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You can either create the geometry directly in MSC Apex Generative Design or import already existing files. You can import .xt, .xb, .step, and .sldprt files into the program.
Import/create the Design Space including the Non-Design Spaces in MSC Apex Generative Design. For this Bracket theDesign Spacewas imported.
The CAD-file includes several solids. The desired Design Space, as well as the dummy part for an electric motor and the needed screws to connect the parts. The latter ones are the Retained Volumes which will be used later on in the model set up.
Open the Design Space Tool in the Optimization Tools to select the imported Geometry as the Design Space.
Create the material Steel, PA12 and Aluminium in the Materials editor. Assign PA12 to the Design Space, Aluminium to the electric motor housing and Steel for the screws.
The specific values needed are the Young's Modulus, Poisson ratio and Density.
The Tension Strength is the maximum allowable stress for the material.
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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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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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In the next step the interaction between the Retained Volumes and the Design Space is defined. For this the Generative Design Configuration Tool is used. Start the Tool and choose the corresponding objects for each step, then click the MMB. For this configuration, only the Design Space is selected as Initial Design Space and the electric motor and screws as Retained Volumes
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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 Events can be changed by adding/deleting Events to the GD Scenario. The assignment of the boundary conditions to the Events can 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 Event individually.
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The optimisation parameters are selected in the Studies Area as well.
Manufacturing Method: Generic AM
Failure Criteria: Von Mises
Safety Factor: 3,5
Select the Strut Density: Medium
Select the Shape Quality: Balanced
Set the Complexity Setting: 8
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Don’t forget to save the project!
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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 be started.
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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.
The optimisation is finished after 64 iterations (Shape Quality: Balanced).
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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