{"id":847,"date":"2016-04-15T13:52:28","date_gmt":"2016-04-15T03:52:28","guid":{"rendered":"https:\/\/www.finiteelementanalysis.com.au\/?p=847"},"modified":"2016-04-15T13:52:28","modified_gmt":"2016-04-15T03:52:28","slug":"topological-optimisation-with-ansys-17-0","status":"publish","type":"post","link":"https:\/\/www.leapaust.com.au\/blog\/fea\/topological-optimisation-with-ansys-17-0\/","title":{"rendered":"Topological Optimisation with ANSYS 17.0"},"content":{"rendered":"<div id=\"bsf_rt_marker\"><\/div><p><span style=\"font-size: 12pt;\">Utilising the new FREE\u00a0topology optimisation ACT-extension, one can explore new innovative ways to reduce mass that were not available before.\u00a0The DoE (Design of Experiments)\u00a0approach may not be feasible if the design&#8217;s shape\u00a0is not\u00a0yet defined,\u00a0while creating CAD models to capture all the potential design possibilities may be impossible.<\/span><\/p>\n<p><span style=\"font-size: 12pt;\">Now imagine starting with an arbitrary volume and having each element within\u00a0either turned on or off to create the most optimum shape, taking into consideration\u00a0the applied loads, boundary conditions, and\u00a0design constraints (such as, a maximum displacement\/stress limit required for the design) to achieve an overall\u00a0weight reduction.<\/span><\/p>\n<p><span style=\"font-size: 12pt;\">In Shape Optimisation, we have constraints and objectives. Constraints\u00a0define the optimisation&#8217;s bounds, while\u00a0objectives are essentially the goal of the optimisation problem.<\/span><\/p>\n<p><span style=\"font-size: 12pt;\">In the following example, the imposed loadings on the Bell Crank\u00a0must not result\u00a0in excessive deformation, but the component is way too heavy\u00a0so mass needs to be removed.<\/span><\/p>\n<p><span style=\"font-size: 12pt;\">Watch the video to see the topology optimisation ACT-extension in action or read on below:<\/span><\/p>\n<p><script src=\"https:\/\/fast.wistia.com\/assets\/external\/E-v1.js\" async><\/script><\/p>\n<div class=\"wistia_responsive_padding\" style=\"padding:56.25% 0 0 0;position:relative;\">\n<div class=\"wistia_responsive_wrapper\" style=\"height:100%;left:0;position:absolute;top:0;width:100%;\">\n<div class=\"wistia_embed wistia_async_yx9vy0nh9z videoFoam=true\" style=\"height:100%;width:100%\">&nbsp;<\/div>\n<\/div>\n<\/div>\n<p>&nbsp;<\/p>\n<p><span style=\"font-size: 12pt;\">If you would like to see the full demonstration of this process you can <a href=\"https:\/\/leapaust.wistia.com\/medias\/h1pvw9p46e\" target=\"_blank\" rel=\"noopener noreferrer\">watch the complete video here<\/a> (43 minutes).<\/span><\/p>\n<p><span style=\"font-size: 12pt;\">The model setup.<\/span><\/p>\n<p><img fetchpriority=\"high\" decoding=\"async\" class=\"alignleft wp-image-876 size-full\" src=\"https:\/\/www.leapaust.com.au\/blog\/wp-content\/uploads\/2016\/04\/Pic_1-1.png\" alt=\"Topological Optimisation with ANSYS 17.0\" width=\"798\" height=\"432\" srcset=\"https:\/\/www.leapaust.com.au\/blog\/wp-content\/uploads\/2016\/04\/Pic_1-1.png 798w, https:\/\/www.leapaust.com.au\/blog\/wp-content\/uploads\/2016\/04\/Pic_1-1-300x162.png 300w, https:\/\/www.leapaust.com.au\/blog\/wp-content\/uploads\/2016\/04\/Pic_1-1-768x416.png 768w\" sizes=\"(max-width: 798px) 100vw, 798px\" \/><\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p><span style=\"font-size: 12pt;\">The remote point locations\u00a0shown below (at all hole centres) used to define a revolute joint, load and spring-to-ground connection.