The gap in this solid is a significant feature. Sometimes the STL may not be watertight so the auto fix is used to clean it up, as the shrink wrapper may do some strange things if the starting point is not a watertight STL. This STL file is then opened in SpaceClaim and manipulated using reverse engineering tools, the aim to recover a solid. This capped isosurface is written out as an STL file by right clicking on the result and choosing export as STL file. Moving the slider to a point that produces a viable solid is the aim here, as this is written out to an STL file for further processing. A capped isosurface is created, this shows the solid with underutilised elements removed.
The nodal based value is better for visualisation. Once the solution completes, a contour of 0 -1 is created, this can be nodal based or element based. Alternatively a range can be set, to impose less constraint on the optimisation problem. The mass reduction is another constraint, here the percentage refers to percentage of what is left over after exclusion, so purely by exclusion mass has been removed, and is not included in the percentage reduction consideration, this must be kept in mind when setting mass targets, and can result in a failed solution. The upper bound is specified as a positive number, based on the load this will never be violated, a value of zero would imply infinite stiffness, so it should never be used. The displacements in Y and Z directions cannot be more than 3 mm in the negative direction, this is an optimisation constraint, its location near the load. The faces where the spring and load lugs mount are also excluded to allow for a mounting face. An inflation layer was used here to get a ring of elements around the pivot hole. The blue solid is where mass can be removed and the cylinder of pink elements will be excluded from mass removal as it is a major load-bearing area. mass reduction targets, displacement limits, etc.) Inside ANSYS Mechanical, the completed setup.ĭefinitions for specified regions where mass can be removed, or excluded from mass-removal, as well as objectives. Setting up a topology optimisation starts with a drag & drop over the Static Structural system on the project page. Inside ANSYS Mechanical, the topology optimisation toolbar.
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We could iteratively remove material and rerun analysis (through trial and error) but we would only be considering 1 load-case.ĪNSYS Topology Optimisation, available when the ACT is loaded within the project. The results show a lot of low-stress regions. The remote point locations shown below (at all hole centres) used to define a revolute joint, load and spring-to-ground connection.
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If you would like to see the full demonstration of this process you can watch the complete video here (43 minutes). Watch the video to see the topology optimisation ACT-extension in action or read on below:
In the following example, the imposed loadings on the Bell Crank must not result in excessive deformation, but the component is way too heavy so mass needs to be removed. Constraints define the optimisation’s bounds, while objectives are essentially the goal of the optimisation problem. In Shape Optimisation, we have constraints and objectives. Now imagine starting with an arbitrary volume and having each element within either turned on or off to create the most optimum shape, taking into consideration the applied loads, boundary conditions, and design constraints (such as, a maximum displacement/stress limit required for the design) to achieve an overall weight reduction.
Utilising the new FREE topology optimisation ACT-extension, one can explore new innovative ways to reduce mass that were not available before. The DoE (Design of Experiments) approach may not be feasible if the design’s shape is not yet defined, while creating CAD models to capture all the potential design possibilities may be impossible.
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