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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
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 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 Choose AlSi10Mg as 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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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.
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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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Note: Sometimes the Interface Offset (usually displayed in red) is not visualized due to a limitation. The correct value will be considered in the optimisation.
Step 5: Definition of load cases
The next steps are defined in the Studiesarea.
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Event1: Force-Moment 1, Force-Moment 2, Constraint 1
Event2: Force-Moment 3, Constraint 1
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Step 5: Definition of optimisation parameters and Generative Design Settings
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 Balanced
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.
In this case the Reactive Medium strategy with the default intensity is used.
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The build direction is set scenario specific and can be easily changed. for each scneario scenario 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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Step 7: 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.
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The optimisation is finished after 70 64 iterations (Shape Quality: Fine TuneBalanced).
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).
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The Support Reduction Strategies Reactive and Active with a Support Reduction Intensity value of 5 medium and high reduce the required support structure even more - 78% up to 80% of the initial support structure can be saved.
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The low Support Reduction reduces the required support structure about 27% at 8% more mass.
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The whole MSC Apex Generative Design project with all results can be downloaded here:
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