<\/span><\/p>\n<p><img decoding=\"async\" class=\"alignleft wp-image-849 size-full\" src=\"https:\/\/www.leapaust.com.au\/blog\/wp-content\/uploads\/2016\/04\/Pic_2.png\" alt=\"static structural of a spring joint in ANSYS 17.0\" width=\"842\" height=\"454\" srcset=\"https:\/\/www.leapaust.com.au\/blog\/wp-content\/uploads\/2016\/04\/Pic_2.png 842w, https:\/\/www.leapaust.com.au\/blog\/wp-content\/uploads\/2016\/04\/Pic_2-300x162.png 300w, https:\/\/www.leapaust.com.au\/blog\/wp-content\/uploads\/2016\/04\/Pic_2-768x414.png 768w\" sizes=\"(max-width: 842px) 100vw, 842px\" \/><\/p>\n<p><span style=\"font-size: 12pt;\">The results show a lot of low-stress regions. We could iteratively remove material and rerun analysis (through trial and error) but we would only be considering 1 load-case.<\/span><\/p>\n<p><img decoding=\"async\" class=\"alignleft wp-image-850 size-full\" src=\"https:\/\/www.leapaust.com.au\/blog\/wp-content\/uploads\/2016\/04\/Pic_3.png\" alt=\"ANSYS 17.0 total deformation &amp; equivalent stress results\" width=\"851\" height=\"532\" srcset=\"https:\/\/www.leapaust.com.au\/blog\/wp-content\/uploads\/2016\/04\/Pic_3.png 851w, https:\/\/www.leapaust.com.au\/blog\/wp-content\/uploads\/2016\/04\/Pic_3-300x188.png 300w, https:\/\/www.leapaust.com.au\/blog\/wp-content\/uploads\/2016\/04\/Pic_3-768x480.png 768w\" sizes=\"(max-width: 851px) 100vw, 851px\" \/><\/p>\n<p>&nbsp;<\/p>\n<p><span style=\"font-size: 12pt;\">ANSYS Topology Optimisation, available when the ACT is loaded within the project.<\/span><\/p>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"alignleft wp-image-851 size-full\" src=\"https:\/\/www.leapaust.com.au\/blog\/wp-content\/uploads\/2016\/04\/Pic_4.png\" alt=\"ANSYS 17.0 Topology Optimisation ACT\" width=\"254\" height=\"88\" \/><\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p><span style=\"font-size: 12pt;\">Inside ANSYS Mechanical, the topology optimisation toolbar.<\/span><\/p>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"alignleft wp-image-852 size-full\" src=\"https:\/\/www.leapaust.com.au\/blog\/wp-content\/uploads\/2016\/04\/Pic_5.png\" alt=\"ANSYS 17.0 Topology Optimisation toolbar\" width=\"746\" height=\"56\" \/><\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p><span style=\"font-size: 12pt;\">Setting up a topology optimisation starts with a drag &amp; drop over the Static Structural system on the project page.<\/span><\/p>\n<p><span style=\"font-size: 12pt;\">Inside ANSYS Mechanical,\u00a0the completed setup.<\/span><\/p>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"alignleft size-full wp-image-854\" src=\"https:\/\/www.leapaust.com.au\/blog\/wp-content\/uploads\/2016\/04\/Pic_7.png\" alt=\"ANSYS 17.0 Topology Optimisation Design Modeller completed setup\" width=\"309\" height=\"178\" srcset=\"https:\/\/www.leapaust.com.au\/blog\/wp-content\/uploads\/2016\/04\/Pic_7.png 309w, https:\/\/www.leapaust.com.au\/blog\/wp-content\/uploads\/2016\/04\/Pic_7-300x173.png 300w\" sizes=\"(max-width: 309px) 100vw, 309px\" \/><\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p><span style=\"font-size: 12pt;\">Definitions for specified regions where mass can be removed, or excluded from mass-removal, as well as objectives. (e.g. mass reduction targets, displacement limits, etc.)