6.

View optimization results (file: monitor_bracket_compliance_des.h3d, monitor_bracket_compliance.fem, monitor_bracket_compliance.sh)

Various results file are created during the optimization run: *.res HyperMesh binary results file. HyperView binary results file. *_des.h3d *_s1.h3d *.HM.comp.cmf
element density displacement, stress

HyperMesh command file used to organize elements into components based on their density result values. This file is only used with OptiStruct topology optimization runs. OptiStruct output file containing specific information on the file setup, the setup of the optimization problem, estimates for the amount of RAM and disk space required for the run, information for each optimization iteration, and compute time information. Review this file for warnings and errors that are flagged from processing the *.fem file. Shape file for the final iteration. It contains the material density, void size parameters and void orientation angle for each element in the analysis. This file may be used to restart a run. HyperGraph file containing data for the objective function, percent constraint violations, and constraint for each iteration. OSSmooth file with a default density threshold of 0.3. The user may edit the parameters in the file to obtain the desired results. Contains the iteration history of the objective, constraints, and the design variables. It can be used to plot curves in HyperGraph, HyperView, and MotionView. Contains information about the CPU time used for the complete run and also the break up of the CPU time for reading the input deck, assembly, analysis, convergence, etc

*.out

*.sh

*.hgdata *.oss *_hist.mvw

*.stat

Visualizing the topology optimization results: As discussed earlier, either the HyperMesh window needs to be splitted (in HyperWorks Desktop), or HyperView must be started separately (e.g. from within the analysis/optimization panel in HyperMesh. The topology optimization results (=standardized density value per element) are available with the monitor_bracket_compliance_des.h3d file. To load the results activate

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 select the iteration of interest (here the final iteration is 17) and contour the element density values

Red color indicates elements with a (standardized) density of 1 (load bearing elements; needed), blue refers to elements with a density of 0. The latter do not carry loads and hence, can be neglected. From this very first density contour plot it becomes quite evident which parts of the bracket (design area) are structurally important. However, there is a kind of challenge involved: What is the meaning of the intermediate density elements i.e. elements with a density of e.g. 0.4 or 0.6?

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An iso-contour plot elements.

of the element density helps to better extract the load bearing

The default settings are: o Current value 0.505 o Show values: Above (this threshold) To activate the iso-contour plot, click on Apply.

Standardized density plot with threshold value of 0.4. Manually, the threshold value is then moved to lower or higher values in order to determine a solution (or design) you feel comfortable with (i.e. typically you try to visually erase (these elements are not deleted!) at least the blue colored elements). Interpretation of the density iso-contour plot: Elements with a density value below the threshold (here elements in the density range between 0-0.4) will be neglected, which implies that their respective contribution to the overall stiffness of the structure will also be neglected (minimized). This is counterbalanced by assigning all elements with densities greater 0.4 the new standardized density value 1. This in turn implies that their stiffness is equally increased.
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Reanalysis: How good is our interpretation (concept design) at all? This can be best answered by running a reanalysis: Hereto, a model will be automatically build based on all elements with a density value above the threshold (the elements with a density below the threshold are no longer part of the model then).

The model for the reanalysis is automatically generated inside the OSSmooth panel: OptimizationOSSmoothFEA Topology (file: monitor_bracket_compliance.sh)

Make sure that the corresponding monitor_bracket_compliance.fem file is loaded in HyperMesh

In this automated process, all elements of the design space with a density above the user specified threshold are wrapped, automatically remeshed (with tetrahedral elements) and eventually attached to the non-design space.

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In the next step, save the model (*.hm) and run the re-analysis (*.fem).

Base design (part I) Topology optimized

Displacement (at node 33768) 0.17 mm 0.267 mm

Mass 2.88 kg 1.7 kg

Eventually, this concept design is then taken to the CAD system in order to provide the designer an initial concept design. Hereto, the geometry (IGES format) is derived within the OSSMOOTH panel

based on the before determined density threshold (here 0.4).

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The bluish colored part (=individual surfaces) are automatically exported as IGES files to the corresponding working directory.

Alternatively, the number of outputted surfaces may be reduced by activating the option surface reduction. Eventually, this geometry (any of the two formats) is imported in the CAD system and redesigned.

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