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Relevant data for this tutorial:
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Step 1: Start MSC Apex Generative Design
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Import/create the Design Space including the Interfaces (Non-Design Spaces) in MSC Apex Generative Design as one solid. For this GD-Bracket the already prepared Design Space was imported.
Open the Optimization Tools to select the imported Geometry as the Design Space.
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In this case for the outer, bigger cylinders and the middle cylinder inclusive the front faces are manually selected. A Non-Design Space Thickness of 3 mm and a Machining Allowance of 1 mm is entered.
Note: the Interface Offset (usually displayed in red) is not visualized due to a limitation. The correct value will be considered in the optimisation.
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On the smaller outer cylinders a Non-Design Space Thickness of 1mm and a Machining Allowance of 0.5 mm is applied. For these cylinders the “automatically create interface” option can be used by selecting the corresponding boundary conditions on these surfaces.
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Step 5: Definition of 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.
Event 1: Force -Moment 1, Force -Moment 2, Constraint 1, Constraint 2, Constraint
Event 2: Force 3, Constraint Force 4, Constraint Force 5 and Constraint 6 Event 2: Force-Moment 2, Force-Moment 3, Constraint 1, Force 6, Force 7, Force 8, Force 9, Force 10, Constraint 2, Constraint 3, Constraint 4, Constraint 5 and Constraint 6
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Step 6: Definition of optimisation parameters and Generative Design Settings
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Manufacturing Method: Generic AM
Failure Criteria: Von Mises
Safety Factor: 420
Strut Density: Medium
Shape Quality: Balanced
Complexity Setting: 7Keep Non-Design Spaces: All Constraints and Interfaces 5- 10 are deactivated
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The chosen Safety Factor calculates automatically with the entered maximum allowable Tension Strength the Stress Goal for the optimisation. By clicking on the Gear-Button behind the Safety Factor the detailed menu for the Safety Factor and Stress Goal shows up.
The maximum allowable stress is shown (320 MPa) and the calculated Stress Goal (80 MPa). By changing the Failure Definition to Stress Goal, the Stress Goal can be entered manually as well.
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Step 7: Casting Design Rules via the Advanced User Settings
To change the Manufacturing Method to Casting the Advanced User Settings have to be used.
The following commands are added to the scenario:
configuration.strategy=Casting tool.tool0.draft=5 tool.tool1.draft=5 |
With the first command the optimisation strategy is set to Casting. The following commands defining tools. Each tool is one draw direction for the manufacturing process. The actual draw direction is set as a vector. For each draw direction a draft angle can be set. The draft angle (specified in degrees) is the tapering angle for walls/ribs regarding the draw directions.
In this case two draw directions are defined in positive and negative z-direction and a tapering angle of 5°.
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Step 8: 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 whole MSC Apex Generative Design project with all results can be downloaded here: How the Complexity, Keep-Non-Design Spaces function and Event Specific Safety Factors influence the design is covered in the second part of the Tutorial: Generative Design - GD-Bracket Part 2
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