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Goal of this tutorial
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Import/create the Design Space including the Non-Design Spaces in MSC Apex Generative Design as one solid. For this Jet Engine Bracket the already prepared Design Space was imported.
Open the Optimization Tools to select the imported Geometry as the Design Space
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Non-Design Spaces have to be selected using the optimisation Tools. In this case the four fixation points and two force application points are selected and a Non-Design Space with an offset of 3 mm is created for each (select the inner surface of the holes as shown in the picture).
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Machining Allowances should be applied to every functional surface. Adjacent Faces should be selected at once, to create one continuous geometry. Therefore, the automatic execution mode can be turned off.
In this case a value of 1 mm was chosen and for each screw hole the three functional faces of the Non-Design Space are selected. How much Machining Allowance is necessary, depends on the dimensions of the part and the manufacturing process/machine.
Create the material Steel in the Materials editor and assign it to the Design Space. In this case the material behaviour is Isotropic.
The specific values needed are the Young's Modulus (116e3 MPa), Poisson ratio (0.26) and Density (4.48e-6 kg/mm3).
The Tension Strength is the maximum allowable stress for the material and is set to 1290 MPa.
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By opening the Coordinate Tools a local coordinate systems can be placed on the bottom plane (coordinate system 1).
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For the next steps the Machining Allowances are hidden.
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To apply the forces the Loads & Boundary Condition Tool is needed. Select Faces on the left sidethe two upper faces at the same time. By disabling the Thunderbolt (tool execution mode selector) on in the top left corner of the tool settings, both surfaces of the Non-Design Spaces can be selected simultaneously and a Remote Force between them can be applied. In the Orientation field an external (local) coordinate system can be selected (coordinate system 1).
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For Force - Moment 4 a second local coordinate system is needed. This one is rotated by 42 degrees for the z-axis (beta-angle). This can be done by adding 42° to the beta-angle after choosing the same plane as coordinate system 1.
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Force - Moment 4 is also applied on the surfaces of both Non-Design Spaces in z-direction. Now the orientation is referred to the coordinate system 2.
Name | Force/Moment/Pressure/Gravity | Direction (depending on local coordinate system) | Value |
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Force - Moment 4 | Force | Z (Local coordinate system 2) | -42273,00 N |
One constraints which includes all four fixated Non-Design Spaces is Four constraints are created:
Name | Direction |
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Constraint 1 | x, y, z (=0) |
Therefore, the Loads & Boundary Condition Tool is needed. Under Displacement Constraints a “clamped” constraint can be chosen, which locks translations in all three directions. On the left side of the Tool the relevant geometry choice can be selected. In this case surfaces are selected to attach the constraints on the Non-Design Spaces.
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Step 4: Interface Creation
Interfaces have to be created for every functional surface - so every surface where a boundary condition is applied to. With this Tool an offset to the inside with the input “Interface Thickness”(Non-Design Space) and an offset to the outside with the input “Machining Allowance” is created. The Offset Distance is expanding the Interface to the set value to create material on front faces.
Two Interfaces are created for the load application surfaces. Therefore, an Interface Thickness of 2 mm and a Machining Allowance of 1 mm is entered. Because not only the inner faces touching the screw but also the front and back face are supposed to contain material and have sharp, functional faces, an Offset Distance of 3 mm is entered. Now select the inner surfaces of the force application face and confirm the selection (MMB). When the Interface Thickness is equal or bigger than the Offset Distance, the inner offset (Non-Design Space) is t visualized but will be considered correctly in the optimisation.
Four Interfaces are created on the faces of the fixations. Therefore, an Interface Thickness of 3 mm and a Machining Allowance of 1mm is entered. Now select the top plate and confirm the selection (MMB). Because not only the inner faces touching the screw but also the front and back face are supposed to contain material and have sharp, functional faces, an Offset Distance of 3 mm is entered. Now select the inner surfaces of the fixations and confirm the selection (MMB).
Step 5: Definition of Events (load cases)
The next steps are defined in the Studies area.
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For each Force - Moment a separate Event is created including the Constraint:
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6: Definition of optimisation parameters
The optimisation parameters are selected in the Studies Area as well.
Manufacturing Method: Generic AM
Failure Criteria: Von Mises
Stress Goal: 600 MPa
Select the Strut Density: Medium
Select the Shape Quality: Balanced
Set the Complexity Setting: 14
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7: Starting the optimisation and visualize the 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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You can check the status of the optimisation in the GD Status and get more information on Warning and Error messages. This can be done directly in the Post-Processing as well as in the Studies tab for an optimisation that has already run.
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8: Visualization of Stresses & Displacements
Inside the Post Processing the von Mises stress and the displacements are visible for all iterations and for every Event
The Scale can be influenced individually
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You can go back to the model setup by clicking the Exit button in the right bottom corner.
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For more information have a look at the MSC Apex Generative Design project:
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You might also be interested in these tutorials:
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