Training:

Relevant data for this tutorial:

Step 1: Start MSC Apex Generative Design 2021

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 Spaceincluding the Non-Design Spacesin MSC Apex Generative Design. For this Pedal the already prepared Design Space and Non-Design 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 Non-Design Spaces.
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 YZ plane to set up the symmetric optimisation.
Non-Design Spaces have to be selected using the Non-Design Spaces Tools. In this case all already existing cells (partitions) can be selected
Machining Allowances should be applied to every functional surface. Adjacent Faces should be selected at once, to create one coherent Machining Allowance. Therefore the automatic execution mode can be turned off.
In this case a value of 1 mm was chosen. How much Machining Allowance is necessary, depends on the dimensions of the part and the manufacturing process/machine.
For the next steps, the Non-Design Spaces as well as the Machining Allowances are hidden.
Create the material Steel in the Materials editor and assign it to the Design Space
The specific values needed are the Young's Modulus (192372 MPa), Poisson ratio (0.3) and Density (7.97e-6 kg/mm³)

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:

Name	Force/Moment/Pressure/Gravity	Direction	Value in N
Force-Moment1	Force	y	-1000

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

Name	Direction
Constraint 1	x, y, z (=0)

Step 4: Definition of Events (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 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 5: Definition of optimisation parameters

The optimisation parameters are selected in the Studies Areaas well.

Select the Strut Density: Medium
Select the Shape Quality: Balanced
Set the Complexity Setting: 10
Enter the Stress Goal: 50 MPa

Don’t forget to save the project!

Step 6: Starting the optimisation and visualizing 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.

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 for a higher resolution and more detailed result (increased calculation time!)
The Strut Density influences the structures which are formed during optimisation

Step 7: Visualization of Stresses, Displacements & Mass

The legend can be influenced in different ways. You can add and reduce the stress/displacement steps, enlarge different steps and set new minimum and maximum values.