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Training:

Relevant data for this tutorial:

Step 1: Reimport your already optimised geometry

The optimised geometry can be reimported into a new project or into the already existing optimisation project. For this Tutorial the project of the Bridge GD-Bracket is used.

For a Retransition to a NURBS CAD-Geometry a non-intersected optimisation result is needed. Therefore, a STLthe Smooth-file from the scenario result folder in the workspace is imported.

Documents → Apex Generative Design Workspace→ Bridge_NURBS → Meshless Generative Design Scenario 1 Step 1.v1 → buildSpace_MC_MainData_Loop_64.stl

Take care to choose the right unit system. Projects calculated directly in MSC Apex Generative Design are always calculated in SI-Units (meters).

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After importing the non-intersected Geometry from the Post Processing should be exported. The geometry of this file stays always inside the Design Spaces limits except of the Non-Design areas, they intentionally exceed the Design Space limits to enable an easy and clean Boolean Intersection.

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After importing the Smooth-Geometry STL-file the optimisation result is displayed as a Faceted Solid inside the model tree.

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Step 2: Mesh to CAD

With the Facet Body Facet to NURBS Geometry Tool under in the Geometry Edit Tools the STL-file can be transitioned to a CADNURBS-fileGeometry. Therefore, the Automatic Size Calculation and the Partition Preview can stay active. With the middle mouse button (MMB) the operation can be executed.

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If the partition looks satisfying the NURBS patch creation can be started by confirming with the middle mouse button (MMB). If finer, smaller patches are desired the NURBS Face size can be varied manually. Depending on the Geometry this step can take some time.

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When the transition is finished, the status bar in the bottom left displays “NURBS is created based on partitioned Facet Body” and a new solid shows up in the model tree.

From time to time and depending on the geometry some NURBS patches might fail. These will be displayed in the status bar as well. If this happens the geometry can be repaired manually. How this works is described here.

Step 3: Geometry Cleanup

We recommend to use the Geometry Cleanup Tools after the NURBS CAD-Geometry is created.

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Step 4: Creation of functional surfaces and sharp edges with Boolean

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Operations

To create the final CADNURBS-Geometry all functional surfaces and sharp edges have to be created with boolean operationsBoolean Operations. The best way for this is a boolean intersection Boolean Intersection between the retransitioned optimisation result and the Design space Space of the optimisation. A copy of the Design space Space is needed for the following operation.

With the Transform Tool the Solid of the Design space Space can be copied by activating the Copy option and transforming with 0.

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To create one solid without any cells or partitions the boolean merge Boolean Merge function for cells has to be used. With this a Solid only for the Intersection with the NURBS Retransition is created.

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The next step is a boolean intersection Boolean Intersection between the created NURBS Geometry of the optimisation result and the edited just copied Design Space solid.

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In some cases this intersection fails due to overlaying surfaces from the optimised result and Design space. In the picture below a critical area is displayed. What to do if this happens is described here.

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The result is an intersected CAD-Geometry with all functional sharp edges and surfaces. At this point it is also possible to create machining allowances Machining Allowances on functional surfaces which are post processed by milling or other manufacturing processesif a geometry was not already created directly by the optimisation.

The finished Geometry can be used in any CAD software and for all further steps like a FE-Reanalysis with MSC Nastran.

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The whole MSC Apex Generative Design project with the retransitioned intersected CAD-file can be downloaded here:

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