Step 1: Start MSC Apex Generative Design

The program starts and you can directly create your optimisation model

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 Non-Design Spaces in MSC Apex Generative Design. For this Bracket the Design Space was imported.

• The CAD-file includes several solids. The desired Desin Space, as well as the dummy part for an electric motor and the needed screws to connect the parts. We will use these as retained volumes in the later on in the optimisation.

• 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.

  

• Create the material Steel, Pa12 and Aluminium in the Materials editor. Assign PA12 to the Design Space, Aluminium to the Motor Housing and Steel for the Screws.

• 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 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.

In this case only one force is defined on the contact plate with the foot:

One constraint is created and attached on the inner surface of the cylinder:

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.

• One Interface is 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 Interface is 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)

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 Events can be changed by adding/deleting Events to the GD Scenario. The assignment of the boundary conditions to the Events can 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 Event individually.

• Active in Event1: Force-Moment 1 and Constraint1

Step 6: Definition of optimisation parameters

The optimisation parameters are selected in the Studies Area as well.

• Manufacturing Method: Generic AM

• Failure Criteria: Von Mises

• Safety Factor: 6,4

• Select the Strut Density: Medium

• Select the Shape Quality: Balanced

• Set the Complexity Setting: 10

Don’t forget to save the project!