Topology optimization is a great tool to use to come up with a good design concept, especially for challenging load scenarios. Although I trust the algorithms to come up with the best design it’s essential to understand the mechanics of the proposed design. Another interesting question in this phase is also to investigate how variations in the load conditions impact the design concept. To make this easier I came up with a workflow to automate and make the design exploration and understanding as easy as possible.

We asked Michael Werner, Portfolio Introduction Specialist with SIMULIA who developed this workflow, to provide answers to some common questions.

Q. Why does this workflow need to be analyzed?

A. The understanding of a design concept is essential, especially when topology optimization has been used to create a design for complex load scenarios. Here an automotive steering axle beam is picked to showcase the investigation of load scenario variations on the design. However, any design with changing load conditions can be explored with this approach to come up with a more robust design concept in the end.

Q. Describe the workflow.

A. The design process for a steering axle beam is driven by two misuse load scenarios: a left and a right curbstone misuse case. Together with the available design space a topology optimization is used to create a design concept fulfilling the defined requirements. For this Tosca Structure and Abaqus are used.

To investigate the impact of different load amplitudes or slightly different load vector directions an Isight workflow is created around the topology optimization. Within the Isight workflow the load scenario data in Abaqus is automatically modified based on the user input. The topology optimization is then rerun with e.g. slightly different loading directions. Afterwards the various design concepts can be compared to understand the impact of the load changes on the design.

Q. Which SIMULIA solutions did you use? 

A. The simulation part is of course just a subpart of the overall design process. So we used the 3DEXPERIENCE platform to create the CAD design space for the topology optimization. From there using the ‘Power’ By’ approach Abaqus/CAE is started from within the platform. The existing CAD geometry in the platform is directly opened in Abaqus/CAE on the local machine. This brings collaboration and data management capabilities to Abaqus/CAE. It’s becoming much easier to work together with colleagues on the same model.

In Abaqus/CAE the Abaqus FEA model is set up. This FEA is used for topology optimization with Tosca Structure. Having the Tosca Structure parameter file and Abaqus FEA input file on the local machine the Isight workflow can be created around the topology optimization. The Isight workflow is build portable having all file and data mentions relative to make sure the automated workflow can easily be zipped and used on another machine. Executing the Isight task one can select if the optimizations are performed on the local machine or on a high performance cluster. The resulting different design concepts are then further investigated using the 3DEXPERIENCE platform with its deviation analysis to visualize and compare the designs. Once the design concepts are understood and the important design features are identified the topology optimization result can be reconstructed to gain a parameterized CAD geometry. For this the Functional Generative Design app in the 3DEXPERIENCE platform with its new reconstruction capabilities are used. Pipe and strip drawing on the smoothed topology optimization surface help to come up rather quickly with a CAD concept geometry. From there it’s just another few clicks to create a realistic rendering of the design concept to have nice visuals when presenting the work.

Q. What were the advantages of using (more) simulation?

A. The value of simulation here is the help of virtual physics to come up with an efficient design concept as early as possible. Process automation enables a much wider design exploration having the chance to easily investigate more design variants when not having to build up model variants manually. The 3DEXPERIENCE platform brings in the CAD capabilities, data management for easier collaboration and new tools for design concept reconstruction. Overall a better understanding of the design can be achieved to improve the robustness of design concepts.