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You can either create the geometry directly in MSC Apex Generative Design or import already existing files. You can import for example .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 Pedal the already prepared Design Space and Non-Design Spaces were imported.

• The CAD-file includes several solids. The file Pedal_body_1 is used to split the upper surface of the pedal to create the area for the load application point. Therefore, open the Split Surface Tool in the Geometry Edit Tools and select the top left surface as the split surface. Now select all curves that separate the surface as in the picture below.

  

• Open the Design Space Tool in the Optimization Tools to select the imported Geometry as the Design Space. Activate the Symmetric Design Constraint and select the XZ plane to set up the symmetric optimisation.

• If symmetry is activated, the Z-direction (blue) of the symmetry coordinate system is the build direction. The Z-direction shouldn’t be orientated normal to a symmetry plane. Further information regarding build direction and support reduction can be found here.

  

• The other solid of the pedal Pedal_body_1 is no longer needed and can be hidden or even deleted.

• Create the material Steel in the Materials editor and assign it to the Design Space. In this case the material behaviour is Isotropic.

• The specific values needed are the Young's Modulus (192372 MPa), Poisson ratio (0.3) and Density (7.97E-6 kg/mm³).

• The Tension Strength is the maximum allowable stress for the material and is set to 320 MP
  

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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.

All surfaces on which a boundary condition is applied can be selected directly as an interface with the “Select Faces from Loads and Boundary Conditions” button. The Boundary Condition surfaces will be highlighted and can be selected/deselected. With “Apply” the Non-Design Space Thickness, Machining Allowance and if available Offset Distance values will be applied to the selected surfaces.

• One Interfaceis created on the force application surface. Therefore, an Non-Design Space Thickness of 1 mm and a Machining Allowance of 1 mm is entered. Now select the surface and confirm the selection (MMB).

  

• One Interfaceis created on the inner surfaces of the fixation. Therefore, an Non-Design Space Thickness of 2 mm and a Machining Allowance of 1 mm is entered. Now select the inner surfaces and confirm the selection (MMB). The outer most surface of the Fixation is not selected because is would create material outside of the Design Space.

  

Step 5: Definition of Events (load cases)

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All boundary conditions must be assigned to the 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 Eventscan 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.

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The whole MSC Apex Generative Design project with all results can be downloaded here:

You might also be interested in these tutorials:

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