Training:

Relevant data for this tutorial:

Step 1: Start MSC Apex Generative Design 2020

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 Nondesign spaces in MSC Apex Generative Design 2020 as one solid. For this Jet Engine Bracket the already prepared Design space was imported.

• Create the material in the Materials editor and assign it to the Design space

• The specific values needed are the Young's Modulus (115e3 MPa), Poisson ratio (0.3) and density (4.40e-6 kg/mm³)

• Nondesign spaces have to be selected using the optimisation Tools. In this case the four fixation points and two force application points are selected and a Nondesign space with an offset of 3 mm is created for each.

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.

Creation of local coordinate systems to apply forces

Because the imported Jet Engine Bracket CAD-file is shifted and rotated to the global coordinate system, local coordinate systems can be used to apply the forces and moments.

By opening the Coordinate Tools a local coordinate system can be placed on the bottom plane (coordinate system 1).

To apply the forces the Loads & Boundary Condition Tool is needed. Select cells on the left side. By disabling the Thunderbolt (tool execution mode selector) on the top, both Nondesign spaces can be selected simultaneously. In the Orientation field an external (local) coordinate system can be selected (coordinate system 1).

Two loads are created (Force - Moment 1 and Force - Moment 2) with the given values in the table in z- and x-direction which are applied on both Nondesign spaces. The fourth condition (Force - Moment 4) is also attached on both Nondesign spaces referring to coordinate system 1.

For Force - Moment 3 a second local coordinate system is needed. This one is rotated by 42 degrees for the z-axis (beta-angle). This can be done by adding 42° to the beta-angle after choosing the same plane as coordinate system 1.

Force - Moment 3 is also applied on both Nondesing spaces in z-direction. Now the orientation is referred to the coordinate system 2.

Four constraints are created and attached on the Nondesign spaces:

Therefore, the Loads & Boundary Condition Tool is needed. Under Displacement Constraints a “clamped” constraint can be chosen, which locks translations in all three directions. On the left side of the Tool the relevant geometry choice can be selected. In this case cells are selected to attach the constraints on the Nondesign spaces.

Step 4: Definition of load cases

The next steps are defined in the Studies area.

All boundary conditions must be assigned to specific load cases, which are defined as Events. The number of Events can be changed by adding/deleting Events to the Meshless Generative Design 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.

• For each Force - Moment an Event is created including all four Constraints:

Step 5: Definition of optimisation parameters

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: 600 MPa

• Advanced User Settings: BF1584446026. Further information here.

Don’t forget to save the project!

Step 6: 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 are provided and the optimisation can start.

All result iterations are displayed as soon as they are available. Furthermore, you are able to stop the optimisation in this selection area. However, a Restart is not directly possible.

The optimisation is finished after 64 iterations (Shape Quality: Balanced).

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!)

Step 7: Visualization of Stresses & Displacements

• Inside the Post Processing the von Mises stress and the displacements are visible for all iterations

• The Scale can be influenced individually

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

You might also be interested in these tutorials:

• Generative Design - Bookshelf

• Generative Design - Pressure

• Restart Optimisation