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You can either create the geometry directly in MSC Apex Generative Design or import already existing files. You can import for example .x_b, .x_t, .step, and .sldprt files into the program.
Import/create the Design Space including the Non-Design Spaces in MSC Apex Generative Design as one solid. For this Gripper the already prepared Design Space was imported.
Open the Optimization Tools to select the imported Geometry as the Design Space
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Material Assignment
Create the material in the Materials editor and assign it to the Design Space
The specific values needed are the Young's Modulus (72 000 MPa) and the Poisson ratio (0.34). The density is set to 2.7e-6 kg/mm3.
The Tension Strength is the maximum allowable stress for the material and is set to 460 MPa.
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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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Name | Direction |
|---|---|
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 the inner surface of the mounting hole is selected to attach the constraint.
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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 “Non-Design Space Thickness” 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.
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The next steps are defined in the Studiesarea.
All boundary conditions must be assigned to the specific load cases, which are defined as Events. The number of Events can 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.
Event1: Force-Moment 1, Force-Moment 2, Constraint 1
Event2: Force-Moment 3, Constraint 1
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The optimisation parameters are selected in the Studies Area as well.
Select the Manufacturing Method: Metal AM
Selected the Failure Criterion: von Mises
Enter the Safety Factor: 15 (30.67 MPa)
Select the Strut Density: Medium
Select the Shape Quality: Fine Tune
Set the Complexity Setting: 6
Step 6: Activating Support Reduction (Design Rules: AM)
For the Support Reduction the Z-direction of the Principal Coordinate System (PCS) is always the build direction.
Three different strategies can be used which are described more detailed here.
For the strategies Reactive and Active the Intensity can be influenced as an additional option. The default value for the intensity is 5.
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The build direction is set scenario specific and can be easily changed. for each scneario Thus the PCS also rotates accordingly which influences not only the build direction for the Support Reduction but also the material orientation (Anisotropic Material Stiffness) and directional dependent Stress Goals.
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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 been executed.
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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.
All result iterations are displayed as soon as they are available. Furthermore, you are able to stop the optimisation in this selection area. However, a Restart is not directly possible.
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Step 8: Visualization of Failure Criteria, Displacements etc.
Inside the Post Processing the Stresses, Failure Criteria, the Displacements, the Optimisation Achievement index and the volume/mass are visible for all iterations
The Scale can be influenced individually
With the buttons in the bottom bar it is possible to switch between the Nominal-, Print- and Smooth-Geometry. All of them can be exported as an STL-file or transferred directly back to the Pre Processing as an NURBS CAD-Geometry.
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Influence of Support Reduction Strategies
The Support Reduction function creates print-ready geometries with a perfect ratio between support reduction and part performance. It reduces the required amount of support structure for the manufacturing process with nearly the same mechanical performance as without Support Reduction (Base-Design).
In the picture below the left side shows the Base-Design without Support Reduction and the right side the design with Support Reduction (reactive strategy). The area where the most support structure is needed is reshaped in such a way that the support structure is reduced significantly.
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The passive Support Reduction reduces the required support structure about 28% at 2% more mass.
The Support Reduction Strategies Reactive and Active with a Support Reduction Intensity value of 5 reduce the required support structure even more - 78% of the initial support structure can be saved.
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The whole MSC Apex Generative Design project with all results can be downloaded here:
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