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Goal of this tutorial
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Training:
Relevant data for this tutorial:
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Step 1: Start MSC Apex Generative Design
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The program starts and you can directly create your optimisation model
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Step 2: Model generation
You can either create the geometry directly in MSC Apex Generative Design or import already existing files. You can import .xb, .xt, .step, and .sldprt files into the program.
Import/create the Design SpaceHow we understand Geometryincluding theHow we understand GeometryNon-Design SpacesHow we understand Geometryin MSC Apex Generative Design 2020 as one solid. For this Jet Engine Bracket the already prepared Design Space was imported.
Create the material in the Materials editor and assign it to the Design Space
The specific values needed are the Young's Modulus (116e3 MPa), Poisson ratio (0.26) and Density (4.48e-6 kg/mm3)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.
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Machining Allowance Allowances should be applied to every functional surface. Thus, at the end two geometries are created: The Norm-Geometry and the Print-Geometry.
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Adjacent Faces should be selected at once, to create one coherent Machining Allowance. Therefore the automatic execution mode can be turned off.
In this case a value of 1 mm was chosen. How much Machining Allowance is necessary, depends on the dimensions of the part and the manufacturing process/machine.
Create the material in the Materials editor and assign it to the Design Space
The specific values needed are the Young's Modulus (116e3 MPa), Poisson ratio (0.26) and Density (4.48e-6 kg/mm3)
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Step 3: Definition of boundary conditions
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.
Creation of local coordinate systems to apply forces
Because the imported Jet Engine Bracket CAD-file is shifted and rotated to the global coordinate system,Local Coordinate Systemlocal coordinate systemsLocal Coordinate Systemcan be used to apply the forces and moments.
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.
To apply the forces the Loads & Boundary Condition Tool is needed. Select Faces on the left side. By disabling the Thunderbolt (tool execution mode selector) on the top, 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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Name | Force/Moment/Pressure/Gravity | Direction (depending on local coordinate system) | Value |
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Force - Moment 1
| Force | Z (Local coordinate system 1)
| 35598,00 N |
Force - Moment 2 | Force | X (Local coordinate system 1) | 37823,00 N |
Force - Moment 3 | Moment | Z (Local coordinate system 1) | 565000 N mm |
Two loads and one Moment are created with the given values in the table. They are all referring to the Local Coordinate System 1.
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.
Force - Moment 4 is also applied on the surfaces of both Non-Desing 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-Desing Design Spaces is 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-Desing Design Spaces.
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Step 4: Definition of Events (load cases)
The next steps are defined in the Studies area.
All boundary conditions must be assigned to 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 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 Eventindividually.
For each Force - Moment an a separate Event is created including the Constraint:
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Step 5: Definition of optimisation parameters
The optimisation parameters are selected in the Studies AreaStudy, Scenario & Eventas well.
Select the Strut Density: Medium
Select the Shape Quality: Balanced
Set the Complexity Setting: 14
Enter the Stress Goal: 600 MPa
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Step 6: 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.
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).
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Generative Design
You can always change the Strut Density, Stress Goal and Complexity to influence the results and try out different options
The Complexitycan be increased to realize a higher resolution (increases calculation time!)
Step 7: 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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Generative Design Results
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