Carsten Gerdes-Götz, FE-Design GmbH Dirk Pieper, pike-engineering & CAE- Forum.de

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1 the optimization company Carsten Gerdes-Götz, FE-Design GmbH Dirk Pieper, pike-engineering & CAE- Forum.de

2 the optimization company Topologieoptimierung als Ansatz für Materialeinsparung und Ressourcenschonung

3 the optimization company Es ist das Gesetz aller organischen und anorganischen, aller physischen und metaphysischen, aller menschlichen und übermenschlichen Dinge, aller echten Manifestationen des Kopfes, des Herzens und der Seele, dass das Leben in seinem Ausdruck erkennbar ist, dass die Form immer der Funktion folgt. aus Sullivans Aufsatz: The tall office building artistically considered, veröffentlicht 1896, in dem er den Ausspruch seines Partners Dankmar Adler zitiert, der ihn seinerseits sinngemäß von Henri Labrouste übernommen hatte. -Quelle: Wikipedia

4 Structural optimization Design process Reduction of weight Enforcing desirable stiffness and dynamic process Optimized design geometry Initial design space geometry Maximize the maximum stresses of several loadcases Minimize damage and increase durability Include manufacturing constraints Design for displacements/forces/ eigenfrequences Shape optimization Validation run Smoothing and generation of validation file Finite element model Optimization model Topology optimization

5 FE-DESIGN Your partner for optimization SOFTWARE-DEVELOPMENT ENGINEERING SERVICES TRAINING, SUPPORT AND CONSULTING FE-DESIGN combines development and application of optimization methods FE-DESIGN has the ability to deliver best solutions for our customers, benefiting from many years of experience Our customers continuously improve their optimization processes due to a steady knowhow transfer through FE-DESIGN Customers leverage FE-DESIGN s knowledge, with long-term business relationships г.

6 Product development values by using TOSCA Virtual prototypes accelerate the product development cycle Numerical simulation increases product quality Economy of energy and resources Higher efficiency through lower masses, higher accelerations, shorter cycle times Lower stresses increase durability Savings of material at ensured product quality Earlier product launches due to shorter development times

7 FE-DESIGN Fields of application Automotive Machine construction Aerospace Wind power generation Marine technology Medical devices Engines & turbo machinery Home appliances Consumer products

8 the optimization company Main Frame Development Courtesy of

9 Topology optimization of a main frame Series production Conventional design Series production Design space for topology optimization Assembly Optimization result Courtesy of

10 Main frame - comparison Norm. mass/load 1 0,9 0,8 0,7 0,6 0,5 0,4 0,3 0,2 0,1 0 S.64 Conventional S.52 Optimized S.82 Optimized 40% savings on weight!!! (>1,0 Mio EUR in one year) Courtesy of

11 the optimization company Hub optimization

12 Topology optimization of a hub CAD surfaces Applying loading Verification of new conceptual design Design space model Verification of new conceptual design Topology optimization

13 the optimization company Topology Optimization Example Transverse Link at AUDI With the friendly permission of

14 Initial situation A modification of the component was necessary, because the load on the part became too high with the new engines. Topology optimization is used to derive a new structure. Transverse link at Audi With the friendly permission of

15 Topology optimization of a transverse link at AUDI Redesign Existing design Cutting splines Design space model Topology optimization Courtesy of

16 Comparison Existing design new design Result Admissible Stress Speed-up of the development process 45% stress reduction, 10% weight reduction The 1st prototype passed all mechanical tests! 20 0 Weight Max. stress Max. displacement Existing design New design (Image ATZ MTZ extra)

17 the optimization company Structural Optimization of Washing Mashine Components

18 Parts in FEA model H2 H1 H3 H4 H5 H6 Traverse (braces) H7 H

19 the optimization company Topology Optimization of a Washing Mashine Spider Arm

20 Definition of the optimization task Objective Minimize volume Constraints Displacement constraint on loaded nodes The maximum absolute displacement in z-direction for all nodes in the displacement nodegroup is restricted to 4.5 mm

21 Optimization I results (without cast constraint) DRESP_VOL_TOPO DRESP_MAX_DISPLACEME Initial design: Optimized design: Volume = (100%) MAX_DISP_1 = MAX_DISP_2 = MAX_DISP_3 = MAX_DISP_4 = MAX_DISP_5 = MAX_DISP_6 = Volume = (53%) MAX_DISP_1 = MAX_DISP_2 = MAX_DISP_3 = E-01 MAX_DISP_4 = MAX_DISP_5 = MAX_DISP_6 =

22 Optimization II results (considering cast constraint) DRESP_VOL_TOPO DRESP_MAX_DISPLACEME Initial design: Volume = (100%) MAX_DISP_1 = MAX_DISP_2 = MAX_DISP_3 = MAX_DISP_4 = MAX_DISP_5 = MAX_DISP_6 = Optimized design: 1 Volume = (85%) MAX_DISP_1 = MAX_DISP_2 = MAX_DISP_3 = MAX_DISP_4 = MAX_DISP_5 = MAX_DISP_6 =

23 the optimization company Optimization of a bike stem

24 Topology optimization of a bike stem Conventional design New design Load cases Smoothed results Design space

25 Customers of FE-DESIGN Excerpt г.

26 the optimization company Thank you for your attention

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