For this Tutorial the project of the GD-Bracket with different complexities is used. The retransition of the final optimisation result of the second scenario is already performed.
To create the final CAD-Geometry all functional surfaces and sharp edges have to be created with boolean operations. The best way for this is a boolean intersection between the retransitioned optimisation result and the Design space of the optimisation. A copy of the Design space is desired needed for the following operation.
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To create one solid without any cells or partitions the 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 between the created NURBS Geometry of the optimisation result and the edited Design Space solid.
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The next step is a boolean intersection between the created NURBS Geometry of the optimisation result and the edited Design Space solid.
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In some cases this intersection fails due to overlaying surfaces from the optimised result and Design spaceSpace. In the picture below a critical area is displayed.
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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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Workaround: Boolean Subtraction
For some really complex parts it is maybe not fully might not be at once clear which areas are the critical ones for the intersection. In this case these cases boolean subtractions can help to create the functional surfaces and sharp edges.
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The result of the boolean subtraction are functional surfaces and as well as sharp edges as well.
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The example geometry used here is from the GD-Bracket Tutorial. The input file is the result of the second scenario.