Tosca Structure 810

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Version 8.1.0 Rev. 1 - 05.2014
SIMULIA Tosca Structure

Documentation 8.1
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Tosca Structure
SIMULIA
Tosca Structure
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all rights reserved
Tosca Structure is a registered trademark of FE-DESIGN GmbH. All other
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SIMULIA
Tosca Structure
Tosca Structure makes use of several software components of Ceetron AS. to

provide certain features.
GLview Express Writer API
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Tosca Structure.view
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SIMULIA
Tosca Structure
Table of Contents
SIMULIA Tosca Structure Documentation 8.1
General Remarks
0-i
Volume I
Start Manual
Preface
1-3
Getting Started with Tosca ANSA environment
1-5
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1.1 User Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

1.1.1 General Buttons toolbar
1.1.1.1 FOCUS panel
1.1.1.2 VISIBILITY panel
1.1.2 Database and selection windows
1.1.3 Task Manager window
1.1.4 Input of an existing parameter file
1.1.5 Saving task and saving database
1.1.6 Highlighting
1.1.7 Input and output using Task Manager
1.1.8 Input and output using the main menu
1.1.9 Modules Buttons window
1.1.10 Selecting and deselecting the geometric objects
1.1.10.1 Selecting single objects
1.1.10.2 Box selection
1.1.10.3 Polygon area selection
1.1.11 View control
1.1.11.1 Rotating
1.1.11.2 Translating
1.1.11.3 Zooming
1.1.11.4 Faster view selection
1.1.11.5 Function keys related to view control
1.1.12 Keys facilitating input in dialogs
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Tosca Structure
1.1.13 Managing Groups

1.1.13.1 SET HELP window
1.1.13.2 Selection of objects in group selection mode
1.1.13.3 List of Tosca Structure commands with groups
1.1.14 Configuration of Tosca ANSA environment
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1.2.1
1.2.2
1.2.3
1.2.4
1.2.5
1.2.6
1.2.7
1.2.8
1.2.9
1.2.10
What is Topology Optimization?

The Model
Optimization Task
Step by Step Manual: Summary
Preprocessing
1.2.5.1 Choice of the optimization type
1.2.5.2 Loading the input model file
1.2.5.3 Choice of the design area
1.2.5.4 Choice of the design constraints
1.2.5.5 Choice of the objective function
1.2.5.6 Choice of the constraints
1.2.5.7 Saving Tosca Structure parameter file
Start Optimization
1.2.6.1 Start Tosca Structure
1.2.6.2 Logging and monitoring
Postprocessing
Report Generation
Result Transfer and Validation Run (Smooth)
1.2.9.1 Generating smooth surface
1.2.9.2 Modifying the surface using RECONSTRUCT
1.2.9.3 Remeshing the model
1.2.9.4 Saving the resulting model in solver format
1.2.9.5 Running the solver with the new model
1.2.9.6 Saving the resulting model in solver format (alternative)
1.2.9.7 Running the solver with the new model (alternative)
Result Discussion
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1.3 Shape Optimization with Tosca ANSA environment . . . . . . . . . . . 1-67

1.3.1
1.3.2
1.3.3
1.3.4
1.3.5
0 - vi
What is Shape Optimization?

The Model
Optimization Task
Preprocessing
1.3.5.3 Selection of mesh smoothing elements
1.3.5.4 Choice of design area
1.3.5.5 Choice of design variable constraint
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1.2 Topology Optimization with Tosca ANSA environment . . . . . . . . . 1-33
SIMULIA
Tosca Structure
1.3.6 Node Displacement Check (Check Inputs)

1.3.7 Start Optimization
1.3.7.3 Viewing the results in the optimized model
1.3.8 Postprocessing
1.3.9 Report Generation
1.3.10 Result transfer (Smooth)
1.3.11 Result Discussion
1.3.12 Extensions
1.3.12.1 Design variable constraints
1.3.12.2 Define a volume constraint
1.3.12.3 Redefine the global stop condition
1.3.12.4 Selecting mesh smooth elements automatically
1.3.13 Troubleshooting
1.3.13.1 Suggestions in case of mesh problems
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1.4 Bead Optimization with Tosca ANSA environment . . . . . . . . . . . 1-113

1.4.1 What is Bead Optimization?
1.4.1.1 Tosca Structure.bead
1.4.2 The Model
1.4.3 Optimization Task
1.4.4 Step by Step Manual: Summary
1.4.5 Preprocessing
1.4.5.5 Choice of the constraint
1.4.5.6 Optimization settings
1.4.6 Node Displacement Check (Check Inputs)
1.4.10 Result Transfer (Smooth)
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1.5 Sizing with Tosca ANSA environment . . . . . . . . . . . . . . . . . . . . . 1-145

1.5.1 What is Sizing Optimization?
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Tosca Structure
1.5.2
1.5.3
1.5.4
1.5.5
1.5.6
1.5.7
1.5.8
1.5.9
Model
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Optimization Task
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Preprocessing
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1.5.5.4 Choice of thickness bounds (design variable constraint)1-155
1.5.5.5 Optional: Cluster groups
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Start Optimization
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Postprocessing
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Report Generation
1-162
Result Discussion
1-167
Getting Started with Tosca Structure.gui
1-171
2.1.1 Requirements, Settings and Program Start

2.1.2 Tosca Structure.pre
2.1.2.1 Overview
2.1.2.2 Creating, modifying and saving parameter files
2.1.2.3 Defining optimization tasks
2.1.2.4 Simplifications for the user
2.1.3 Starting the Optimization
2.1.4 Tosca Structure.smooth
2.1.5 Visualization with Tosca Structure.view
2.1.6 Postprocessing (Tosca Structure.report)
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2.2 Topology Optimization with Tosca Structure.gui . . . . . . . . . . . . . 1-189

2.2.1
2.2.2
2.2.3
2.2.4
2.2.5
0 - viii

The Model
Optimization Task
Preprocessing
2.2.5.1 Starting Tosca Structure Preprocessor
2.2.5.3 Group creation (Nastran users only)
2.2.5.4 Define the design area
2.2.5.5 Choice of the design variable constraints
2.2.5.6 Definition of design responses
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2.1 User interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-171
SIMULIA
Tosca Structure
2.2.6
2.2.7
2.2.8
2.2.9
2.2.10

2.2.5.9 Definition of the optimization task
Start Optimization
Postprocessing
Report Generation
Result Transfer and Validation Run
2.2.9.1 Surface generation using Tosca Structure.smooth.
2.2.9.2 Processing the optimized structure
Result Discussion
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2.3 Shape Optimization with Tosca Structure.gui . . . . . . . . . . . . . . . 1-223

2.3.1
2.3.2
2.3.3
2.3.4
2.3.5
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2.3.6
2.3.7
2.3.8
2.3.9
2.3.10
2.3.11
2.3.12
2.3.13

The Model
Optimization Task
Preprocessing
2.3.5.4 Select design area
2.3.5.6 Choice of the design variable constraint
2.3.5.8 Select mesh smoothing elements
2.3.5.10 Define a stop condition
Check Inputs
2.3.6.1 TEST_SHAPE
2.3.6.2 Starting the test optimization
2.3.6.3 Viewing the test results
Start Optimization
Postprocessing
Report Generation
Result Transfer
Result Discussion
Extensions
2.3.12.3 Updating the optimization task
Troubleshooting
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SIMULIA
Tosca Structure
2.3.13.1 How to workaround mesh problems?
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2.4 Bead Optimization with Tosca Structure.gui . . . . . . . . . . . . . . . . 1-271

2.4.1 What is Bead Optimization?
2.4.2 Model
2.4.3 Optimization Task
2.4.4 Step by Step Manual: Summary
2.4.5 Preprocessing
2.4.5.7 Create bead height constraint
2.4.6 Check Inputs
2.4.6.1 TEST_BEAD
2.4.6.3 Viewing test results
2.4.8.1 Result Transfer
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2.5.1
2.5.2
2.5.3
2.5.4
2.5.5
What is Sizing Optimization?

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Model
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Optimization Task
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Preprocessing
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2.5.5.4 Choice of thickness bounds (design variable constraint)1-313
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2.5 Sizing Optimization with Tosca Structure.gui. . . . . . . . . . . . . . . . 1-305
SIMULIA
Tosca Structure
Getting Started with Tosca Extension for ANSYS/WB
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3.1 User Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-335

3.1.1 Buttons
3.1.2 Handling Tips
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3.2 Topology Optimization with Tosca Extension for ANSYS/WB. . . 1-347

3.2.1
3.2.2
3.2.3
3.2.4
3.2.5
3.2.6
The model
Loading the Extension
Example files
Preparing the model
Optimization preprocessing
Postprocessing
3.2.6.1 Optimization result view options
3.2.6.2 Iteration Animation
3.2.7 Validation Run
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3.3 Shape Optimization with Tosca Extension for ANSYS/WB . . . . . 1-371
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3.3.1
3.3.2
3.3.3
3.3.4
3.3.5
3.3.6
The model
Loading the extension
Example files
Preparing the model
Postprocessing
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Volume II
User Manual
Preface
2-3
Overview of Tosca Structure
2-5
1.1 The Tosca Structure Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

1.1.1 Abaqus CAE
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SIMULIA
Tosca Structure
1.1.2
1.1.3
1.1.4
1.1.5
1.1.6
1.1.7
1.1.8
Tosca ANSA environment

Tosca Structure.gui
Tosca Extension for ANSYS/WB
Tosca Structure optimization modules
Tosca Structure.report
Tosca Structure.smooth
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1.2 Overview of the Optimization Process . . . . . . . . . . . . . . . . . . . . . . . 2-8

1.2.1
1.2.2
1.2.3
1.2.4
1.2.5
1.2.6
Planning
Preprocessing: Model generation
Check Run
Optimization Loop
Postprocessing: Evaluation of Optimization results
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1.3 Workflow for Optimization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Working with Tosca Structure
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2.1 Working with Tosca ANSA environment . . . . . . . . . . . . . . . . . . . . 2-13

2.1.1
2.1.2
2.1.3
2.1.4
2.1.5
Preprocessing
Check Run
Start Optimization
Postprocessing
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2.2.1
2.2.2
2.2.3
2.2.4
2.2.5
Preprocessing
Check Run
Start Optimization
Postprocessing
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2.3 Working with Tosca Extension for ANSYS/Workbench . . . . . . . . . 2-22

2.3.1
2.3.2
2.3.3
2.3.4
Preprocessing
Start Optimization
Postprocessing
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2.4 Working with Tosca Structure in the Command Shell . . . . . . . . . . 2-26

2.4.1
2.4.2
2.4.3
2.4.4
2.4.5
0 - xii
Logging in command shell

Preprocessing
Check Run
Start optimization
Postprocessing
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2.2 Working with the Graphical User Interface Tosca Structure.gui . . 2-17
SIMULIA
Tosca Structure
2.4.6 Result Transfer
The Model
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3.1 Models for Optimization. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31

3.1.1
3.1.2
3.1.3
3.1.4
Models for topology optimization

Models for shape optimization
Models for bead optimization
Models for sizing
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3.2 Optimizable Element Types. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33

3.3 Preprocessing FE Models for Optimization . . . . . . . . . . . . . . . . . . 2-34
3.3.1 Abaqus/CAE
3.3.2 Preprocessing with ANSYS/Prep7
3.3.2.1 Generation of the finite element input file
3.3.2.2 Load cases
3.3.2.3 Check of the batch input file
3.3.2.4 Generation of groups
3.3.3 Preprocessing with ANSYS Workbench
3.3.3.1 Export of finite element input model
3.3.3.3 Suitable meshes for topology optimization
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3.4 Loading FE Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41
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3.4.1
3.4.2
3.4.3
3.4.4
3.4.5
3.4.6
3.4.7
Analysis Files for Optimization (FEM_INPUT)

LIFE_FILE
TEMPERATURE_FILE
ADD_FILE
COPY_FILE
Special FEM_INPUT-commands
Options for loading FE Data (OPTIONS)
3.4.7.1 Loading displacement restrictions
3.4.7.2 Identifying surface nodes for shape optimization
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3.5 Include Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47

3.6 Group Definition (GROUP_DEF, GROUP_AUTO_DEF) . . . . . . . . . . 2-47
3.6.1
3.6.2
3.6.3
3.6.4
3.6.5
Default predefined groups

Group definition in Tosca ANSA environment
Group definition in Tosca Extension for ANSYS/WB
Manual group definition in Tosca Structure.gui
Automatic node group definition (GROUP_AUTO_DEF)
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3.7 Selection of Objects in Tosca Structure.gui. . . . . . . . . . . . . . . . . . 2-53

3.8 Coordinate Systems (CS_DEF) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-59
3.8.1 Definition by three nodes
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Tosca Structure
3.8.2 Definition by coordinates of three points

3.8.3 Definition by origin and rotation angles
3.8.4 General remarks about coordinate systems
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3.9 Solids (Geometric Primitives). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-68

3.9.1 Definition in Tosca ANSA environment
3.9.2 Definition in Tosca Structure.gui
Terms for Optimization
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4.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-71

4.1.1 Mathematical formulation
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4.2 Objective Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-72

