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Goal of this tutorial
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Training:
Relevant data for this tutorial:
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Step 1: Create a new project
In a first step, you need to create a new project. All data (geometry and configuration) will be copied and saved directly in a new project folder, located in your workspace:
Start MSC Apex Generative Design 2019
Create a new project using the symbol
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Enter a project name and save the project
Open the newly created project
Step 2: Model generation
Upload all relevant stl files by clicking on the symbol in the objects/surfaces area
Select all stl files
The field at the bottom shows notifications to help you generate an optimization model
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The uploaded objects are listed in the objects/surfaces area
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Step 1: Start MSC Apex Generative Design 2020
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 .xb, .step, and .sldprt files into the program.
Import/create the Design space including the Nondesign spaces in MSC Apex Generative Design 2020. For this Pedal the already prepared Design space and Nondesign spaces were imported.
The CAD-file includes several solids. Thus, only one solid is supported for an optimisation, with a Boolean operation the solids can be merged to one. Activate Merge Solids as Cells to create partitions which can be used for Nondesign spaces.
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Create the material Steel in the Materials editor and assign it to the Design space
The specific values needed are the Young's Modulus (210e3 MPa) and poisson , Poisson ratio (0.28) in the Material Editor
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Activate the option design space for the relevant stl file. Only one volume can be selected as such.
In this case: Pedal - design-1
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and density (7.85e-6 kg/mm3)
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Nondesign spaceshave to be selected using the optimisation Tools. In this case with the direct method all already existing cells (partitions) can be selected
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The Nondesign spaces will change the colour and are listed in the model tree
Step 3: Definition of boundary conditions
Go to the boundary conditions tab Loads & Boundary Condition Tool to enter the loads and fixations. For each boundary condition a name, a space and the specification of the boundary condition is entered as follows:
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Name
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. Displacements, Forces, Moments, Gravity and Pressure Loads can be applied using different selection options.
In this case a symmetrical optimisation using the Advanced User Settings is carried out. Therefore, the loads are only applied on a half (quarter/eighth…)
The loads will be automatically mirrored through the symmetry planes
Attention: The loads are only allowed to be applied in the positive coordinate direction. More information about how to use the symmetry function here.
In this case only one force is defined in the positive coordinate half (on the top plate):
Name | Force/Moment/Pressure/Gravity | Direction | Value in N |
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Force-Moment1 |
Force | y | -1000 |
Object "Pedalfootsurface1" experiences a force of -1000 N in y-direction (Force). The force of the whole pedal is -2000 N. If you are using the symmetry option, the force must be adjusted to the calculation model. If only half of the component is calculated (symmetry about the XY-Plane), the force must also be cut in half. The example already considers this restriction.
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Name
Object
Direction
Fixation
Pedalaxle1
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One constraint is created and attached on the inner surface of the cylinder:
Name | Direction |
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Constraint 1 | x, y, z (=0) |
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A total of 1 force and 1 fixation should have been created as a result
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Step 4: Definition of load cases
The next steps are defined in the Studies area.
All boundary conditions must be assigned to the specific load cases, which are defined as Events. The number of load cases Events can be changed using the "+" or "-" charactersby adding/deleting Events to the Meshless Generative Design Scenario. The assignment of the boundaries boundary conditions to the load cases Events can be made in the boundary conditions or load cases area by selecting the different boundary conditions while the load case is activated 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 Event individually.
Active in Loadcase1Event1: Force-Moment and Fixation
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Constraint1
Step
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5: Definition of
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optimisation parameters
Switch to the optimization area. You can find more information about the parameter selection here.
Choose the design type normal
Enter the optimization goal stress: 60 MPa
Set the symmetry setting: XY-Plane
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Open Result File Formats. The following result files should be activated:
stl File: results of each iteration in stl file format
stl Files Intersected: result of each iteration intersected with the design space in stl file format
ply Files with Stress: results with the information of stresses of each iteration (must be activated to show the results in the Visualization space)
ply Files with Displacement: results with the information of displacements of each iteration (must be activated to show the results in the Visualization space)
More information on result file formats here
All Inputs can be viewed and checked in the configuration file. The file should look like this.
Please make sure only one .amendate file is in your project folder.
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You can always change the design type, stress and solverMaxMemory to influence the results and try out different options. You can find further information here.
Step 5: Save the Project
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Step 6: Starting the optimization and visualizing the results
If all data are correct, the optimization can be started and tracked in the results area.
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The optimisation parameters are selected in the Studies Area as well.
Select the Strut Density: Medium
Select the Shape Quality: Balanced
Enter the Stress Goal: 50 MPa
Advanced User Settings: BF1584446026. Further information here.
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Step 6: Adding Advanced User Settings (Symmetry)
Advanced User Settings can be added to each scenario by activating the text field with a right click on the specific scenario.
To use the symmetry constraints correctly some conditions have to be satisfied:
The geometry has to be symmetrical
The boundary conditions have to be symmetrical
The model has to be placed in the global coordinate origin
In this case the symmetry constraints are added. Therefore, the Advanced User Command symmetry.z (symmetry plane X-Y) is entered.
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To ensure the model is placed suitable to the global coordinate origin the Transform Tool can be used. If the Model is shifted to the global planes, it can be moved to the global coordinate origin.
Don’t forget to save the project!
Step 7: Starting the optimisation and visualize the results
Before starting the optimisation, a look inside the Generative Design Solver Settings can be useful. (Options-Application Settings-Generative Design Solver)
The choice between local or remote and GPU or CPU solving can be made. Furthermore, the complexity value can be changed.
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If all data is correct, the optimisation can be started and tracked in the Post Processing. The Analysis Readiness function checks if all information are provided and the optimisation can start.
All result iterations are displayed as soon as they are available. The progress of the optimization can also be monitored via the AMendate log file. Furtheremore Furthermore, you are able to stop the optimization optimisation in this selection area. A restart however However, a Restart is not directly possible.
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The optimization optimisation is finished after 64 iterations (optimizationtypeShape Quality: optimizingBalanced).
Step
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8: Visualization of Stresses & Displacements
The legend can be influenced using the slider. The function "Automatically set to local minimum and maximum" considers the stresses of each iteration and sets the values from the current iteration.
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Step 8: Visualization of Displacements
The legend can be influenced using the slider. The function "Automatically set to local minimum and maximum" considers the displacements of each iteration and sets the values from the current iteration.
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Step 9: Influence of different settings
By varying the settings the optimization results can be influenced
The solverMaxMemory can be increased for a higher resolution (increased calculation time!). You can find further information here.
The Design Type influences the strucures which are formed during optimization. You can find further information here.
You can generate all the designs below by adjusting these two values (depending on your workstation).
You might also be interested in these tutorials:
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Introductory Optimization - Jet-Engine-Bracket
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Introductory Optimization - Eccentric
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Introductory Optimization - Pedal
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Introductory Optimization - Hook
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in different ways. You can add and reduce the stress/displacement steps, enlarge different steps and set new minimum and maximum values.
Von Mises stress
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Displacement
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The mass of each iteration can be visualized with a diagram
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Generative Design
You can always change the Strut Density, Stress Goal and Complexity to influence the results and try out different options
The Complexity can be increased to realize a higher resolution (increases calculation time!) Options - Application Settings - Generative Design Solver