<\/span><\/p>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"alignleft wp-image-855 size-full\" src=\"https:\/\/www.leapaust.com.au\/blog\/wp-content\/uploads\/2016\/04\/Pic_8.png\" alt=\"ANSYS Spring Model\" width=\"822\" height=\"512\" srcset=\"https:\/\/www.leapaust.com.au\/blog\/wp-content\/uploads\/2016\/04\/Pic_8.png 822w, https:\/\/www.leapaust.com.au\/blog\/wp-content\/uploads\/2016\/04\/Pic_8-300x187.png 300w, https:\/\/www.leapaust.com.au\/blog\/wp-content\/uploads\/2016\/04\/Pic_8-768x478.png 768w\" sizes=\"(max-width: 822px) 100vw, 822px\" \/><\/p>\n<p>&nbsp;<\/p>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"alignleft wp-image-856 size-full\" src=\"https:\/\/www.leapaust.com.au\/blog\/wp-content\/uploads\/2016\/04\/Pic_9.png\" alt=\"ANSYS Model Close Up of Hole\" width=\"579\" height=\"469\" srcset=\"https:\/\/www.leapaust.com.au\/blog\/wp-content\/uploads\/2016\/04\/Pic_9.png 579w, https:\/\/www.leapaust.com.au\/blog\/wp-content\/uploads\/2016\/04\/Pic_9-300x243.png 300w\" sizes=\"(max-width: 579px) 100vw, 579px\" \/><\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p><span style=\"font-size: 12pt;\">The blue solid is where mass can be removed and the cylinder of pink\u00a0elements will be excluded from mass removal as it is a major load-bearing area. An inflation layer was used here to get a ring of elements around the pivot hole. The faces where the spring and load lugs mount are also excluded to allow for a mounting face.<\/span><\/p>\n<p><span style=\"font-size: 12pt;\">The displacements in\u00a0Y and Z directions cannot be more than 3 mm in the negative direction, this is an optimisation constraint, its location near the load. 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.<\/span><\/p>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"alignleft size-full wp-image-857\" src=\"https:\/\/www.leapaust.com.au\/blog\/wp-content\/uploads\/2016\/04\/Pic_10.png\" alt=\"Pic_10\" width=\"457\" height=\"206\" srcset=\"https:\/\/www.leapaust.com.au\/blog\/wp-content\/uploads\/2016\/04\/Pic_10.png 457w, https:\/\/www.leapaust.com.au\/blog\/wp-content\/uploads\/2016\/04\/Pic_10-300x135.png 300w\" sizes=\"(max-width: 457px) 100vw, 457px\" \/><\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p><span style=\"font-size: 12pt;\">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. Alternatively a range can be set, to impose less constraint on the optimisation problem.<\/span><\/p>\n<p><span style=\"font-size: 12pt;\">Once the solution completes, a contour of 0 -1 is created, this can be nodal based or element based. The nodal based value is better for visualisation. A capped isosurface is created, this shows the solid with underutilised elements removed. 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.<\/span><\/p>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"alignleft size-full wp-image-858\" src=\"https:\/\/www.leapaust.com.au\/blog\/wp-content\/uploads\/2016\/04\/Pic_11.png\" alt=\"Pic_11\" width=\"383\" height=\"124\" srcset=\"https:\/\/www.leapaust.com.au\/blog\/wp-content\/uploads\/2016\/04\/Pic_11.png 383w, https:\/\/www.leapaust.com.au\/blog\/wp-content\/uploads\/2016\/04\/Pic_11-300x97.png 300w\" sizes=\"(max-width: 383px) 100vw, 383px\" \/><\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"alignleft size-full wp-image-859\" src=\"https:\/\/www.leapaust.com.au\/blog\/wp-content\/uploads\/2016\/04\/Pic_12.png\" alt=\"Pic_12\" width=\"295\" height=\"93\" \/><\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"alignleft size-full wp-image-860\" src=\"https:\/\/www.leapaust.com.au\/blog\/wp-content\/uploads\/2016\/04\/Pic_13.png\" alt=\"ANSYS Topology Optimisation Average node values\" width=\"822\" height=\"448\" srcset=\"https:\/\/www.leapaust.com.au\/blog\/wp-content\/uploads\/2016\/04\/Pic_13.png 822w, https:\/\/www.leapaust.com.au\/blog\/wp-content\/uploads\/2016\/04\/Pic_13-300x164.png 300w, https:\/\/www.leapaust.com.au\/blog\/wp-content\/uploads\/2016\/04\/Pic_13-768x419.png 768w\" sizes=\"(max-width: 822px) 100vw, 822px\" \/><\/p>\n<p><span style=\"font-size: 12pt;\">This capped isosurface is written out as an STL file by right clicking on the result and choosing export as STL file.