4.2.1 Overview
4.2.2 Minimization or maximization of an objective function
4.2.3 Multidisciplinary objectives (minmax formulation)
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4.4.1 Compliance (Stiffness Optimization)

4.4.1.1 Compliance example
4.4.2 Energy stiffness measure
4.4.2.1 Example for energy stiffness measure
4.4.3 Displacement and rotation
4.4.3.1 Example of a displacement design response
4.4.4 Reaction force
4.4.4.1 Example of reaction force design response
4.4.5 Internal force
4.4.5.1 Example internal force
4.4.6 Eigenfrequency
4.4.6.1 Eigenvalue example
4.4.6.2 Mode tracking
4.4.7 Equivalent stress
4.4.8 Stress in topology optimization
4.4.8.1 Example: Stresses in objective function
4.4.8.2 Example: Stresses in constraint definition
4.4.9 Center of gravity
4.4.10 Moment of inertia
4.4.11 Volume
4.4.11.1 Volume design response example
4.4.12 Weight
4.4.12.1 Example of a weight design response
4.4.13 DENSITY_MEASURE
4.4.14 Bead height
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4.5 Combined Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-143

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4.3 Constraints. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-79

4.4 Design Responses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-83
SIMULIA
Tosca Structure
4.5.1 Group operations for design responses

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4.5.1.1 Group Operations for Stresses
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4.5.1.2 Group Operations for Stiffness
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4.5.1.3 Group Operations for Displacements
2-146
4.5.1.4 Group operations for reaction forces/moments
2-152
4.5.1.5 Group Operations for Internal Forces
2-156
4.5.2 Load case combination and selection
2-160
4.5.2.1 Load case specification (LC_SET)
2-160
4.5.2.2 Selection criteria for load cases (LC_SEL)
2-164
4.5.3 Design response combination
2-165
4.5.3.1 Combined responses in sensitivity based optimization 2-167
4.5.3.2 Combining design responses (Tosca ANSA environment)2-171
4.5.3.3 Combining displacements and rotations
2-174
4.5.3.4 Combining reaction forces and internal forces
2-175
4.5.3.5 Combining absolute values of responses
2-176
4.5.3.6 Controller based combined terms
2-176
4.5.3.7 Other operators for controller based shape optimization2-178
4.6 Logging and Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-178
Topology Optimization
2-179
5.1 General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-179

5.2 The Optimization Task. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-180
5.2.1 Controller versus sensitivity based topology optimization
5.2.2 How to create the optimization model
2-181
2-183
www.3ds.com/tosca
Version 8.1.0 Rev. 1 - 05.2014
5.3 Design Area. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-186

5.3.1 Design variables
2-186
5.3.1.1 Results from previous runs as initial material distribution2-188
5.3.2 Manufacturing conditions and geometrical restrictions
2-189
5.3.2.1 Frozen areas
2-190
5.3.2.2 Prevention of undercuts in the model
2-192
5.3.2.3 Tightness constraint for the resulting structure
2-199
5.3.2.4 Stamping restriction
2-203
5.3.2.5 Minimum truss thickness (minimum member size)
2-203
5.3.2.6 Maximum truss thickness (maximum member size)
2-207
5.3.2.7 Symmetry conditions
2-210
5.3.2.8 Combination of manufacturing restrictions
2-215
5.3.2.9 Tips on defining restrictions with Tosca Structure.gui 2-216
5.4 Objective Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-217

5.4.1 Overview
5.4.2 Minimization or maximization of an objective
5.4.3 Multidisciplinary objective (minmax formulation)
2-217
2-217
2-219
5.5 Constraints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-220

5.5.1 Multiple material constraints and constitutive laws
2-223
0 - xv
SIMULIA
Tosca Structure
5.6 Typical Tasks for Static Analysis . . . . . . . . . . . . . . . . . . . . . . . . . 2-226

5.6.1
5.6.2
5.6.3
5.6.4
5.6.5
5.6.6
5.6.7
Minimizing compliance under volume constraint

Minimizing displacement/rotation under volume constraint
Constraint for difference between two displacements
Minimization of a reaction or internal force
Minimization of the volume under displacement constraint
Minimize the maximum stress with volume constraint
Minimize the material volume with stress constraint
2-226
2-228
2-235
2-240
2-250
2-254
2-256
5.7 Typical Optimization Tasks for Modal Analysis . . . . . . . . . . . . . . 2-257

5.7.1
5.7.2
5.7.3
5.7.4
Maximization of the first eigenfrequencies

Maximizing the eigenfrequency of a certain eigenmode
Maximization of the band gap
Constraining an eigenfrequency
2-258
2-262
2-267
2-270
5.8 Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-273

5.8.1 Parameters for standard linear static topology optimization
5.8.1.1 Increments of volume modification (SPEED)
5.8.1.2 Volume reduction in first iteration (START_DELETE)
5.8.1.3 Tips on speed control
5.8.1.4 Relation between relative density and stiffness
5.8.2 Settings for the general sensitivity based optimization
5.8.2.2 Initial values of density
5.8.2.3 Removing soft elements for increasing performance
5.8.2.4 Limits for design variables and changes
5.8.2.5 Update strategy of the method of moving asymptotes
5.8.2.6 Settings of the mesh filter
5.8.2.7 FILTER_TYPE
5.8.2.8 Material interpolation
2-273
2-273
2-274
2-274
2-274
2-276
2-276
2-278
2-279
2-285
2-286
2-287
2-288
2-289
5.9.1 Convergence Criteria

5.9.1.1 Stop criterion: change in objective function
5.9.1.2 Stop criterion: change in element densities
5.9.1.3 Start iteration for convergence check
5.9.2 Global Stop Criterion (Number of iterations)
2-292
2-293
2-293
2-294
2-294
5.10 References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-295
Shape Optimization
2-297
6.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-297

6.1.1 Theoretical background
2-298
6.2 The Optimization Task . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-298

2-298
6.3 Design Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-301

0 - xvi
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Version
Version
8.1.0 8.1.0
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- 05.2014
1 - 05.2014
5.9 Stop Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-292
www.3ds.com/tosca
Version 8.1.0 Rev. 1 - 05.2014
SIMULIA
Tosca Structure
6.3.1 Design variables (DV_SHAPE)

2-302
6.3.2 Mesh smoothing (MESH_SMOOTH)
2-305
6.3.2.1 Element group for mesh smoothing
2-306
6.3.2.2 Fixation of free surface nodes (FREE_SF)
2-309
6.3.2.3 Fixation of the MESH_SMOOTH area boundary
2-311
6.3.2.4 Automatic MESH_SMOOTH area (MS_LAYER)
2-311
6.3.2.5 Convergence of the smoothed mesh (LEVEL_CONV) 2-312
6.3.2.6 Enforcing restrictions (LEVEL_DVCON)
2-313
6.3.2.7 Quality control and improvement (LEVEL_QUAL)
2-313
6.3.2.8 Quality criteria of the solver (SOLVER_CHECK)
2-316
6.3.2.9 Correction of distorted elements (CORRECT_ELEMENTS) 2317
6.3.2.10 Mesh smooth strategy (STRATEGY)
2-318
6.3.2.11 Definition in Tosca ANSA environment
2-319
6.3.3 Restrictions (DVCON_SHAPE)
2-320
6.3.3.1 Node group for design variable constraints
2-322
6.3.3.2 Restricting the amount of displacement
2-323
6.3.3.3 Minimum or maximum member size
2-324
6.3.3.4 Displacement check against solids (CHECK_SOLID) 2-326
6.3.3.5 Penetration check (CHECK_ELGR, PENETRATION_CHECK)
2-328
6.3.3.6 Restricting displacement directions (CHECK_BC, CHECK_DOF)
2-329
6.3.3.7 Restricting displacement to a slide surface
2-330
6.3.3.8 Assigning link/coupling conditions (CHECK_LINK)
2-333
2-334
6.3.3.10 Definition in Tosca Structure.gui
2-334
6.3.3.11 Command syntax
2-334
6.3.4 Link and coupling conditions (LINK_SHAPE)
2-336
6.3.4.1 Determining the master node (MASTER)
2-338
6.3.4.2 Displacement of the client nodes (CLIENT)
2-340
6.3.4.3 Plane symmetry (PLANE_SYM)
2-342
6.3.4.4 Plane symmetry for non-symmetric meshes
(SURF_PLANE_SYM)
2-343
6.3.4.5 Cyclic symmetry for non-symmetric meshes
(SURF_CYCLIC_SYM)
2-344
6.3.4.6 Cyclic-plane symmetry combination
(SURF_CYCLIC_PLANE_SYM)
2-345
6.3.4.7 Point symmetry (POINT_SYM)
2-347
6.3.4.8 Rotational symmetry (ROTATION_SYM)
2-348
6.3.4.9 Coupling displacement coordinates (VECTOR)
2-349
6.3.4.10 Coupling displacement direction (DIRECTION)
2-350
6.3.4.11 Coupling amount of displacement (LENGTH)
2-351
6.3.4.12 Coupling coordinates in the FE displacement coordinate system
(DISP_CS)
2-352
6.3.4.13 Stampable surface (SURF_STAMP)
2-352
0 - xvii
SIMULIA
Tosca Structure
6.3.4.14 Turnable surface (SURF_TURN)

6.3.4.15 Drillable surface (SURF_DRILL)
6.3.4.16 Demoldable surface (SURF_DEMOLD)
6.3.4.17 Command examples
2-353
2-354
2-354
2-357
6.4 Objective Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-358

6.4.1 Overview
6.4.2 Reference stress
6.4.3 Objective function terms
2-358
2-359
2-360
6.5 Constraints. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-362

6.5.1 Volume constraint
6.5.2 Weight constraint
2-362
2-364
6.6 Typical Optimization Tasks for Static Analysis . . . . . . . . . . . . . . 2-364

6.6.1 Minimization of maximum equivalent stress
6.6.2 Notch optimization with fixed reference value
6.6.3 Notch relief with variable reference value
2-364
2-367
2-369
6.7 Advanced Tosca Structure.shape Optimizations . . . . . . . . . . . . . 2-371

6.7.1 Highly nonlinear shape optimization
6.7.2 Minimization of contact pressure
2-371
2-373
6.8 Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-376

6.8.1
6.8.2
6.8.3
6.8.4
6.8.5
6.8.6
Scale of displacement (SCALE)

Treatment of the midside nodes (MID_NODES)
Curvature based modification of optimization displacements
Filter function for the optimization displacements (FILTER)
Updating the optimization displacement vectors (VECTOR)
Control of the amount of optimization displacement (DISP)
2-377
2-378
2-379
2-380
2-382
2-383
6.9.1
6.9.2
6.9.3
6.9.4
General
Test run (CHECK_INPUTS) in Tosca ANSA environment
Test run in Tosca Structure.gui
Command syntax
2-383
2-384
2-385
2-385
6.10 Morphing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-387

6.10.1 General
6.10.1.1 Morphing areas
6.10.1.2 Morphing displacement
6.10.1.3 Morphing task
6.10.2 Morphing in Tosca ANSA environment
6.10.3 Morphing in Tosca Structure.gui
6.10.4 Command Syntax
6.10.6 Evaluation
2-388
2-389
2-392
2-393
2-395
2-396
2-396
2-398
2-399
6.11 Stop Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-399

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- 05.2014
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6.9 Check run (TEST_SHAPE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-383
SIMULIA
Tosca Structure
6.11.1
6.11.2
6.11.3
6.11.4
6.11.5
Global Stop Condition

Local Stop Condition
Stop Condition in Tosca ANSA environment
Stop Condition in Tosca Structure.gui
Examples
2-400
2-400
2-401
2-402
2-403
6.12 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-404
Bead Optimization
2-405
7.1 General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-405

7.2 The Optimization Task. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-406
7.2.1
7.2.2
7.2.3
7.2.4
Controller based bead optimization

Sensitivity based bead optimization
Differences between bead optimization algorithms
How to create the optimization model
2-407
2-408
2-408
2-413
7.3 Design Area. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-416

7.3.1 Design variables (DV_BEAD)
2-416
7.3.2 Restrictions (DVCON_BEAD)
2-418
7.3.2.1 General
2-418
7.3.2.2 Restricting the absolute displacement
2-420
7.3.2.3 Displacement check against solids (CHECK_SOLID) 2-422
7.3.2.4 Displacement check against elements (CHECK_ELGR)2-423
7.3.2.5 Restricting the direction of displacement
2-424
7.3.2.6 Symmetry conditions (CHECK_LINK)
2-425
7.3.2.7 Example LINK_BEAD
2-426
7.4 Objective Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-428

7.4.1 Overview
2-429
www.3ds.com/tosca
Version 8.1.0 Rev. 1 - 05.2014
7.5 Typical Optimization Tasks for Linear Static Analysis . . . . . . . . . 2-430

7.5.1 Maximize stiffness with controller based algorithm
2-430
7.5.1.1 Combining static load cases (controller based algorithm)2-431
7.5.2 Linear static sensitivity based optimization
2-432
7.5.2.1 Minimize compliance
2-432

7.6.1 Maximization of the lowest natural frequency (controller)
7.6.2 Sensitivity based eigenvalue optimization
7.6.2.1 Maximize the first natural mode (first eigenvalue)
7.6.2.2 Maximize a range of modes
7.6.2.3 Maximize a certain mode
7.6.2.4 Adjust eigenvalue
7.6.2.5 Maximize band gaps
2-433
2-434
2-434
2-435
2-437
2-438
2-439
7.7 Constraints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-440

