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Goal of this tutorial
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Project Data
Training:
Relevant data for this tutorial:
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Create the material in the Materials editor and assign it to the Design Space
Assuming the part should be printed with a Manufacturing Method like FFF, a Transversely Isotropic material is applied. The z-axis of the PCS is always the build direction ( * ) and differs from the two in-plane directions y and x. The values for the materials have to be entered accordingly. For the input the main axis (1-2-3) are used which are equal to (z-y-x).
The specific values needed are the Young's Modulus in build direction (E1) (1700 MPa) and in in-plane direction (E2) (1900 MPa), the Shear Modulus (G12) (730 MPa) and the Poisson ratio (0.3) for xy (NU23) and (0.39) for yz (NU12). The density is set to 0.9e-6 kg/mm3.
As the last input the material limits should be entered. Which of these are required depends on the optimisation intention and the chosen Failure Criterion. In this case we want to take advantage of the directional dependent material limits as well as different limits for tension and compression (directional dependent Tsai-Wu).
These values are optional, if a different Failure Criterion is selected, less material input is required
Axis | In-Plane | |
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Tension Strength | 48 MPa | 62 MPa |
Compression Strength | 96 MPa | 124 MPa |
Shear Strength | 50 MPa | |
After assigning the material to the solid, a material coordinate system has to be placed which indicates the build direction in x-direction.
The top surface can be selected so that the material coordinate system is aligned with the global coordinate system
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* The Build Direction will be adjusted later (Step 6)
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Step 3: Definition of boundary conditions
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Event1: Force-Moment 1, Constraint 1
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Step
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6: Definition of optimisation parameters and Generative Design Settings
The optimisation parameters are selected in the Studies Area as well.
Now the Build Direction will be adjusted. Therefore the Build Direction Tool can be activated with the coordinate system symbol and any surface can be selected. To rotate the Build Direction either the visualized coordinate system can directly be manipulated to align the Build Direction with the x-Axis of the model or the Euler Angles can be entered directly (90,00 °; 90,00 °; 270,00 °).
For each scenario the Build Direction can be easily changed, then the Build Direction for the Design Rules as well the material properties are rotated accordingly. This way multiple Build Directions can be checked in one project. Afterwards the optimisation results can be compared in the Post Processing and the best build orientation can be picked
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Select the Manufacturing Method: FFF
Selected the Failure Criterion: Directional Dependency (Tsai Hill)
Leave the Build Direction to the X Axis*
Enter the Safety Factor: 4
Select the Strut Density: Medium
Select the Shape Quality: Balanced
Set the Complexity Setting: 10
*Hint: The build direction can be modified in the studies tab. This is the same coordinate system as for the material, thus the material properties will change/rotate accordingly.
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Tip: Take a look at the Safety Factor calculation:
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The material limits are scaled with the Safety Factor! The values in brackets are the goal of the optimisation.
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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
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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 64 iterations (Shape Quality: Balanced).
Step
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8: Visualization of Failure Criteria, Displacements etc.
Inside the Post Processing the Failure Criteria, the displacements, the optimisation achievement index and the volume/mass are visible for all iterations
The Scale can be influenced individually
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The whole MSC Apex Generative Design project projects with all results for the different anisotropic behaviour settings can be downloaded here:
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File Name | Material Stiffness | Failure Criterion |
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Hook_2022-4_Iso_vM.7z | Isotropic | von Mises |
Hook_2022-4_Iso_TR.7z | Isotropic | FFF Thumb Rule |
Hook_2022-4_TransIso_TH.7z | Transversely Isotopic | Directional Dependency (Tsai-Hill) |
Hook_2022-4_TranIso_TW.7z | Transversely Isotopic | Directional Dependency (Tsai-Wu) |
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In case of anisotropic material stiffness and the directional dependent Tsai-Wu transversely isotropic Failure Criterion with huge material property differences for the in-plane directions and the build direction, as well for the maximum allowable tensile and compression strength, the optimisation may not give stable results. How to handle this here. |
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