<\/span><\/p>\n<p><span style=\"font-size: 12pt;\">This STL file is then opened in SpaceClaim and manipulated using <a href=\"http:\/\/www.spaceclaim.com\/en\/Solutions\/ReverseEngineering.aspx\" target=\"_blank\" rel=\"noopener noreferrer\">reverse engineering tools<\/a>, the aim to recover a solid.<\/span><\/p>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"alignleft size-full wp-image-861\" src=\"https:\/\/www.leapaust.com.au\/blog\/wp-content\/uploads\/2016\/04\/Pic_14.png\" alt=\"SpaceClaim auto fix tool\" width=\"354\" height=\"170\" srcset=\"https:\/\/www.leapaust.com.au\/blog\/wp-content\/uploads\/2016\/04\/Pic_14.png 354w, https:\/\/www.leapaust.com.au\/blog\/wp-content\/uploads\/2016\/04\/Pic_14-300x144.png 300w\" sizes=\"(max-width: 354px) 100vw, 354px\" \/><\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p><span style=\"font-size: 12pt;\">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. An imperfect STL shows holes or cracks.<\/span><\/p>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"alignleft wp-image-862 size-full\" src=\"https:\/\/www.leapaust.com.au\/blog\/wp-content\/uploads\/2016\/04\/Pic_15.png\" alt=\"SpaceClaim gap in solid\" width=\"425\" height=\"358\" \/><\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p><span style=\"font-size: 12pt;\">The gap in this solid is a significant feature.<\/span><\/p>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"alignleft size-full wp-image-900\" src=\"https:\/\/www.leapaust.com.au\/blog\/wp-content\/uploads\/2016\/04\/Pic_16.png\" alt=\"Pic_16\" width=\"469\" height=\"439\" srcset=\"https:\/\/www.leapaust.com.au\/blog\/wp-content\/uploads\/2016\/04\/Pic_16.png 469w, https:\/\/www.leapaust.com.au\/blog\/wp-content\/uploads\/2016\/04\/Pic_16-300x281.png 300w\" sizes=\"(max-width: 469px) 100vw, 469px\" \/><\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p><span style=\"font-size: 12pt;\">The shrink wrap from the Faceted Data tab is applied, selecting a size that doesn\u2019t defeature too much away, a good guide, use the element size or smaller, half element size gives good results.<\/span><\/p>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"alignleft size-full wp-image-864\" src=\"https:\/\/www.leapaust.com.au\/blog\/wp-content\/uploads\/2016\/04\/Pic_17.png\" alt=\"Pic_17\" width=\"361\" height=\"167\" srcset=\"https:\/\/www.leapaust.com.au\/blog\/wp-content\/uploads\/2016\/04\/Pic_17.png 361w, https:\/\/www.leapaust.com.au\/blog\/wp-content\/uploads\/2016\/04\/Pic_17-300x139.png 300w\" sizes=\"(max-width: 361px) 100vw, 361px\" \/><\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"alignleft size-full wp-image-865\" src=\"https:\/\/www.leapaust.com.au\/blog\/wp-content\/uploads\/2016\/04\/Pic_18.png\" alt=\"Pic_18\" width=\"618\" height=\"632\" srcset=\"https:\/\/www.leapaust.com.au\/blog\/wp-content\/uploads\/2016\/04\/Pic_18.png 618w, https:\/\/www.leapaust.com.au\/blog\/wp-content\/uploads\/2016\/04\/Pic_18-293x300.png 293w\" sizes=\"(max-width: 618px) 100vw, 618px\" \/><\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p><span style=\"font-size: 12pt;\">Shrink wrap and 1 smooth level.<\/span><\/p>\n<p><span style=\"font-size: 12pt;\">We then can either directly convert to solid, or overlay skins that approximate the geometry.<\/span><\/p>\n<p><span style=\"font-size: 12pt;\">At this stage we can take solid to ANSYS\u00a0Mechanical and mesh it but because it has so many face patches the need for virtual topology arises, or one can use a patch independent\u00a0tetrahedron mesh to walk over the sometimes small face patches.