7.8 Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-441
0 - xix
SIMULIA
Tosca Structure
7.8.1 Parameters for controller based bead optimization

2-444
7.8.1.1 Scaling of displacements (SCALE)
2-445
7.8.1.2 Update of optimization displacement vectors (VECTOR)2-445
7.8.1.3 Bead width (BEAD_WIDTH)
2-445
7.8.1.4 Number of iterations (BEAD_ITER)
2-446
7.8.1.5 Penalty conditions (BEAD_MIN_STRESS and
BEAD_MAX_MEMBRANE)
2-446
7.8.1.6 Mesh enhancing parameters
(CURV_SMOOTH and BEAD_NODE_SMOOTH)
2-448
7.8.2 Optimization parameters (sensitivity based bead optimization) 2-449
7.8.2.1 Filtering (FILTER_RADIUS)
2-449
7.8.2.2 MMA parameters
2-449
7.8.2.3 Optimization parameters for mode tracking
2-450
7.8.2.4 Optimization parameters for frequency response
2-450
7.9
7.10
7.11
7.12
Check run (TEST_BEAD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Stop Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Remarks Using Sensitivity Based Algorithm . . . . . . . . . .
References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sizing Optimization
2-451
2-455
2-456
2-458
2-459
8.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-459

8.2 The Optimization Task . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-460
2-461
8.3.1 Design variables

8.3.2 Manufacturing conditions and geometrical restrictions
8.3.2.2 Shell thickness bounds
8.3.2.3 Cluster groups
8.3.2.4 Width control (minimum cluster width)
8.3.2.5 Definition of symmetry conditions
8.3.2.6 Tips on defining restrictions
2-463
2-465
2-466
2-467
2-469
2-471
2-473
2-476
8.4 Objective Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-477

8.4.1 Overview
8.4.2 Minimization or maximization of an objective
8.4.3 Multidisciplinary objective (minmax formulation)
2-477
2-477
2-479
8.5 Constraints. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-481

8.6 Typical Tasks for Static Analysis . . . . . . . . . . . . . . . . . . . . . . . . . 2-483
8.6.1 Minimizing mass with stiffness restrictionst
2-483

8.7.1 Maximization of the first eigenfrequencies
8.7.2 Maximizing the torsional modal eigenfrequency
0 - xx
2-487
2-491
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8.1.0 8.1.0
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- 05.2014
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8.3 Design Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-463
SIMULIA
Tosca Structure
8.8 Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-495

8.8.1
8.8.2
8.8.3
8.8.4
Mode tracking
Update strategy of the method of moving asymptotes
Settings of the mesh filter
FILTER_TYPE
2-495
2-497
2-498
2-499
8.9 Stop Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-499

8.9.1 Convergence Criteria
8.9.1.2 Stop criterion: change in element thickness
8.9.2 Global Stop Criterion (Number of iterations)
2-499
2-500
2-500
2-501
2-501
2-505
9.1 Tosca Structure.smooth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-505
www.3ds.com/tosca
Version 8.1.0 Rev. 1 - 05.2014
9.1.1 Starting Tosca Structure.smooth (Tosca ANSA environment)

9.1.2 Starting Tosca Structure.smooth (Tosca Structure.gui)
9.1.3 Starting Tosca Structure.smooth (Tosca Extension for ANSYS/
Workbench)2-508
9.1.4 Defining the parameters for Tosca Structure.smooth
9.1.5 Processing results of topology optimization
9.1.6 Processing results from shape or bead optimization
9.1.7 Isosurface and smoothing parameters
9.1.8 Reduction parameters
9.1.9 Output parameters
9.1.10 Slices through 3D models and border of 2D models
9.1.11 Processing of groups
9.1.12 Volume control
9.1.13 Correction of defects in topology optimization results
2-506
2-507
2-510
2-516
2-519
2-520
2-525
2-529
2-533
2-536
2-538
2-540
2-542
9.2 Validation Run in Tosca ANSA environment . . . . . . . . . . . . . . . . 2-544

9.2.1
9.2.2
9.2.3
9.2.4
BATCH_RECONSTRUCT and MANUAL_RECONSTRUCT

SOLID_MESH
Generating the model for validation run
Starting the validation run
2-545
2-549
2-549
2-552
9.3 Validation Run in Tosca Extension for ANSYS/Workbench . . . . 2-553

9.4 Workarounds Using Other Environments . . . . . . . . . . . . . . . . . . 2-561
9.5 Result Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-562
9.5.1 Result transfer to CATIA RSO module
9.5.2 Result transfer to NX
2-562
2-562
0 - xxi
SIMULIA
Tosca Structure
10 Postprocessing of Optimization Results
2-565
10.1 Generation of Postprocessing Data . . . . . . . . . . . . . . . . . . . . . . . 2-565

10.1.1 Tosca Structure.report in Tosca ANSA environment
2-566
10.1.2 Tosca Structure.report in Tosca Structure.gui
2-568
10.1.3 Tosca Structure.report in Tosca Extension for ANSYS/Workbench 2571
10.1.4 Starting Tosca Structure.report in Commandline
2-573
10.1.5 Standard Reports
2-574
10.1.5.1 Tosca Structure.topology results
2-574
10.1.5.2 Tosca Structure.shape results
2-575
10.1.5.3 Tosca Structure.bead results
2-577
10.1.5.4 Tosca Structure.sizing results
2-577
10.1.5.5 Morphing results
2-578
10.1.5.6 Sensitivity plots
2-579
10.2 Tosca Structure.view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-580

10.2.1
10.2.2
10.2.3
10.2.4
10.2.5
10.2.6
10.2.7
10.2.8
10.2.9
Starting and using Tosca Structure.view

User Interface Tosca Structure.view
Model and group visualization
Visualization of topology optimization results
Visualization of shape optimization results
Visualization of bead optimization results
Visualization of sizing results
Visualization of morphing results
VTFX PlugIn for Office applications and Webbrowser
10.2.9.1 Prerequisites and installation
10.2.9.2 Embedding the PlugIn into PowerPoint
10.2.10Integrating VTFX files in internet pages
10.2.11Limitations of the PlugIn
2-580
2-582
2-588
2-591
2-592
2-594
2-595
2-596
2-596
2-596
2-597
2-599
2-600
10.3.1 Optimization result view options

10.3.2 Iteration Animation
10.3.3 Result files
2-600
2-602
2-603
10.4 Tosca Structure Report Builder. . . . . . . . . . . . . . . . . . . . . . . . . . 2-603

10.4.1 Capturing Data for the Report
10.4.2 Report generation
10.4.3 Add-Ins for Tosca Structure Report Builder
10.4.3.1 Add-in for MS Word
10.4.3.2 Add-in for MS Powerpoint
10.4.3.3 Templates
2-604
2-606
2-607
2-608
2-609
2-610
10.5 Toolbox for Postprocessing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-611

10.5.1 Numerical variables (VARIABLE)
10.5.2 Logical variables (LOGICAL)
0 - xxii
2-611
2-612
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- 05.2014
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10.3 Postprocessing with Tosca Extension for ANSYS/Workbench . . 2-600
SIMULIA
Tosca Structure
10.5.3 Stop conditions (STOP)

10.5.4 User defined output files (USER_FILE)
10.5.4.1 Tabular output
10.5.4.2 Modification file for CATIA RSO module
10.5.4.3 Modification file for NX
10.5.4.4 ONF output
11 Solver Specific Features
2-613
2-615
2-616
2-616
2-617
2-618
2-619
11.1 Abaqus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-622

11.1.1
11.1.2
11.1.3
11.1.4
11.1.5
11.1.6
11.1.7
11.1.8
11.1.9
Files and formats

Supported element types
Node and Element Groups
Coordinate Systems
Materials and Properties
Analysis Types
Loads and Boundary Conditions
Remarks for sensitivity based optimizations
Nonsupported Features (Cards/Keywords...)
2-622
2-624
2-630
2-632
2-632
2-635
2-637
2-638
2-639
11.2 ANSYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-639

11.2.1
11.2.2
11.2.3
11.2.4
11.2.5
11.2.6
11.2.7
11.2.8
Files and Formats

Supported Element Types
Node and Element Groups
Coordinate Systems
Analysis Types
2-640
2-642
2-644
2-645
2-645
2-647
2-649
2-649
www.3ds.com/tosca
Version 8.1.0 Rev. 1 - 05.2014
11.3 Marc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-652

11.3.1
11.3.2
11.3.3
11.3.4
11.3.5
11.3.6
11.3.7
11.3.8
Files and Formats

Supported Element Types
Coordinate Systems
Analysis Types
Frequency spectrum
2-652
2-653
2-657
2-657
2-657
2-658
2-658
2-659
11.4 MSC Nastran . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-659

11.4.1 Files and Formats
11.4.2 Supported Element Types
11.4.3 Coordinate Systems
2-659
2-660
2-662
0 - xxiii
SIMULIA
Tosca Structure
11.4.4
11.4.5
11.4.6
11.4.7
11.4.8

Analysis Types
Frequency spectrum
2-663
2-663
2-666
2-667
2-668
11.5 PERMAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-668

11.5.3 Node and Element Groups
11.5.5 Materials and Properties
11.5.6 Analysis Types
11.5.7 Loads and Boundary Conditions
11.5.8 Remarks for sensitivity based optimizations
11.5.9 PERMAS Configuration for use with Tosca Structure
11.5.10Nonsupported Features (Cards/Keywords...)
11.5.11Frequency spectrum
2-669
2-670
2-673
2-674
2-674
2-674
2-675
2-676
2-676
2-676
2-677
11.6.1 Supported durability solvers

11.6.2 Workflow
11.6.2.1 Preprocessing
11.6.2.2 Optimization loop
11.6.2.4 Start of the optimization
11.6.2.5 Postprocessing
11.6.3 FEMFAT
11.6.3.1 General
11.6.4 fe-safe
11.6.5 ONF
11.6.5.1 General
12 Tosca Structure Control
2-677
2-678
2-678
2-679
2-679
2-680
2-682
2-682
2-682
2-685
2-687
2-687
2-689
12.1 Program Sequence and Data Flow of Tosca Structure . . . . . . . . 2-689

12.2 Starting Tosca Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-691
12.2.1 List of command line options
12.2.1.1 Deprecated command line options
12.2.2 General
12.2.3 Logging
12.2.3.1 TOSCA.OUT
12.2.3.2 Special logfiles
12.2.3.3 Viewing TOSCA.OUT using Tosca ANSA environment
12.2.3.4 Viewing TOSCA.OUT using Tosca Structure.gui
0 - xxiv
2-691
2-694
2-695
2-695
2-696
2-697
2-698
2-699
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
11.6 Shape Optimization Based on a Durability Analysis . . . . . . . . . . 2-677
SIMULIA
Tosca Structure
12.2.3.5 Viewing TOSCA.OUT using Tosca Extension for ANSYS/WB2700

12.2.3.6 Changing logging using the command shell
2-701
12.2.3.7 Tips and tricks viewing TOSCA.OUT
2-701
12.2.4 Solver interface
2-703
12.2.5 Durability interface
2-703
12.2.6 Tosca Structure.report run
2-703
12.2.6.1 Configuring default Tosca Structure.report run
2-704
12.2.7 Automatic Tosca Structure.smooth run
2-704
12.2.7.1 Configuring default Tosca Structure.smooth run
2-705
12.2.8 Testing the optimization process
2-705
12.2.8.1 Test level 1
2-705
2-706
2-707
2-708
12.2.9 Restart modes
2-709
12.2.9.1 Requirements for a restart
2-709
12.2.9.2 Restart process
2-709
12.2.10Online help
2-710
12.2.11Sequential temperature analysis
2-711
12.2.12Arbitrary analysis sequence
2-711
12.3 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-712

12.3.1 Configuration files
12.3.2 Environment variables
2-712
2-714
12.4 Script Entry Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-715

12.4.1 Adding files to the working directory
2-719
12.5 Optimization Preprocessing (TOSCA_PREP) . . . . . . . . . . . . . . . 2-719
www.3ds.com/tosca
Version 8.1.0 Rev. 1 - 05.2014
12.5.1 TOSCA_PREP
12.5.2 Files after preprocessing (TOSCA_PREP)
2-719
2-720
12.6 Solver Run. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-720

12.7 Optimization Module (TOSCA_OPT). . . . . . . . . . . . . . . . . . . . . . 2-720
12.7.1 RES2VTM
12.7.2 TOSCA_OPT
12.7.3 FEM_MODIF
2-721
2-721
2-721
12.8 Completion of the Optimization Process . . . . . . . . . . . . . . . . . . . 2-721

12.8.1 Directories and files after the completion of optimization
13 Troubleshooting
2-721
2-723
13.1 Errors During Optimization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-723

13.2 Determining the Point of Program Termination . . . . . . . . . . . . . . 2-724
0 - xxv
SIMULIA
Tosca Structure
13.3 Program Abort at the Start of the Optimization . . . . . . . . . . . . . . 2-728

13.3.1 Check of program installation and paths
13.3.2 Analysis files not found
2-728
2-730
13.4 Program Abort in TOSCA_PREP. . . . . . . . . . . . . . . . . . . . . . . . . 2-731

