. Only the faces around the middle of it are chosen, cause the rest is already covered with the acces regions.
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To create the Access Region the Access Region Tool is used again - only this time the “cross section” method
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Definition of Machining Allowances
Machining Allowances should be applied to every functional surface. Adjacent Faces should be selected at once, to create one coherent Machining Allowance. Therefore the automatic execution mode can be turned off.
Tip: To have an easier access to the Non-Design Spaces choose the picking Filter “Cells” and hide the Design Space Cell so that only the Non-Design Spaces are visible. Simply choose a whole Non-Design Space by drawing a rectangle like shown in the picture below.
Now your Assembly chould look like this
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Click create Configuration and a GD Configuration will be created
Click appy Configration and the function will executed every needed boolean operation
The final Design Space is created and looks like the picture
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Create the material in the Materials editor and assign it to the Design Space and the retained part
The specific values needed are the Young's Modulus (70000 MPa), Poisson ratio (0.27) and Density (2.7e-6 kg/mm3)
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Go to the Loads & Boundary Condition Tool to enter the loads and fixations. Displacements, Forces, Moments, Gravity and Pressure Loads can be applied using different selection options.
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In this case four forces and one moment are defined. The first two on the retained part and the last three on the Non-Design Space that is connected to the sensor:
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Three constraints are created and attached on the Non-Design Spaces on the lower side:
Name | Direction |
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Constraint 1 | x, y, z (=0) |
Constraint 2 | x, y, z (=0) |
Constraint 3 | x, y, z (=0) |
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The next steps are defined in the Studies area.
All boundary conditions must be assigned to the specific load cases, which are defined as Events. The number of Eventscan be changed by adding/deleting Eventsto the GD Scenario. The assignment of the boundary conditions to the Eventscan be made in the Loads & Constrains Window. The already created loads and constraints that concern the Design Space are listed in this window and can be activated for each Eventindividually.
Active in Event1: Force-Moment 1, Force-Moment 3, Force-Moment 5, Constraint 1, Constraint 2 and Constraint 3
Active in Event1: Force-Moment 2, Force-Moment 4, Constraint 1, Constraint 2 and Constraint 3
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The optimisation parameters are selected in the Studies Area as well.
Select the Strut Density: Medium
Select the Shape Quality: Balanced
Set the Complexity Setting: 16
Enter theStress Goal: 17 MPa
Don’t forget to save the project!
Step 6: Starting the optimisation and visualizing the results (Old results)
If all data is correct, the optimisation can be started and tracked in the Post Processing. The Analysis Readiness function checks if all information is provided and the optimisation can start.
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The optimisation is finished after 64 iterations (Shape Quality: Balanced).
Generative Design
You can always change the Strut Density, Stress Goal and Complexityto influence the results and try out different options
The Complexitycan be increased for a higher resolution and more detailed result (increased calculation time!)
The Strut Densityinfluences the structures which are formed during optimisation
The whole MSC Apex Generative Design project with all results can be downloaded here:
New Project needed!
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