<\/span><\/p>\n<p><span style=\"font-size: 12pt;\">Taking the convert to solid option:<\/span><\/p>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"alignleft size-full wp-image-866\" src=\"https:\/\/www.leapaust.com.au\/blog\/wp-content\/uploads\/2016\/04\/Pic_19.png\" alt=\"Pic_19\" width=\"613\" height=\"472\" \/><\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p><span style=\"font-size: 12pt;\">We switch out the optimised solid for the original solid, and import into ANSYS Mechanical. Some items go missing, and need a geometry assignment.<\/span><\/p>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"alignleft size-full wp-image-867\" src=\"https:\/\/www.leapaust.com.au\/blog\/wp-content\/uploads\/2016\/04\/Pic_20.png\" alt=\"Pic_20\" width=\"508\" height=\"398\" srcset=\"https:\/\/www.leapaust.com.au\/blog\/wp-content\/uploads\/2016\/04\/Pic_20.png 508w, https:\/\/www.leapaust.com.au\/blog\/wp-content\/uploads\/2016\/04\/Pic_20-300x235.png 300w\" sizes=\"(max-width: 508px) 100vw, 508px\" \/><\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p><span style=\"font-size: 12pt;\">Virtual topology applied to hole, it is composed of many small facets, this face is used as pivot point remote point location and also for a co-ordinate system, everything else is attached to unchanged parts, contacts are done automatically.<\/span><\/p>\n<p><span style=\"font-size: 12pt;\">All that remains is to apply a patch independent tet mesh, using a size of 3.5 mm max and 3 mm min give a mesh that walks over the small faces, there are just over 42000 faces in the model.<\/span><\/p>\n<p><span style=\"font-size: 12pt;\">This is the resulting mesh.<\/span><img loading=\"lazy\" decoding=\"async\" class=\"alignleft size-full wp-image-868\" src=\"https:\/\/www.leapaust.com.au\/blog\/wp-content\/uploads\/2016\/04\/Pic_21.png\" alt=\"Pic_21\" width=\"953\" height=\"572\" srcset=\"https:\/\/www.leapaust.com.au\/blog\/wp-content\/uploads\/2016\/04\/Pic_21.png 953w, https:\/\/www.leapaust.com.au\/blog\/wp-content\/uploads\/2016\/04\/Pic_21-300x180.png 300w, https:\/\/www.leapaust.com.au\/blog\/wp-content\/uploads\/2016\/04\/Pic_21-768x461.png 768w\" sizes=\"(max-width: 953px) 100vw, 953px\" \/><\/p>\n<p>&nbsp;<\/p>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"alignleft size-full wp-image-869\" src=\"https:\/\/www.leapaust.com.au\/blog\/wp-content\/uploads\/2016\/04\/Pic_22.png\" alt=\"Pic_22\" width=\"1025\" height=\"625\" srcset=\"https:\/\/www.leapaust.com.au\/blog\/wp-content\/uploads\/2016\/04\/Pic_22.png 1025w, https:\/\/www.leapaust.com.au\/blog\/wp-content\/uploads\/2016\/04\/Pic_22-300x183.png 300w, https:\/\/www.leapaust.com.au\/blog\/wp-content\/uploads\/2016\/04\/Pic_22-768x468.png 768w\" sizes=\"(max-width: 1025px) 100vw, 1025px\" \/><span style=\"font-size: 12pt;\">The stress is now higher showing more material is being utilised to carry load, the boss where we elected to keep, is not highly stressed, indicating it could have been thinner.<\/span><\/p>\n<p><span style=\"font-size: 12pt;\">1.02 Kg compared to 0.46 Kg not quite the 40% we aimed for, but there is no science behind choosing the capped limit.<\/span><\/p>\n<p><span style=\"font-size: 12pt;\">Some important concepts here:<\/span><br \/>\n<span style=\"font-size: 12pt;\"> Only 1 solid optimised so compare parts associatively will aid in having to reconstruct all loads, as only some objects will need attention.<\/span><\/p>\n<p><span style=\"font-size: 12pt;\">As an alternative to converting faceted mesh to a solid, we overlay skins that approximate the geometry, this gives a cleaner geometry with fewer face patches, and relies on creating a watertight geometry as you go. The skin overlay tools are amazing at capturing the local details. Some planning is required to get good looking faces. The goal is to reduce the many facets to fewer nurbs surfaces, and as a consequence remove the need for virtual topology.