13.5 Program Abort During FE Analysis . . . . . . . . . . . . . . . . . . . . . . . 2-733
13.5.1 Error in the analysis model
13.5.2 Error with the solver license
13.5.3 Incorrect solver settings
2-733
2-735
2-735
13.6 Program Abort in the Optimization Module . . . . . . . . . . . . . . . . . 2-735

13.6.1 FE model of the next iteration is not calculated
13.6.2 Insufficient disk space
2-735
2-737
13.7 Tosca ANSA environment Specific Tips . . . . . . . . . . . . . . . . . . . 2-737
14 Appendix
2-741
14.1 Additional Tosca Structure optimization modules . . . . . . . . . . . . 2-741

14.1.1 Tosca Structure.durability
14.1.2 Tosca Structure.nonlinear
14.1.3 Tosca Structure.morph
2-741
2-741
2-742
14.2 Limits of Tosca Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-743

14.3 Predefined Output Macros . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-744
Volume III
CONFIG
CONSTRAINT
CONTOURPLOT
CS_DEF
DRESP
DVCON_AUTO_SHAPE
DVCON_BEAD
DVCON_SHAPE
DVCON_SIZING
DVCON_TOPO
DV_BEAD
DV_SHAPE
DV_SIZING
0 - xxvi
3-3
3-24
3-26
3-29
3-31
3-52
3-53
3-55
3-58
3-61
3-67
3-68
3-69
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Commands Manual
DV_TOPO
FEM_INPUT
GROUP_AUTO_DEF
GROUP_DEF
GROUP_IMPORT
INCLUDE
LINK_BEAD
LINK_SHAPE
LINK_SIZING
LINK_TOPO
LIST
LIST, info
LOGICAL
MESH_SMOOTH
MORPH
MORPH_AREA
OBJ_FUNC
OPTIMIZE
OPTIONS
OPT_PARAM
REPORT
SELECT
SF_IDENT
SMOOTH
SOLID
STOP
TEST_BEAD
TEST_SHAPE
USER_FILE
VARIABLE
3-70
3-72
3-75
3-78
3-81
3-82
3-83
3-84
3-95
3-97
3-100
3-106
3-107
3-109
3-115
3-117
3-118
3-120
3-123
3-129
3-143
3-146
3-153
3-154
3-162
3-163
3-166
3-168
3-170
3-178
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SIMULIA
Tosca Structure
0 - xxvii
SIMULIA
Tosca Structure
Volume IV
Examples Manual
Preface
4-3
4-5
1.1 Example overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

1.2 Airbeam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
1.2.1
1.2.2
1.2.3
1.2.4
1.2.5
1.2.6
Model
Optimization Task
Procedure: Summary
Procedure in Detail: Tosca ANSA environment
Procedure in Detail: Tosca Structure.gui
Results
4-6
4-6
4-7
4-7
4-7
4-10
1.3 Picker_arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

1.3.1
1.3.2
1.3.3
1.3.4
1.3.5
1.3.6
Model
Optimization Task
Procedure: Summary
Optimization results
4-11
4-11
4-11
4-12
4-13
4-15
1.4 Crane Hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

1.4.1 Procedure: Summary
1.4.2 Procedure in Detail: Tosca ANSA environment
1.4.3 Procedure in Detail: Tosca Structure.gui
4-18
4-18
4-19

4-22
4-22
4-23
1.6 Minimum und Maximum Member Size (plate_min_max) . . . . . . . . 4-26

Sensitivity Based Topology Optimization
4-26
4-27
4-28
4-31
2.1 Example overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31

2.2 Crane hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
2.2.2 Procedure in detail: Tosca ANSA environment
0 - xxviii
4-34
4-35
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Version
Version
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Rev. 1Rev.
- 05.2014
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1.5 Beam with Symmetry Restrictions (airbeam_sym) . . . . . . . . . . . . 4-21
SIMULIA
Tosca Structure
2.2.3 Procedure in detail: Tosca Structure.gui

2.2.4 Optimization results
4-37
4-40
2.3 Symmetric Plate (plate_sym_freq) . . . . . . . . . . . . . . . . . . . . . . . . 4-44

2.3.1
2.3.2
2.3.3
2.3.4
Procedure: Summary
Procedure in detail: Tosca ANSA environment
Procedure in detail: Tosca Structure.gui
4-45
4-45
4-46
4-49
2.4 Bonnet with Minmax Formulation . . . . . . . . . . . . . . . . . . . . . . . . . 4-50

2.4.1
2.4.2
2.4.3
2.4.4
Procedure: Summary
4-50
4-51
4-51
4-53
2.5 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-56

2.5.1
2.5.2
2.5.3
2.5.4
2.5.5
The model
Optimization task
Optimization task definition in Tosca ANSA environment
Optimization task definition in Tosca Structure.gui
Result discussion and validation run
4-56
4-57
4-57
4-59
4-62
2.6 Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-64

4-66
4-66
4-67
2.7 Internal Forces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-68

2.7.1
2.7.2
2.7.3
2.7.4
Procedure: Summary
Optimization results when considering force constraints
4-70
4-71
4-72
4-77
www.3ds.com/tosca
Version 8.1.0 Rev. 1 - 05.2014
2.8 Temperature Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-78

2.8.1
2.8.2
2.8.3
2.8.4
Procedure: Summary
4-79
4-79
4-80
4-83
2.9 Stress Constraint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-84

2.9.1
2.9.2
2.9.3
2.9.4
Procedure: Summary
4-84
4-85
4-86
4-88
0 - xxix
SIMULIA
Tosca Structure
Shape Optimization
4-89
3.1 Example overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-89

3.2 Holeplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-91
3.2.1
3.2.2
3.2.3
3.2.4
Procedure: Summary
4-92
4-92
4-93
4-94
3.3 Two Hole (Relief Notch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-94

3.3.1
3.3.2
3.3.3
3.3.4
Procedure: Summary
4-95
4-96
4-96
4-97
3.4 Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-98

3.4.1
3.4.2
3.4.3
3.4.4
Procedure: Summary
4-98
4-99
4-99
4-103
3.5 Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-103

3.5.1
3.5.2
3.5.3
3.5.4
Procedure: Summary
4-104
4-104
4-105
4-108
3.6 Carrier_stamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-108

Procedure: Summary
Optimization result
4-110
4-111
4-111
4-112
3.7 Shaft_turn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-112

4-114
4-115
4-116
3.8 Shaft_drill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-117

4-118
4-119
4-120
3.9 Clip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-122

3.9.1
3.9.2
3.9.3
3.9.4
0 - xxx
Procedure: Summary
4-123
4-124
4-124
4-127
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8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
3.6.1
3.6.2
3.6.3
3.6.4
SIMULIA
Tosca Structure
3.10 Rim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-127

3.10.1
3.10.2
3.10.3
3.10.4
3.10.5
The model
Optimization task
Result discussion
4-128
4-128
4-128
4-132
4-134
3.11 Threehole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-135

3.11.1
3.11.2
3.11.3
3.11.4
Procedure: Summary
4-136
4-136
4-136
4-137
3.12 Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-138

3.12.1
3.12.2
3.12.3
3.12.4
3.12.5
The model
Procedure: Summary
Bead Optimization
4-139
4-140
4-140
4-141
4-143
4-147
4.1 Example overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-147

4.2 Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-148
4-149
4-149
4-150
4.3 Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-152
www.3ds.com/tosca
Version 8.1.0 Rev. 1 - 05.2014
4.3.1
4.3.2
4.3.3
4.3.4
Procedure: Summary
4-153
4-153
4-154
4-157
4.4 Hood_eig and Hood_eig_sens . . . . . . . . . . . . . . . . . . . . . . . . . . 4-157

4.4.1
4.4.2
4.4.3
4.4.4
4.5
Eigenfrequency optimization with Tosca Structure.bead

Eigenfrequency optimization using controller algorithm
Eigenfrequency optimization using sensitivity algorithm
Discussion of differences
4-157
4-158
4-160
4-162
Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-164
Sizing
4-169
5.1 Examples overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-169

5.2 Beam2D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-170
0 - xxxi
SIMULIA
Tosca Structure
5.2.1
5.2.2
5.2.3
5.2.4
5.2.5
5.2.6
Model
Optimization Task
Procedure: Summary
Results
4-170
4-171
4-171
4-171
4-173
4-176
5.3 Beam with Symmetry Restrictions (beam_sym) . . . . . . . . . . . . . 4-177

5.3.1
5.3.2
5.3.3
5.3.4
Procedure: Summary
Shape Optimization in
Combination with Durability Analysis
4-178
4-178
4-179
4-181
4-183
6.1 Holeplate_dam: Femfat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-184

6.2 Holeplate_dam: fe-safe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-186
Morphing
4-189
7.1 Crane hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-189

Procedure: Summary
4-191
4-191
4-198
4-200
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- 05.2014
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7.1.1
7.1.2
7.1.3
7.1.4
0 - xxxii
SIMULIA
Tosca Structure
General Remarks
General Remarks
Documentation Manuals
Tosca Structure documentation is contained in the following manuals:
Getting Started with Tosca Structure (volume 1)
User Manual (volume 2)
Commands Manual (volume 3)
Examples Manual (volume 4)
Installation Manual
Description of Manuals
A short description and comment of the content of each manual is given
below:
Getting Started Manual (volume 1)
This manual gives a compact introduction to Tosca Structure and the work
with the frontends Tosca ANSA environment, Tosca Structure.gui and Tosca
Extension for ANSYS/Workbench. The set-up, running and evalution of typical optimization tasks for each type of optimization are explained in detail.
Thus in particular new users are able to find an access to Tosca Structure
quickly and efficiently whereas experienced users can look up detailed
descriptions of specific work steps.
www.3ds.com/tosca
Version 8.1.0 Rev. 1 - 05.2014
User Manual (volume 2)

The main usage of the Tosca Structure functionalities are explained here
along with entry of the control instructions required to generate an optimization model. A description of the individual command syntax is not given, only
how they work and interact with each other. The Commands Manual lists a
full description of the command syntax.
The User Manual is divided into various parts: firstly, the user receives an
overview of the program procedures and the program modules. Requirements for optimizable finite element models are described.
Next a detailed explanation of the functionalities for topology, shape, bead
and sizing optimization is given. Visualization and postprocessing possibilities
are also shown. Finally, a description of additional tools and examples of control records for topology, shape, bead and sizing optimization is presented.
0-i
SIMULIA
Tosca Structure
Commands Manual (volume 3)

The Commands Manual is the lexicon of Tosca Structure.topology, Tosca
Structure.shape, Tosca Structure.bead and Tosca Structure.sizing. The lexicon contains a complete description of all commands used.
Each command and its syntax is listed in alphabetical order with an explanation. Cross-references on how to use other commands are also listed here.
Most commands are listed with an entry example.
How to use the main functionalities is explained in the Users Manual.
Examples Manual (volume 4)
The examples provided with the installation are described in more detail in
this manual. Not only does this aid in creating a better understanding of the
problems involved in finding a solution, but also gives an understanding of the
obtained solutions to the problems.
Reference to Spelling Used in the Manuals

To differentiate between command names, parameters, fixed and open
parameter values, several different styles of fonts are used as highlighted in
the examples below:
Command names and parameter labels are always written in capital letters.
Fixed options used for switching parameters are written in capital letters
and are also emphasized where necessary.
Names selected by the user are written in small letters.
Names which are addressed in detail in the text or which have a special
meaning in context are written in bold letters.
Chosen values are marked in square brackets.
Tosca ANSA environment buttons and functions are denoted in Courier
New.
Tosca Structure commands and parameters are either linked to the corresponding commands manual entry or denoted in Courier New.
If an action (normally right mouse click) or choice is required, brackets []
are used.
0 - ii
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Names which refer to a predefined ID are written in small, cursive letters.
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Tosca Structure
General Remarks
Examples for Tosca Structure commands:

GROUP_DEF
ID_NAME
TYPE
FORMAT
=design_elements--> user name

=ELEM--> given option
=SELECTED--> given option
END_
DV_TOPO
ID_NAME
EL_GROUP
= dv_design_elements--> user name

= design_elements--> reference to a group
END_
STOP
ID_NAME
ITER_MAX
= stop_condition--> user name

= <value>--> chosen value
END_
Examples for Tosca ANSA environment functions:

PRE-PROCESSING| SHAPE_OPTIMIZATION_CONTROLLER |
DESIGN_AREA | [EDIT]
In the task manager choose (evtl. open / expand) Folder PRE-PROCESSING,
subfolder SHAPE_OPTIMIZATION_CONTROLLER, subfolder DESIGN_AREA,
right mouse click and choose EDIT.
The entire content of the documentation is available as context sensitive

online help directly accessible from Tosca Structure.gui or the windows start
menu.
Further, a printable pdf document can be found under the filename:
$tosca/docu/tosca_structure_v810.pdf
The online documentation supports hypertext functions, therefore the navigation through the various manuals is easy and fast.
Acrobat Reader from Adobe or another pdf reader is needed to visualize the
pdf document. The reader is available at the internet address http://
www.adobe.com.
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Documentation and Introduction to Optimization
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Volume I
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SIMULIA Tosca Structure 8.1.0
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SIMULIA
Tosca Structure
Preface
Preface
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This manual demonstrates how to work with the structural optimization package Tosca Structure. In the chapters chapter 1 Getting Started with Tosca
ANSA environment, chapter 2 Getting Started with Tosca Structure.gui and
chapter 3 Getting Started with Tosca Extension for ANSYS/WB, it is explained
how these three different front ends can be used in order to define, start and
process the optimization task. The following tutorials demonstrate for all front
ends how to set up, run and evaluate typical topology, shape, bead and sizing optimization tasks. The step by step explanation contained in the tutorials
enables a user inexperienced with Tosca Structure to set up a simple optimization task. No emphasis has been placed on details about the single optimization settings. These details are covered in vol.2 User Manual and vol.3
Commands Manual.
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Tosca Structure
Getting Started with Tosca ANSA

environment
Tosca ANSA environment is used in order to define an optimization task for
Tosca Structure based on an existing finite element input deck. The finite element model, including the loads and boundary conditions, is loaded into
Tosca ANSA environment, so that the user is able to examine the model in
detail. Then, the optimization task is defined by the user step by step. The
geometric information represented in Tosca ANSA environment enables the
interactive group selection as well as other actions that facilitate the definition
of optimization task.
Then, the optimization in Tosca Structure is started from within Tosca ANSA
environment using the original finite element model and the optimization task
definition. The results of optimization are used in order to create a postprocessing model or a model for validation run; the processed optimization
results can be saved in a format suitable for CAD transfer.
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Please note:
The current version of Tosca ANSA environment does not yet support sizing
optimization.
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User Interface
1.1
User Interface
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The position of different toolbars is configurable. In order to show or hide a

specific toolbar or window, use the corresponding command in the menu
items Windows, Containers and Tools :
The most important toolbars and
windows are the following:
Modules Buttons: provides
the access to optimization task
related information defined
using Task Manager; it is
necessary to use this window for
several commands (e.g., definition of a new coordinate system)
that are not supported in Task
Manager.
General Buttons: manages
the representation of geometry,
including the visibility of
elements and nodes;
Ansa Info: window for
logging, warnings and errors;
Settings: configuration dialog;
Task Manager: represents

Tosca Structure tasks;
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Database: represents the

contents of the finite element
model in a structured form;
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User Interface
Certain windows and toolbars can also be shown or hidden using Windows
toolbar:
Task manager
Includes
Properties
Materials
Sets
Database
Mesh Parameters
1.1.1
General Buttons toolbar

The buttons on General Buttons toolbar define the visualization parameters and serve for the selection or deselection of geometric objects as well as
some other geometric operations. Each button corresponds to a command
with a certain name; this name is shown in the tool tip for the button.
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1.1.1.1 FOCUS panel

This panel represents the commands in TOPO>FOCUS group:
OR: select the elements that remain visible (hide
the remaining ones).
AND: select the elements, then their neighbors
will become visible.
NOT: select the elements to be hidden.
!NOT: select entities that will remain visible. The

selected entities temporary (during selection) are
excluded from the visible area and as soon as the
middle mouse is pressed (selections' termination)
they -and only them- remain visible (invert operation).
ALL: makes all geometric objects visible.
INVERT: shows hidden objects while hiding

shown objects.
LOCK: saves the current view so that ALL command returns to this view.
PEEL: hides one layer of outer elements.
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NEAR: Logical operation that brings to visible all

the nearby items of selected entities, according to
a specified tolerance value.
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User Interface
NEIGHB: makes one layer of neighbor elements

(or all connected elements) visible.
1.1.1.2 VISIBILITY panel

This panel represents the commands in TOPO>VISIB group:
WIRE: defines if the grid is to be shown; note that
the grid is hidden at some point when the model
is zoomed out.
SHADOW: defines if the shaded faces are to be
shown.
HIDDEN: an alternative to SHADOW: shows the
faces colored black.
FE-Mod.: makes the elements visible or hidden.
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GRIDs: makes the nodes visible or hidden.
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Draw Mode: defines how the model is to be colored: according to the type of geometric object
(ENT), property ID of elements (PID), material ID
of elements (MID) or another element-related
value.
Database and selection windows

Database window represents the
information from the finite element
model as well as the commands
defined in Task Manager (Tosca
Structure item). Next to some
items, there is a checkbox that
defines if the contents of the item
is shown or hidden. Double clicking an item in Database opens
the selection window (in the figure, the element selection window
is shown).
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User Interface
That allows the user to inspect the

single objects. While the selection
window is active, the corresponding objects can be selected by
clicking on the model; e.g., this is
a quick way to retrieve the ID of
an element or node. In this selection window, it is also possible to
edit, copy or delete selected
entries. Using Modify command
from the context menu, it is possible to set a certain property of all
selected items (e.g., PID for elements) to a chosen value.
The buttons of the selection window provide the following functionality:

sets the selection to the objects that were
selected previously;
sets the selection to the objects that were
selected next;
updates the list in the selection window;
turns the highlighting of selected objects on or off;
sets the active filter or opens the filter definition

window;
unsets the current filter.
defines the properties to be displayed in columns.
list of all action items
actual entity is highlighted and the only selectable
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the text field serves for the selection of objects by

their IDs, other properties (e.g. property ID) or
with the help of filters;
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1.1.3
Task Manager window

Task Manager represents the
topology optimization task and
allows the user to start the optimization in Tosca Structure as well
as to perform the actions that follow the optimization. The information is displayed in a tree form; the
user interacts with it by creating
new items and running the commands in context menu for specific items.
The marked button expands the tree making all items show. A new Tosca
Structure task is created by a command in Tasks | Tosca Structure task
| ... group that corresponds to the desired optimization type; this command produces a new top level item as well as the uninitialized children items
for each part of the process.
calls Update command for the current item (see
below);
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attempts to call Update commands for all items

and thus run all actions;
turns on or off the highlighting of the group associated with the active item.
The context menu for an item in Task Manager
(e.g., START_OPTIMIZATION | RUN as shown
in the figure) contains the following commands:
Edit: opens the dialog for editing the parameters
for the item or data associated with it.
Delete: removes the item and all its subitems.
Change: if the item is checked (as indicated in
the checkbox next to it), it gets unchecked so that
Update command can be applied to it again.
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User Interface
Update: for the items associated with some action (as in the example, with
the start of the optimization), this action is performed and the item is marked
as checked in case of success. Calling Update for an item automatically
invokes this command for all unchecked items that the current item depends
upon.
View: for the items associated with groups, the group is shown (View |
Show), hidden (View | Hide) or shown alone (View | Show Only).
Edit Comments: opens the window for editing the comments for the item.
Disable: marks the item as disabled, so that its name is shown struckthrough and all actions proceed as if the item were not present. A disabled
item is returned to normal state by Enable command in context menu.
Set Break: sets the breakpoint to the item, so that, once this item is
reached while calling Update for another item (or with "update all" button),
the user is given the choice to either stop the actions or continue.
For some items, the subitems can be created using New | ... command of
the context menu. All items can be renamed: to do this, click an already
selected item once and wait until its text becomes editable. Note that, in some
cases, the name of the item is important because it defines some file name
(or a part of it).
1.1.4
Input of an existing parameter file
All standard parameters are added to the task manager, advanced parameters will only appear in the database list.
Remarks
1. When importing an existing Tosca Structure parameter file, the output item
for the name of the parameter file and the job directory is named Output
by default and not automatically after the name of the imported parameter
file.
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In order to load an existing parameter file into Tosca ANSA environment,

select File | Input | Tosca Structure:
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2. In case the parameter file contains commands not recognized by Tosca

ANSA environment, e.g. CONFIG block, those commands are stored as
comments in the Tosca ANSA environment database in Output | Edit
Comments. The commands are automatically added to the parameter file
on output. If needed, the commands can be edited directly in Output |
Edit Comments.
1.1.5
Saving task and saving database

There are two possibilities to save: You can save the task only, or you save
the whole database
If you want to save the task only
press Tasks | Save Task in
Task Manager.
You save only the task settings,
not the model related content and
results. For example, if you did
the optimization of a model and
you want to smooth it another day,
it is not enough to save the task,
because you have to run the optimization step again.
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If you want to save the complete

database, which also includes the
task, press File | Save As.
The file size is much bigger than
that of the task, of course, but you
can access the model and all
existing results.
1.1.6
Highlighting
There are two possibilities of highlighting:
You can use the highlighting button or you can put a checkmark at several
groups in database window.
highlighting button: switch the highlighting on and
off
With the highlight button in the Task Manager you can, for example, check the
demolding direction or other task definitions: Mark the corresponding defini-
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User Interface
tion and switch the highlight on. Direction definitions are shown as arrows in
the graphic window and the design group is marked in color.
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Another important feature of highlighting is to visualize properties, grids, elements and so on, listed in the database. Doubleclick at the corresponding
topic, property in this case, and a new window opens. Now you can highlight
one or more definitions of the topic by using the corrsponding button.
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The same highlight button can also be found in selection windows like SET,
for example. So it is possible to check definitions of sets like frozen or design
areas.
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By using checkmarks in the database, you are able to switch on or off the visibility of database parameters like forces or boundary conditions, for example:
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User Interface
1.1.7
Input and output using Task Manager

In order to load a finite element
model into Tosca ANSA environment and use it for the definition
of an optimization task, create a
Tosca Structure task first using a
command in Tasks | Tosca
Structure task | ... group.
Then, apply Edit command on
MODEL_LINK item and choose
the solver corresponding to your
model (unless the correct solver is
already chosen).
Both the model file name and the directory can be changed; however, keep in
mind that the file name and the directory should lead to the model not only
during the loading of the model but also after that. The directory where the
model is located is recognized as the working directory for Tosca ANSA environment, and the job directory of Tosca Structure will be created in it. Therefore, in order for Tosca Structure to access the model, it should be located in
the working directory. Note that Tosca Structure always starts with the initial
finite element model as supplied by the user, and all modifications done in
Tosca ANSA environment (e.g., deleting elements) will not influence the optimization but might affect the processing of optimization results. Therefore, it
is recommended not to modify the input model prior to the optimization.
As the working directory stored in PRE-PROCESSING item, a relative path can
be used; it can even be set to "./" indicating that the working directory is the
current directory. However, this path is relative to the directory Tosca ANSA
environment is started from, and not the path of the workspace. In order to
avoid confusion, it is recommended to define the workspace by an absolute
path. A reason to use a relative path might be that the workspace and the
model are expected to be moved from one location to another; in this case,
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When Edit command is applied

on FILE item, the open file dialog
is shown. Once a file is chosen,
the item gets the file name as its
text, and the directory of the file is
stored in PRE-PROCESSING item.
Then, load the model using
Update command on what was
previously FILE item.
SIMULIA
Tosca Structure
use the relative path but take care concerning the directory where Tosca
ANSA environment is started from.
There is no quick way to unload an already loaded model; the only solution is
to delete all relevant entries in Database manually. However, this is rarely
needed since the model is unloaded at the moment when another model is
selected using Edit command of FILE item.
The job directory for Tosca Structure where all intermediate files as
well as optimization results are
stored is named after Tosca Structure parameter file that contains
the optimization task. The name
of this file equals Output.par by
default; it can be modified by
renaming the item Output that
represents the Tosca Structure
parameter file.
The parameter file as well as the job directory for Tosca Structure are created
in the working directory that is specified in PRE-PROCESSING item. The
actions after the optimization require the files stored in Tosca Structure job
directory, mostly from the subdirectories SAVE.onf and TOSCA_POST. See
for the details on log files created by Tosca Structure.
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1.1.8
Input and output using the main menu

Using File | Input | <solver name> command from the main menu,
a finite element model is loaded into Tosca ANSA environment but is not used
for the definition of an optimization task or any further actions, except that
SOLID_MESH attempts to remesh it alongside the result of RECONSTRUCT.
For most applications, loading of an external model is not needed, however it
might serve as a workaround in certain situations.
At any moment, the current geometry together with the defined loads, boundary conditions, etc., can be saved in a solver format by File | Output |
<solver name> menu command. Still, it is recommended to use the command VALIDATION_OUTPUT described in in details, in order to make sure
that the saving is done at appropriate moment.
The output (as well as input) in VRML format is supported; however, the output in IGES format using File | Output CAD | IGES v5.1 does not
work.
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User Interface
1.1.9
Modules Buttons window

In Modules Buttons window,
the optimization task related
information that is later written to
Tosca Structure parameter file is
edited. For most applications,
the optimization task can be
defined using Task Manager
alone; however, the advanced
actions such as definition of a
new coordinate system or selection of another MESH_SMOOTH
command, can only be done
using the commands in Modules Buttons window. The
names of buttons as well as the
names of dialog fields follow the
command names from Tosca
Structure parameter file.
1.1.10 Selecting and deselecting the geometric objects
A click with the middle mouse button confirms the

selection or terminates the current action.
Using the right mouse button, the selected
objects are deselected.
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The selection of geometric objects (elements,

nodes, etc.) is done using the left mouse button.
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1.1.10.1 Selecting single objects
To select, click the left mouse button on an object or close to it. Selected
objects become highlighted. Repeat for multiple selections. In order to deselect an object, click it with the right mouse button. Double clicking an object
selects its neighbors.
The selection is confirmed with the middle mouse button. In case that the
selection window is active (see the previous section), the properties window
will open for the first selected object.
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1.1.10.2 Box selection
Multiple geometric objects are selected by drawing a frame with the mouse
while holding the left mouse button. A frame with the right mouse button
pressed deselects the objects that lie inside it. Note that it is possible to select
nodes while they are hidden, but not hidden elements.
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User Interface
1.1.10.3 Polygon area selection
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Set the first node of polygon by clicking a point with the left mouse button (or,
for deselection, with the right mouse button) while holding Shift key. Then set
the consequent nodes by clicking the points with the mouse (holding Shift key
is not necessary), and finally click the middle mouse button to end the selection. Then, the polygon will close and the objects located inside it will be
selected (or deselected).
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1.1.11 View control

