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

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

the optimization company Topologieoptimierung als Ansatz für Materialeinsparung und Ressourcenschonung

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

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 03.12.2012

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 3.12.2012 г.

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 03.12.2012

FE-DESIGN Fields of application Automotive Machine construction Aerospace Wind power generation Marine technology Medical devices Engines & turbo machinery Home appliances Consumer products 03.12.2012

the optimization company Main Frame Development Courtesy of

Topology optimization of a main frame Series production Conventional design Series production Design space for topology optimization Assembly Optimization result 03.12.2012 Courtesy of

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) 03.12.2012 Courtesy of

the optimization company Hub optimization

Topology optimization of a hub CAD surfaces Applying loading Verification of new conceptual design Design space model Verification of new conceptual design Topology optimization 03.12.2012

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

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 03.12.2012

Topology optimization of a transverse link at AUDI Redesign Existing design Cutting splines Design space model Topology optimization 03.12.2012 Courtesy of

Comparison Existing design new design Result 100 80 60 40 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) 03.12.2012

the optimization company Structural Optimization of Washing Mashine Components

Parts in FEA model H2 H1 H3 H4 H5 H6 Traverse (braces) H7 H9 03.12.2012

the optimization company Topology Optimization of a Washing Mashine Spider Arm

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 03.12.2012

Optimization I results (without cast constraint) 450000 6 400000 350000 5 300000 4 250000 200000 3 150000 2 100000 DRESP_VOL_TOPO 1 50000 DRESP_MAX_DISPLACEME 0 0 0 5 10 15 20 25 30 35 Initial design: Optimized design: Volume = 398746. (100%) MAX_DISP_1 = 3.94601 MAX_DISP_2 = 3.93227 MAX_DISP_3 = 1.84903 MAX_DISP_4 = 2.29052 MAX_DISP_5 = 2.23707 MAX_DISP_6 = 1.83949 03.12.2012 Volume = 214208. (53%) MAX_DISP_1 = 4.44915 MAX_DISP_2 = 4.46176 MAX_DISP_3 = 0.619918E-01 MAX_DISP_4 = 3.81158 MAX_DISP_5 = 3.93099 MAX_DISP_6 = 1.07937

Optimization II results (considering cast constraint) 410000 7 400000 390000 380000 370000 360000 350000 DRESP_VOL_TOPO DRESP_MAX_DISPLACEME 6 5 4 3 2 340000 330000 0 0 10 20 30 40 50 60 Initial design: Volume = 398746. (100%) MAX_DISP_1 = 3.94601 MAX_DISP_2 = 3.93227 MAX_DISP_3 = 1.84903 MAX_DISP_4 = 2.29052 MAX_DISP_5 = 2.23707 MAX_DISP_6 = 1.83949 03.12.2012 Optimized design: 1 Volume = 340751. (85%) MAX_DISP_1 = 4.46618 MAX_DISP_2 = 4.40698 MAX_DISP_3 = 1.72442 MAX_DISP_4 = 4.32224 MAX_DISP_5 = 4.52701 MAX_DISP_6 = 0.731727

the optimization company Optimization of a bike stem

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

Customers of FE-DESIGN Excerpt 3.12.2012 г.

the optimization company Thank you for your attention