<\/span><\/p>\n<p><span style=\"font-size: 12pt;\">Here we see a facet mesh as output by ANSYS optimiser.<\/span><\/p>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"alignleft size-full wp-image-870\" src=\"https:\/\/www.leapaust.com.au\/blog\/wp-content\/uploads\/2016\/04\/Pic_23.png\" alt=\"Pic_23\" width=\"569\" height=\"391\" srcset=\"https:\/\/www.leapaust.com.au\/blog\/wp-content\/uploads\/2016\/04\/Pic_23.png 569w, https:\/\/www.leapaust.com.au\/blog\/wp-content\/uploads\/2016\/04\/Pic_23-300x206.png 300w\" sizes=\"(max-width: 569px) 100vw, 569px\" \/><\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p><span style=\"font-size: 12pt;\">Here we see rough a shrink wrap 2mm used.<\/span><\/p>\n<p>&nbsp;<\/p>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"alignleft size-full wp-image-871\" src=\"https:\/\/www.leapaust.com.au\/blog\/wp-content\/uploads\/2016\/04\/Pic_24.png\" alt=\"Pic_24\" width=\"654\" height=\"425\" \/><\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p><span style=\"font-size: 12pt;\">Note the loss of detail<\/span><\/p>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"alignleft size-full wp-image-872\" src=\"https:\/\/www.leapaust.com.au\/blog\/wp-content\/uploads\/2016\/04\/Pic_25.png\" alt=\"Pic_25\" width=\"578\" height=\"387\" srcset=\"https:\/\/www.leapaust.com.au\/blog\/wp-content\/uploads\/2016\/04\/Pic_25.png 578w, https:\/\/www.leapaust.com.au\/blog\/wp-content\/uploads\/2016\/04\/Pic_25-300x201.png 300w\" sizes=\"(max-width: 578px) 100vw, 578px\" \/><\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p><span style=\"font-size: 12pt;\">With a setting of 1 mm the detail is retained, the element size used was 2 mm in the FEA mesh.<\/span><\/p>\n<p><span style=\"font-size: 12pt;\">With 1 level of global smoothing on top of 1 mm shrink wrap:<\/span><\/p>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"alignleft size-full wp-image-873\" src=\"https:\/\/www.leapaust.com.au\/blog\/wp-content\/uploads\/2016\/04\/Pic_26.png\" alt=\"Pic_26\" width=\"577\" height=\"389\" srcset=\"https:\/\/www.leapaust.com.au\/blog\/wp-content\/uploads\/2016\/04\/Pic_26.png 577w, https:\/\/www.leapaust.com.au\/blog\/wp-content\/uploads\/2016\/04\/Pic_26-300x202.png 300w\" sizes=\"(max-width: 577px) 100vw, 577px\" \/><\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p><span style=\"font-size: 12pt;\">This smoothed mesh is now overlaid with nurbs skins in a series of patches, below is a partially completed geometry<\/span><\/p>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"alignleft size-full wp-image-874\" src=\"https:\/\/www.leapaust.com.au\/blog\/wp-content\/uploads\/2016\/04\/Pic_27.png\" alt=\"Pic_27\" width=\"551\" height=\"409\" srcset=\"https:\/\/www.leapaust.com.au\/blog\/wp-content\/uploads\/2016\/04\/Pic_27.png 551w, https:\/\/www.leapaust.com.au\/blog\/wp-content\/uploads\/2016\/04\/Pic_27-300x223.png 300w\" sizes=\"(max-width: 551px) 100vw, 551px\" \/><\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p><span style=\"font-size: 12pt;\">With a straight conversion to solid:<\/span><\/p>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"alignleft size-full wp-image-875\" src=\"https:\/\/www.leapaust.com.au\/blog\/wp-content\/uploads\/2016\/04\/Pic_28.png\" alt=\"Pic_28\" width=\"558\" height=\"377\" srcset=\"https:\/\/www.leapaust.com.au\/blog\/wp-content\/uploads\/2016\/04\/Pic_28.png 558w, https:\/\/www.leapaust.com.au\/blog\/wp-content\/uploads\/2016\/04\/Pic_28-300x203.png 