1.1.11.1 Rotating
Moving the mouse while holding
Ctrl key and the left mouse button
rotates the view around an axis
that is perpendicular to the mouse
track and lies on the screen plane.
The rotation axis goes through the
closest shown node or the closest
point of a shown element, with
respect to the point where the
mouse has been clicked for the
first time.
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Ctrl key and the right mouse button rotates the view in plane. The
center of rotation is the rotation
pole is the closest shown node or
the closest point of a shown element, with respect to the point
where the mouse has been
clicked for the first time.
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User Interface
1.1.11.2 Translating
Ctrl key and the right mouse button translates the view.
1.1.11.3 Zooming
By moving the mouse while holding Ctrl key and left and middle
mouse buttons simultaneously,
the view is zoomed in or out
according to the direction the
mouse is moved (see the figure).
A simpler alternative is to use the
mouse wheel; the zooming center is always the center of the visible area. Yet another possibility is
to use the keys F7 (zoom in) and
F8 (zoom out): then, the zooming
center is the current mouse position.
The modification of a view is

faster when both Ctrl and Shift
keys are pressed, as certain
items are not drawn during
movement.
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1.1.11.4 Faster view selection
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1.1.11.5 Function keys related to view control
1.1.12 Keys facilitating input in dialogs
If a text input field requires a

group name, then the window SET
HELP is opened when "?" key is
pressed inside the text field.
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The list of all keys supported by an input text field in some dialog and the
description of the field are shown in its tool tip:
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User Interface
Double clicking an item in this window inserts the group name in the text
field and closes SET HELP window. See the next section for more information about this window as well as about the definition of new groups.
If a field requires a node or element ID, then pressing F1 key closes the window temporarily and waits until the user selects a node or element from the
current view. Then, the window reappears and the ID of the selected object is
inserted in the text field. Pressing F2 key opens the options dialog for the
node or element with the ID from the text field. With F7 key, the current view
is zoomed in at the node or element with the selected ID.
When F3 key is pressed in any
text input field, the window
A_PARAMETERs is opened in
which the user defined parameters can be defined and then
selected.
Later, changing the value of a parameter is reflected in all text fields where
this parameter is used. The parameters can be assigned to numerical or literal values.
1.1.13 Managing Groups

1.1.13.1 SET HELP window
To make this window appear, do one of the following:

apply Edit command on GROUPS item in Task Manager
press "?" key in a text field that requires the input of a group name (e.g., the
dialog DV_TOPO opened by Edit command applied on DESIGN_AREA
item in Task Manager)
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For the group management, the window SET HELP is used:
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double clicking the item SET in Database window opens the selection window for groups that is basically equivalent to SET HELP window
In this window, the groups loaded from the input model as well as the new
groups defined in Tosca ANSA environment are represented. Although only
the new groups are written to Tosca Structure parameter file, the optimization
task may contain references to already defined groups as well,
When SET HELP window is active, clicking an element or a node of the
model highlights all groups that this element or node belongs to.
The button Highlight turns on or off the highlighting of the selected group.
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The command NEW creates a new group and starts the group selection mode
described in the next section. When the group selection ends, the group
properties window titled S E T [SET] is shown.
This window is also opened by Edit command applied on an item in SET

HELP window. In this dialog, the name of the group is specified as well as
other properties that normally need not be modified.
1.1.13.2 Selection of objects in group selection mode

To start the selection mode for an already existing group, apply the command
Modify Contents on the group item. Note that in SET HELP window
opened by "?" key, this command is named MODIFY. To start the selection
mode with a new group, press the button NEW in SET HELP window; in group
selection window, you need to choose the command New from the popup
menu to create a new empty group, and then to apply the command Modify
Contents.
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User Interface
When the selection mode starts, Database window title changes to

Modifying SET: <group name> (ID: <ID>), reflecting the name of
the group and its ID, as well as the selection window for the objects of current
type (GRID in the figure below) appears:
In the column In SET of Database window, the red number
next to an item shows how many
objects of this type belong to the
group. The highlighted item in
Database shows what objects
are currently being selected. In
order to change the type of
selected objects (e.g., from nodes
to elements), highlight the corresponding line (e.g., ELEMENT) by
clicking the item once. If you have
selected some objects of wrong
type by mistake, you need to
deselect them first and then
change the type of selected
objects, since otherwise a mixed
group will be produced.
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The selection or deselection of objects with desired IDs can be done in the
selection window. See for details on the selection window.
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Selection of nodes or elements is done by drawing a frame with the left

mouse button pressed:
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Note that, in this example, Database item GRID is highlighted, therefore the
nodes will be selected. The selection window is also titled GRID. To change
the type of objects being selected, click the corresponding Database item.
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User Interface
Once the mouse button is released, the selected nodes appear:
The number of selected nodes is shown in red in Database column In SET.

In the selection window, the IDs of selected nodes are highlighted. If needed,
the selection can be expanded or decreased; refer to for details. The selection is confirmed with the click by the middle mouse button.
The specification of groups is necessary for several items:

Design Variables
Design Responses for Objective Function Terms
Design Responses for Constraints
Manufacturing Constraints
Tabular Output
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1.1.13.3 List of Tosca Structure commands with groups
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1.1.14 Configuration of Tosca ANSA environment

The options of Tosca ANSA environment are edited in the dialog opened by
Windows | Options... menu command:
Tosca ANSA environment: Options dialog.
The settings edited in this dialog are divided into two types: general settings
(TOSCA.defaults file) and GUI settings (TOSCA.xml file). On start of
Tosca ANSA environment, both files are first read from the directory config
located in the installation directory; then, the same files are searched for in
.BETA directory located in your home directory; if found, these files are
loaded and the settings defined in them override the ones read previously.
Please refer to for the details about Tosca Structure configuration.
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Fig. 1
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User Interface
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1.2
Topology Optimization with Tosca ANSA

environment
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At the beginning of the conventional design process the design engineer

defines the shape and the topology of new components using the experience
and the results gained from the forerunner. This results in an evolution process which might lead to an optimum design after some iterations and a long
period of time.
Nowadays it is necessary to shorten the development process of new components. Therefore tools are necessary that replace the natural evolution process by an automatic procedure.
With Tosca Structure it is possible to carry out topology and shape optimization in the CAE environment.
1.2.1

Topology optimization is a tool to generate a design proposal and is often
used within the concept finding for a new component. Starting with the design
area which is the maximum allowed area for the component and with the
boundary conditions, such as loads, fixtures and manufacturing conditions
the optimization system will determine a new material distribution by removing material from the design area. This design proposal fulfills all mechanical
requirements and represents a weight-optimal design proposal.
For the optimization the following constraints and objectives can be realized:
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Topology Optimization with Tosca ANSA environment
stiffness (compliance and displacements)

eigenfrequencies
internal and reaction forces
weight, volume
center of gravity
moment of inertia
In addition a number of manufacturing constraints can be applied so that the
design proposal can be produced with casting, stamping. For this casting
constraints, member size constraints, freezing and symmetry and coupling
constraints can be defined.
As result the optimization system creates a design proposal with the information where the material has to be positioned. This design proposal has to be
interpreted and has to be used for the more detailed analysis.
For supporting this step Tosca Structure supports the generation of a verification model within Tosca ANSA environment. This means a new model based
on the results of the topology optimization can be created easily without the
necessity of applying the loads and boundary conditions to the verification
model. All loadcases and boundary conditions of the optimization model are
transferred automatically to the verification model.
With the results of the verification run it is possible to perform a normal FE
postprocessing step within the postprocessing environement suitable for your
solver or a CAD model can be generated which then can be transferred back
to your CAD system.
The Model
The component to be used within the tutorial represents a control arm for a
car and is found in the Tosca Structure installation directory (<tosca>) according to your FE-solver (<solver>) :
<tosca>/<solver>/examples/topo/control_arm
The model is loaded with one loadcase consisting of two fixtures in the upper
left and right areas and is loaded with one load in the lower bearing area. The
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1.2.2
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original design is the realized design which has to be strengthened by the

optimization.
Design Area
Fig. 2
Existing design of a control arm with the design area
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The model for the topology optimization was modified in such a way that the
inner areas of the component are filled with elements to create a design area
where the optimization system can remove or rearrange elements for getting
a better mechanical behavior of a component with a lower weight with the
same mechanical behavior .
The start model for the optimization represents a design of a control arm for a
car. The component has to be manufactured by forging and consists of aluminum. The red areas of the component are not free for the optimization
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Fig. 3
Loads of the model
The fixture is realized with spring elements on the right upper side. The
springs represent a rubber bearing. The left bearing is fixed in all three translation degrees of freedom, but is able to rotate about the x-axis. As loading a
force is applied in the center of the lower bearing.
Due to symmetry reasons only one half of the model is meshed so the symmetry plane is fixed in z-direction for ensuring the symmetry condition.
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because they are used for the fixtures and for the load application. One red
area is used for the mounting of a sensor for the headlight range adjustment.
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1.2.3
Optimization Task
The optimization task is to find a structure with the maximum stiffness for the
component with a volume or weight restriction. This represents the most common standard optimization task for the topology optimization.
The value to be optimized is the compliance which is the reciprocal value of
the stiffness. The compliance is represented as the sum of the strain energy
of the complete model. This value has to be minimized.
The constraint is the weight or volume constraint which is defined to be 70%
of the initial volume/weight of the structure.
As manufacturing constraint a casting/forging constraint has to be defined.
The idea of the constraint is to ensure that the created structure of the topology optimization has no undercuts and can be demolded (or removed from
the forging die).
1.2.4

Preprocessing
1. Create Tosca Structure task: Tasks | Tosca Structure Task |
TOPO_CONTROLLER command of Task Manager
2. Input file: PRE_PROCESSING | MODEL_LINK | FILE
3. Design area: PRE_PROCESSING |
TOPOLOGY_OPTIMIZATION_CONTROLLER | DESIGN_AREA
4. Design constraints: PRE_PROCESSING |
TOPOLOGY_OPTIMIZATION_CONTROLLER | DESIGN_AREA |
DV_CONSTRAINTS
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5. Objective function: PRE_PROCESSING |

TOPOLOGY_OPTIMIZATION_CONTROLLER | OBJ_FUNC_ITEM_1
6. Constraints: PRE_PROCESSING |
TOPOLOGY_OPTIMIZATION_CONTROLLER | CONSTRAINTS
7. Saving Tosca Structure parameter file: PRE_PROCESSING |
TOPOLOGY_OPTIMIZATION_CONTROLLER | Output
Start optimization
8. Running Tosca Structure: START_OPTIMIZATION | RUN
Postprocessing
9. Viewing the intermediate results: POST-PROCESSING |
GENERATE_REPORT_FILE
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Result transfer and validation run

10.Smooth surface: SMOOTH | SMOOTH_INSTANCE | RUN_SMOOTH
11.Modified surface: SMOOTH | SMOOTH_INSTANCE | VALIDATE |
BATCH_RECONSTRUCT
12.Remeshing: SMOOTH | SMOOTH_INSTANCE | VALIDATE |
SOLID_MESH
13.Saving the result: SMOOTH | SMOOTH_INSTANCE | VALIDATE |
VALIDATION_OUTPUT
14.Running the solver: SMOOTH | SMOOTH_INSTANCE | VALIDATE |
VALIDATION_RUN
Please note that Tosca Structure 7.0 or higher is required in order to complete the optimization task. With previous versions of Tosca Structure
some changes may be necessary to achieve the same results.
1.2.5
Preprocessing
2. In Task Manager, select

Tasks |
Tosca Structure TASK |
TOPO_CONTROLLER.
3. In Task Manager, press the

expand-button.
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1. If Task Manager panel is

hidden, click the button to make
it appear in the left side of
ANSA window.
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1. Right click the item
MODEL_LINK in Task
Manager and select Edit or
double click the item
MODEL_LINK.
2. In the window titled MODEL

LINK, choose as WORKING
DECK the solver that matches
your input file (MSC Nastran in
this example) and click OK.
Note that the steps 1 and2 are
not needed if the correct solver
is already chosen in
MODEL_LINK.
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3. Right click FILE item in Task

double click FILE.
4. In the Open dialog, choose the

input file and click Open. The
items FILE and PRE-PROCESSING in Task Manager get
renamed: the file name is used
as the name of FILE item,
while the directory of the file is
appended to
PRE_PROCESSING item name.
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5. Right click the item named after

the file you have just chosen
and select Update. The input
file is loaded and the model is
shown in the main window.
1.2.5.3 Choice of the design area

In topology optimization, the design area denotes the set of elements that
may be removed during the optimization, in contrast to the frozen areas
that remain unchanged.
DESIGN_AREA in Task
double click DESIGN_AREA.
3. Activate the text field with the

title GROUP_DEF and press "?"
key.
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2. In the DV_TOPO window,

choose GROUP_DEF from the
dropdown list below EL_GROUP.
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4. The SET HELP window opens.

