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Definition of available package space

The CAE Driven Design Process. Topology Optimization – Conceptual Design. Setup of optimization problem, definition of design constraints. Mesh generation, definition of loads and boundary conditions. Computation. Interpretation of results. CAD Design.

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Definition of available package space

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  1. The CAE Driven Design Process Topology Optimization – Conceptual Design Setup of optimization problem, definition of design constraints Mesh generation, definition of loads and boundary conditions Computation Interpretation of results CAD Design Definition of available package space

  2. Case study – Bracket Redesign Engine Mount Bracket - Material saving Design Proposal (1997) Design Space 7 Loadcases Objective: Minimize the Mass Stiffness should be the same Annual Cost Savings Weight reduction per part = 0,22 kg Annual Prodution Volume = 200,000 pcs Total Mass Reduction = 44,000 kg Nominal Material Cost = $0.80/kg (1997) Total cost Savings in Material = $35,200/yr Initial Design Mass: 950g Design Mass: -20%

  3. Case Study – Bracket Redesign New Design Multivan V6 3,2l 173 KW Old Design Altair OptiStructProposal Mass Reduction: 23%

  4. Case Study – Bracket Redesign Stress Anal.Des. Adj. Topology Optimization Test CAD Topology Result Design Development Bracket VW Multivan Design space CAD Stress check Entwicklung Aggregate, Volkswagen

  5. Case Study – Bracket Redesign Base Design 2.000g New Design 1.550g Mass Reduction 23% << Entwicklung Aggregate, Volkswagen

  6. Case Study - Topology Optimization Process Fairchild Dornier 728 – door support arm Design Problem • Connector element between door and fuselage • Three static load cases • Door blocking • Emergency opening • Hit of damper mechanism on door Optimization Statement • Minimize Mass • Stress Constrains Methodology • Topology Optimization followed by Size&Shape Optimization

  7. Case Study - Topology Optimization Process Meshing of Design Space Determination of Design Space Topology Optimization Export of Geometry with OSSmooth Fairchild Dornier 728 – door support arm Analysis of OriginalDesign

  8. Case Study - Topology Optimization Process Drafting of Design Proposal DV Analysis of Design Proposal Size&Shape Optimization Export of final Geometry from HyperMesh Fairchild Dornier 728 – door support arm

  9. Case Study - Topology Optimization Process Fairchild Dornier 728 – door support arm -14% -19% m = 9.15 kg m = 7.90 kg m = 7.5 kg Original Design After Topology Optimization After Shape Optimization

  10. Optimization In The Design Process topoGRAPHYoptimization (Conceptual Design)

  11. Topography Optimization – Conceptual Design Definition of desired bead dimensions and optimization targets OptiStruct proposal of optimized bead pattern Interpretation of proposed bead pattern

  12. Case Study – Topography Optimization Muffler -10 dB sound emission <<

  13. Case Study -Reducing Heating Boiler Sound Emission • Challenge • Reduce noise emission of heating boiler • Increase stiffness of cover through innovative bead pattern • Solution • OptiStruct topography optimizationfor initial bead pattern layout • Shape optimization for further optimization of bead width • Results • 20% stiffness improvement • 30% reduction of parts (needed to stiffen the old design) “Thanks to OptiStruct, the stiffness of the boiler was significantly improved leading to a accoustically superior heating boiler.” Andreas SchubertCAE Manager VIESMANN GmbH, Germany

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