300w\" sizes=\"(max-width: 558px) 100vw, 558px\" \/><\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p><span style=\"font-size: 12pt;\">The flow chart below outlines the overall workflow:<\/span><\/p>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"alignleft size-full wp-image-885\" src=\"https:\/\/www.leapaust.com.au\/blog\/wp-content\/uploads\/2016\/04\/Flow-Chart.png\" alt=\"Flow-Chart\" width=\"550\" height=\"1005\" srcset=\"https:\/\/www.leapaust.com.au\/blog\/wp-content\/uploads\/2016\/04\/Flow-Chart.png 550w, https:\/\/www.leapaust.com.au\/blog\/wp-content\/uploads\/2016\/04\/Flow-Chart-164x300.png 164w\" sizes=\"(max-width: 550px) 100vw, 550px\" \/><\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p><span style=\"font-size: 14pt;\">More information on ANSYS Topology tools can be found on the <a href=\"http:\/\/www.spaceclaim.com\/en\/Solutions\/PrototypingandManufacturing\/AdditiveManufacturingandRapidPrototyping.aspx\" target=\"_blank\" rel=\"noopener noreferrer\">SpaceClaim website<\/a> and this previously published article on <a href=\"https:\/\/www.finiteelementanalysis.com.au\/featured\/topological-optimisation-with-fea\/\" target=\"_blank\" rel=\"noopener noreferrer\">ANSYS GTAM<\/a>.<\/span><\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n","protected":false},"excerpt":{"rendered":"<p>Utilising the new FREE\u00a0topology optimisation ACT-extension, one can explore new innovative ways to reduce mass that were not available before.\u00a0The DoE (Design of Experiments)\u00a0approach may not be feasible if the design&#8217;s shape\u00a0is not\u00a0yet defined,\u00a0while creating CAD models to capture all the potential design possibilities may be impossible. Now imagine starting with an arbitrary volume and&hellip;&nbsp;<a href=\"https:\/\/www.leapaust.com.au\/blog\/fea\/topological-optimisation-with-ansys-17-0\/\" rel=\"bookmark\">Read More &raquo;<span class=\"screen-reader-text\">Topological Optimisation with ANSYS 17.0<\/span><\/a><\/p>\n","protected":false},"author":0,"featured_media":980,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"neve_meta_sidebar":"","neve_meta_container":"","neve_meta_enable_content_width":"","neve_meta_content_width":0,"neve_meta_title_alignment":"","neve_meta_author_avatar":"","neve_post_elements_order":"","neve_meta_disable_header":"","neve_meta_disable_footer":"","neve_meta_disable_title":"","neve_meta_reading_time":"","footnotes":""},"categories":[144],"tags":[172,180,42,304],"class_list":["post-847","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-fea","tag-ansys-17-0","tag-ansys-mechanical","tag-fea","tag-topological-optimsation"],"_links":{"self":[{"href":"https:\/\/www.leapaust.com.au\/blog\/wp-json\/wp\/v2\/posts\/847","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/www.leapaust.com.au\/blog\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/www.leapaust.com.au\/blog\/wp-json\/wp\/v2\/types\/post"}],"replies":[{"embeddable":true,"href":"https:\/\/www.leapaust.com.au\/blog\/wp-json\/wp\/v2\/comments?post=847"}],"version-history":[{"count":0,"href":"https:\/\/www.leapaust.com.au\/blog\/wp-json\/wp\/v2\/posts\/847\/revisions"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/www.leapaust.com.au\/blog\/wp-json\/wp\/v2\/media\/980"}],"wp:attachment":[{"href":"https:\/\/www.leapaust.com.au\/blog\/wp-json\/wp\/v2\/media?parent=847"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/www.leapaust.com.au\/blog\/wp-json\/wp\/v2\/categories?post=847"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/www.leapaust.com.au\/blog\/wp-json\/wp\/v2\/tags?post=847"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}