Click the "Actions"-button in the
toolbar or right click in the
empty space and select New.
The window titled Modifying
SET: Untitled (Id:1)
appears in the right part of the
screen.
5. In this window, click ELEMENT
item once in order to highlight it.
Now, the elements of the model
can be chosen using the
mouse.
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6. First, select the whole model by

enclosing it in a frame made
with the left mouse button
pressed. Note that you may
move, rotate in plane, rotate in
space or zoom the model using
CTRL + middle mouse button,
CRTL + right mouse button,
CTRL + left mouse button and
CTRL + mouse wheel resp.
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7. Deselect the 4 parts shown in

the figure by moving the mouse
with the right mouse button
pressed. It is recommended to
rotate the model in plane and
zoom in and out to make the
selection more accurately. Click
with the middle mouse button to
confirm the selection and to
proceed to SET window.
9. In SET HELP window, double

click the name of the group you
have just created to assign the
group to your design variable
selection. The window will then
close.
10. Click OK in DV_TOPO window.
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8. Enter the desired group name

(my_design_group in this
example) in Name field. You
may also proceed with the
default group name and click
OK.
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11. If you want to check your

group selection switch on the
highlight button in Task
Manager and click Design
Area under
TOPOLGY_OPTIMIZATION.
Your group definition will be
marked in color in the model.
1.2.5.4 Choice of the design constraints

Design constraints introduce restrictions on the shape of the optimized
model. In addition to the demolding constraint discussed below, other types
of design constraints such as symmetry and member size restrictions are
supported by Tosca Structure.
1. Right click DV_CONSTRAINTS
item under DESIGN_AREA and
Select New |
DEMOLD_CONTROL.
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2. In DEMOLD_CONTROL window,
dropdown list below EL_GROUP
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Tosca Structure

key.
4. In the SET HELP window,

double click
my_design_group item. The
window will then close.
6. In DEMOLD_CONTROL window,
enter the values 0, 0, 1 in the
fields PULL_DIR_1,
PULL_DIR_2 and
PULL_DIR_3. These values
are the components of the pull
direction needed for the definition of the demolding
constraint.
Click OK.
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5. Repeat the last 3 steps for

CHECK_GROUP. Now, the same
element set
my_design_group is used in
both EL_GROUP and
CHECK_GROUP fields
SIMULIA
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7. Check the demold direction by clicking DEMOLD_CONTROL and switching

on highlight button. The arrow shows the demold direction and the
coloured area shows that part of the model for which the restriction is
applied (my_design_group in this case).

The objective function will be minimized or maximized by Tosca Structure,
depending on the settings.
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1. Right click COMPLIANCE item

under OBJ_FUNC_ITEM_1 and
select EDIT or double click
COMPLIANCE.
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2. Click OK without any change.
3. Right click OBJ_FUNC_ITEM_1

item and select Edit or double
click OBJ_FUNC_ITEM_1.
4. Set TARGET field to the correct

value MIN and click OK.
Note that although no changes
are needed since TARGET field
has already set to the correct
value MIN, this step is required
in order to proceed.
Constraints are equations or inequations that are maintained by Tosca

Structure during the optimization.
1. Right click
VOLUME_CONSTRAINT item
under CONSTRAINTS and
select EDIT or double click
VOLUME_CONSTRAINT.
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2. Enter 0.7 in the field VALUE

and click OK.

The Tosca Structure parameter file contains commands which define all
settings for the optimization task.
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1. Right click Output item. Select

Update.
The parameter file
Output.par for Tosca Structure is written at this point. The
file is saved in the same directory where the input model is
located. The optimization with
Tosca Structure will also start in
this directory.
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1.2.6
Start Optimization

1. Right click RUN item under
START_OPTIMIZATION.
Select Update.
Tosca Structure will start in
background. Wait until it
finishes. Then close the TOSCA
Job and the
OPTIMIZATION_RUN window
to continue.

To see the optimization history (the values of objective function and constraints for each iteration), open the file optimization_report.csv with
Microsoft Excel or a text editor. Tosca Structure log file TOSCA.OUT from
TOSCA_POST directory contains this information too, along with the warnings
and errors if available.
Postprocessing
Using Tosca Structure.report, the intermediate results of topology optimization, namely the densities of individual elements, can be visualized. This
subsection is optional.
1. Right click TOPO_MAT item
under
GENERATE_REPORT_FILE.
Select Update.
The generated VTFX file
containing the original (nonsmoothed) optimization result
will open in Tosca Structure.view.
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3. The animation starts and stops by clicking on the start forward/backward,

pause and stop symbol in the task menu.
Close the Tosca Structure.view, the TOSCA_POST and the TOSCA Job
window in order to proceed.
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2. If youve just generated the

report file and want to view the
VTFX file again right click
VTF_VISUALIZATION item
under GENERATE_POST_FILE
and select View.
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1.2.8
Report Generation
1. Open your VTFX file again by
clicking
GENERATE_POST_FILE |
VTF_VISUALIZATION and
select View.
2. Under View | Viewports

you can select up to four viewports in different positions.
Choose two viewports: You see
the relative material distribution
of your model on the left side of
the split window. The right side
is still empty.
4. To move both views synchronously select View |

Synchronous Navigation.
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3. Select Original model in

the Table of Cases and
drag it onto the right side of the
window. Another possibility is to
rightclick at case two and select
Assign Case In View |
View 1.
SIMULIA
Tosca Structure
5. Click at the left model: Now, this model is activated and its frame
becomes green. Choose the last iteration step by using the Step Backward button and move both views synchronously in an appropriate position (hold Ctrl and the appropriate mouse button while moving the
mouse).
7. A new window opens: Enter an

appropriate description, select
Image as Situation type and
press OK. A new window
named GLview Report
Builder opens. Keep this
window open till the end of this
chapter!
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6. To generate a report activate

the left window and click
Capture active view in the
quick access toolbar or select
File | Capture Situation.
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8. In GLView Report Builder

window click File | Save
Repository as to save the
actual situations to a file.
9. Switch to Tosca Structure.view window. Repeat step 6 and 7, but select

3D model as situation type for capturing.
10. In the Tosca Structure Report Builder window both siutations are listed.
By rightclicking at the situation you can delete it or change the order.
12. The last setting is used for capturing, thus the smoothed optimization
result is loaded as 3D model into the Tosca Structure Report Builder.
13. Load the smoothed optimization result (right window in Tosca Structure.view) as image into the Tosca Structure Report Builder. (Look at step
6 and 7, if necessary, and do not forget to activate the window).
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11. Switch back to Tosca Structure.view window. Now, select

the right window and click
Quick Capture active
view in the quick access
toolbar or select File |
Quick Capture Situation.
SIMULIA
Tosca Structure
14. In Tosca Structure.view

doubleclick at
CONSTRAINT_NORM in the
Table of Cases. This case
cannot be displayed with
another viewport. By selecting
Capture Situation or
Capture active view load
the plot as Image into the
Tosca Structure Report Builder.
15. Repeat step 13 with the same
plot and capture it using situation type Table.
16. Repeat steps 12,13 and 14
with the objective function
(OBJ_FUNC in the Table of
Cases).
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17. Now there should be 8 entrys

in the Situations window.
Doubleclick at the third entry,
which is the smoothed optimization result as 3D model to
deactivate this situation for the
transfer.
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19. For template selection click Browse and select

TOSCA_Structure_PowerPoint_Template_GenericTags.pptx
in <tosca_installation_directory>\report\Templates. Select an output file
name. Choose the media type which mainly determines how 3d information is included into the report (3D plugin for interactive animated results,
video for animated (but static) results and image only for screenshots).
Click OK.
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18. Transfer these situation into a

powerpoint document by
clicking File | Create
PowerPointReport.
SIMULIA
Tosca Structure
20. A PowerPoint file is created. The order of figures and tables is determined by the template.
21. For tranferring into a word file use Create WordReport and the
template TOSCA_Structure_Word_Template_GenericTags.docx,
for a HTML file Create HTMLReport and the template
TOSCA_Structure_HTML_Template_GenericTags.html.
As the vtfx plug-in only works in combination with the internet explorer,
you can choose Video and image as Media type for other browsers.
1.2.9
Result Transfer and Validation Run (Smooth)

After the optimization an automatic validation run enables quality checks of
the result. An approved result must then be transferred into the product
development process. To this end, the new design proposal must be available
for import and further processing in CAD systems.
Tosca Structure.smooth generates the surface of the material remaining

after the topology optimization and improves the surface quality.
1. Right click RUN_SMOOTH item
under SMOOTH_INSTANCE and
select Edit or double click
RUN_SMOOTH.
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2. In SMOOTH RUN PARAMETERS

window, choose the output
formats for the result transfer
(e.g., STL or IGES) if needed;
click OK
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under SMOOTH and select
Update.
Tosca Structure.smooth will
start in background. When
finished, the generated triangular surface is loaded and
shown in place of the initial
model; see next figure
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1.2.9.2 Modifying the surface using RECONSTRUCT
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1. Right click
BATCH_RECONSTRUCT item
under VALIDATE and select
Edit or double click
BATCH_RECONSTRUCT.
2. Check the check button

Preview and the check button
Freeze SPC Nodes, uncheck
the check button Automatic
feature line recognition at
SMOOTH_CUT_ELEMENTS
area and click OK.
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3. Right click
BATCH_RECONSTRUCT item
and select Update.
BATCH_RECONSTRUCT generates a new, more regular triangular surface that can be used
for the remeshing of the volume
with tetrahedra.
1.2.9.3 Remeshing the model
2. Some time after SOLID_MESH

starts, the window PROPERTIES will appear. Double click
the first (and only) line in the
list, then it will close and
SOLID_MESH will resume.
When it finishes, a new tetrahedral mesh will appear in addition to the triangular surface.
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1. Right click SOLID_MESH under

VALIDATE and select Update.
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1.2.9.4 Saving the resulting model in solver format

Please note, in some cases (ANSYS workbench models) the standard way
may not work, as ANSA does not support some specific solver settings. In
this case continue with chapter 1.2.9.6 Saving the resulting model in solver
format (alternative)
1. Right click
VALIDATION_OUTPUT item
and select Edit or double click
VALIDATION_OUTPUT.
3. Choose the file name for the output model to be saved in the format of
the solver you use and click Save. In the Output Parameters window
click Ok.
4. Right click the item with the
chosen file name under VALIDATE and select Update.
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2. In the Output Parameters

window click
Browse....Depending on
your solver format, several
additional settings can be
made.
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1.2.9.5 Running the solver with the new model

1. Right click VALIDATION_RUN
and select Update.
Then, the solver will start in the
same folder where the output
file has been saved.
1.2.9.6 Saving the resulting model in solver format (alternative)

1. Right click
VALIDATION_OUTPUT and
select Disable.
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2. Right click VALIDATE and

select New |
MODIFICATION_FILES.
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3. Choose the file name for the output model to be saved in .onf format and
click Save.
4. Right click the item with the
chosen file name under VALIDATE and select Update.
5. Tosca Structure modification willstart in background. After finishing, the

newverification file in the format of the solver you usecan be found in the
location specified in the previous step. The file name will be the same
asthe one of the .onf file defined in the previous step.
1.2.9.7 Running the solver with the new model (alternative)

1. After creating a verification file using the MODIFICATION_FILE option,
the execution of the solver job from Tosca ANSA environment is not
possible. Please use your solver specific environment for starting and
postprocessing the verification job.
The topology optimization created a new design proposal for the control arm
component. The result of the topology optimization has to be discussed in
several ways.
First of all the optimization result has to be checked. This can be done with
viewing the convergence plot and with checking TOSCA.OUT file for warnings
and errors. If there is a critical error during the optimization the optimization
loop will be stopped. In other cases (if some results are missing) the optimization system will continue but the result may be not sufficient.
Second the resulting model and the finite element analysis of the model has
to be checked if the displacements, the stresses and all other finite element
related information are suitable.
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Initial model (complete

model with 70% of material
homogeneously
distributed)
Result
Strain Energy
Table 1
1645850
Final model
425093.5
Result comparison
Fig. 4
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Von Mises stresses of optimized structure
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For this optimization task the stresses are in the same range compared to the
initial model but the stiffness of the structure is higher and the material
amount necessary for the structure is lower. The values to be compared are
the volume or weight of the structure and the sum of the strain energy. The
strain energy is the measure for the compliance which is the reciprocal value
of the stiffness.
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Tosca Structure
Fig. 5
Optimization result represented after data reduction: IGES surfaces for CAD transfer
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After checking the results the remaining structure can be passed to the
design department as a CAD model to be used as design proposal for the
fine tuning of the design. If the stresses within the component are not below
the allowed range the shape optimization of Tosca Structure (Tosca Structure.shape) will be able to remove the stress peaks so that the component will
be suitable from the mechanical point of view.
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The results can be transferred as surfaces in STL format or IGES format.

Another way to transfer less data is to export the results as slices.
Optimization result represented as slices
For sharing the result and the animation with colleagues or partners the VTFX
format is a comfortable way. This result format is able to contain a full 3D animated model with the optimization history. The model can be rotated and
zoomed during the animation. The viewer is available for free for different
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platforms and there is also a possibilty to include the files into HTML-pages
and into Powerpoint presentations.
Material distribution after topology optimization
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Fig. 7
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1.3
Shape Optimization with Tosca ANSA

environment
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Shape optimization allows specific detail improvements of existing designs.

Through shape optimization the surface geometry of a given model is modified automatically to avoid material failure and increase durability or comfort.
1.3.1

Shape optimization is mostly used at the end of the design process when the
general layout of a component is more or less fixed and only minor changes
and improvements are allowed. Typically, the objective function is to minimize
stress concentrations. Based on the results of a stress analysis modifications
of the surface geometry of a component are performed until the required
stress level is reached. This process is usually carried out manually by trialand-error.
Tosca Structure.shape allows an automatization of this improvement process.
The surface geometry of a given FE model is modified iteratively based on
the FE results, such that the required optimization target is reached. The start
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Tosca Structure
Shape Optimization with Tosca ANSA environment
model is taken from an existing design, which should be improved, or from a

previous topology optimization.
Tosca Structure.shape enables you to perform the following tasks
Minimization of the equivalent stress
Maximization of selected natural frequencies
Specification of a volume constraint
Surface-based manufacturing constraints for casting, forging, stamping,
extrusion and drilling
Minimum and maximum member size
Symmetry constraints
Specification of design domain restrictions by FE-meshes
Mesh adjustment and mesh smoothing in each optimization cycle
Additional functionalities like optimization using durability results are available with Tosca Structure.durability
Additional functionalities like optimization using nonlinear results or for the
optimization of contact areas are available with Tosca Structure.nonlinear
1.3.2
The Model
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The component optimized in this tutorial is a connecting rod (conrod) and is

found in the Tosca Structure installation directory (<tosca_install_dir>):
<tosca_install_dir>/<solver>/examples/shape/conrod
The model is built with an autogenerated tetrahedron mesh symmetric to the
xz and yz plane. The mesh quality is medium/poor with average element
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De
sig
n
are
a
edge of ~ 2 mm. Outer dimensions: 180 x 84 x 24 mm.

Allowed design and mesh smooth area are shown in Fig. 8.
Mesh smooth area
Fig. 8
Connecting rod (conrod) with design and mesh smooth area
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Loaded nodes are connected with MPCs to the inner side of the conrod
mounts. Nodes in the big eye nodes on the inner radius (crankshaft bearing)
are fixed in all three coordinate directions.
There are five loadcases realized in the model (see Fig. 9):
Loadcase 1:
Centrifugal force (a in Fig. 9), 15000 N applied in z-direction
Screw fixation
Loadcase 2:
Gas pressure (b in Fig. 9), 25000 N applied in negative z-direction
Fixation in nodes of big eye
Loadcase 3:
Bending about the x-axis
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Loadcase 4:
Bending moment about the y-axis
Loadcase 5:
Torsion about the z-axis.
Fig. 9
1.3.3
Loads and boundary conditions of the model conrod: (a) centrifugal force,
right: force caused by gas pressure (b), bending and torsion
about x-, y- and z-axis.
Optimization Task
The goal is to reduce stress peaks on the surface of the component with
small changes at the surface of the component. Thus the optimization task is
to minimize the maximum stresses of the loadcases on the connecting rod,
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see Fig. 9. The design area is shown in Fig. 8 and consists of the surface
nodes of the area in the inner rectangle.
1.3.4

Preprocessing
1. Create Tosca Structure task: Tasks -> Tosca Structure Task ->
SHAPE_CONTROLLER command of Task Manager
3. Design area: PRE_PROCESSING |
SHAPE_OPTIMIZATION_CONTROLLER | DESIGN_AREA
4. Design variable constraint: PRE_PROCESSING |
SHAPE_OPTIMIZATION_CONTROLLER | DESIGN_AREA |
DV_CONSTRAINTS | DOF_CONTROL
5. Mesh smoothing options: PRE_PROCESSING |
SHAPE_OPTIMIZATION_CONTROLLER | DESIGN_AREA |
MESH_SMOOTH
6. Objective function type: PRE_PROCESSING |
SHAPE_OPTIMIZATION_CONTROLLER | OBJ_FUNC_ITEM_1
7. Objective function term: PRE_PROCESSING |
SHAPE_OPTIMIZATION_CONTROLLER | OBJ_FUNC_ITEM_1 |
EQUIVALENT_STRESS
SHAPE_OPTIMIZATION_CONTROLLER | Output
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Node displacement check (Check Inputs)

9. Using test displacements: CHECK_INPUTS | TEST_SHAPE_CHECK |
TEST_SHAPE
Start optimization
10.Running Tosca Structure: START_OPTIMIZATION | RUN
Postprocessing
11.Viewing the intermediate results: POST-PROCESSING |
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Result transfer (Smooth)

12.Smooth surface, output for result transfer: SMOOTH |
SMOOTH_INSTANCE | RUN_SMOOTH
1.3.5
Preprocessing

ANSA window.

expand-button.
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Tasks | Tosca Structure
TASK | SHAPE_CONTROLLER.
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MODEL_LINK in Task
double click MODEL_LINK.

Note that the steps 1 and 2 are
MODEL_LINK.

input file and click Open.
The items FILE and PREPROCESSING in Task
Manager get renamed: the file
name is used as the name of
FILE item, while the directory
of the file is appended to
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double click FILE.
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and select Update.
The input file is loaded and the
model is shown in the main
window.
1.3.5.3 Selection of mesh smoothing elements

During the shape optimization, the displacement of surface nodes usually
leads to distorted elements unless mesh smoothing is performed. Therefore, it is required to select the elements that can be modified during the
mesh smoothing. The general rule is to select the elements at the nodes of
the design area, plus several layers of elements towards the inside of the
model. Usually, selecting too many elements in mesh smoothing area does
not cause any problems except that the calculation time increases.
1. In this case for defining a group

for mesh smoothing the easiest
way is to reduce the model view
to the mesh tightening area first
and to define the element group
afterwards. So press the NOT
button.
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Note that there is an automated method of selection of mesh smoothing

elements: see chapter 1.3.12.4 Selecting mesh smooth elements automatically. Still, the manual method is recommended.
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3. Save this view by clicking the

dropdown menu next to the
Lock button and select Store
Lock. Enter a name, for
example MESH_SMOOTH, and
press Enter
4. Now this view is saved and can
be selected by Lock dropdown
menu | MANAGE LOCKs.
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2. If needed, bring the model to the view shown in the figure by pressing F2
key and select the faces of the part shown in the left figure by enclosing
them in a frame drawn with the mouse while holding the left mouse
button. The enframed part disappears. Then select the faces of the part
shown in the right figure.
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5. The view can be shown by

right clicking the chosen name
| Show only.
6. To see the whole model again,

make sure that the Lock button
is not activated and the view is
unlocked. To deactivate click
once the Lock button.
7. Then press the ALL button. The
whole model will appear.
8. Select your predefined view
(key button | MANAGE LOCKs,
then rightclick on
mesh_smoothing_elements
| Show only) and right click
the item MESH_SMOOTH under
DESIGN_AREA in Task
double click MESH_SMOOTH.

key.
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9. Choose GROUP_DEF in the

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11. The SET HELP window

opens.
space with the group list and
select New.
screen.
12. In this window, activate SOLID
and deactivate all others under
ELEMENT item. If necessary,
click once again at SOLID item
to highlight it. Now, the solids of
the model can be chosen using
the mouse.
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13. Select all faces of the part by

enclosing them in a frame
drawn with the mouse while
holding the left mouse button.
Click with the middle mouse
button to confirm the selection
and to proceed to SET window.
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(mesh_smooth in this
example) in SET window. You
default group name.

have just created. The window
will then close.
Remark to mesh smoothing

If you wish to examine the influence of MESH_SMOOTH on the optimization
result, you may run the optimization (as described below) with following settings and compare the results:
MESH_SMOOTH disabled by using Disable command on MESH_SMOOTH
item;
ALL_ELEMENTS is chosen as the group in EL_GROUP field of MESH_SMOOTH
dialog.

In shape optimization, the design area denotes the set of nodes that may
be displaced during the optimization, in contrast to the frozen areas that
remain unchanged.
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16. Click OK in MESH_SMOOTH

window.
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DESIGN_AREA in Task
2. In the appeared DV_SHAPE
window, choose GROUP_DEF
from the dropdown list below
ND_GROUP. The process of
selecting a group is similar to
one used for defining the mesh
smooth area.

screen.
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key.
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5. In this window, click SOLIDFACET item once in order to

highlight it. Now, the surface
faces of the model can be
chosen using the mouse.
6. Activate the Feature Area

button with an angle of 40. So
all surfaces which are linked
with an angle equal or less of
40 degree are selected.
7. Select the surface outside of geometry and neglect the intersection plane
and the bushing.
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bushing
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8. As the mesh smooth area

should contain more layers than
the design area for a smooth
transition between optimized
and non-optimized part deselect the last three or four layers
at each end: If needed, change
the viewport by pressing F2 key
and deselect the parts by
enclosing them in a frame
drawn with the mouse while
holding the right mouse button.
9. To keep the small eye planar

activate the Feature Area
button with an angle of 10 and
deselect the three layers at the
front and the back side.

OK.
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10. Confirm your selection (click middle mouse button) and proceed to SET
window. Note that although the resulting group consists of faces, it is
later transformed into a node group that is then written to the Tosca
Structure parameter file.
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Tosca Structure

will then close.
13. Click OK in DV_SHAPE

window.
1.3.5.5 Choice of design variable constraint

The interior of the smaller eye of the conrod should not be changed. Therefore the nodes of this area have to be fixed in all directions by a design variable constraint (DOF_CONTROL).
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14. You can check your group selection by clicking Windows | Sets in
main menu. In SET window switch on the highlight button. Selected
groups will be marked in different colors.
SIMULIA
Tosca Structure

item and select New |
DOF_CONTROL.

dropdown list instead of
ALL_NODE. Activate the text
field with the title GROUP_DEF
and press "?" key.

screen.
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4. Activate the Feature Area

button with an angle of 10.
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5. Make sure, that SOLIDFACET is highlighted in Modifying SET window

and select the two inner layers of the eye at the front and back side (see
left figure) and the bushing. Confirm the selection with the middle mouse
button and proceed to SET window. Enter a name and click ok.
6. In SET HELP window doubleclick at the new group. Select
FIXED at the fields DOF_1,
DOF_2 and DOF_3.
Remark:
1. As an alternative it is possible to define a second DOF control at the hidden
outer surface. Then the reduction of the upper half of the conrod eye is not
necessary and the whole small eye can be added to the mesh smooth
area. The second DOF control is necessary as the outer surface of the
upper half of the eye should also remain unchanged.
In the example, the min-max formulation of the objective function is used in

order to minimize the maximal value of von Mises stress over all nodes of
the design area and over two loadcases. A separate design response of
EQUIVALENT_STRESS type is created for each loadcase, therefore the
steps 1-8 have to be done five times.
EQUIVALENT_STRESS.
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dropdown list instead of
ALL_NODES.

key.
In this case, no new group
should be defined since the
design area group is already
selected. Therefore, the
window SET HELP that
appears when "?" key is
pressed is only needed for the
selection of the group name,
that may also be inserted
manually.
5. Select SIG_MISES in the field

TYPE of OBJFUNC_TERM
dialog.
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4. Double click the name of the

design area group
example). The window SET
HELP then closes.
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6. In OBJFUNC_TERM window, set

the value of LC_SET field to
"(ALL,1)". Alternatively, select
the appropriate values of
APPROACH and LOADCASE
fields (ALL and 1, resp.) after
clicking MORE in the dialog
LC_SET that opens when "?"
key is pressed in LC_SET field.
Click OK.
7. Repeat the steps 1-6 four times in order to create the design responses
for the other loadcases. In step 6, enter "(ALL,2)", "(ALL,3)" and so
on instead of "(ALL,1)" in order to specify the other loadcases for the
design response. Finally you have five objective function items.
For better handling and control of the results we recommend to create
one DRESP for each loadcase. This allows for more detailed postprocessing and eventually different weighting of the loadcases in the objective function.
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9. Select MINMAX as the value of

TARGET field and click OK.
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1. Right click Output item and
select Update.
The parameter file
this directory. Note that you
may change the parameter file
name (and, thus, the working
directory that is named after it)
by clicking twice on Output
item.
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1.3.6
Node Displacement Check (Check Inputs)

Using CHECK_INPUTS item, the change of the geometry caused by sample
optimization displacements is examined. This test reveals possible problems with the definition of the design area and the mesh smoothing area,
as well as checks if the syntax of the parameter file is correct. Also, by
viewing the geometry after the test displacements in VTFX format, the user
is able to see if the real optimization displacements are likely to result in
distorted elements or violate some other requirements. This check is
optional; it has no effect on further actions. However, it is recommended in
most cases since it requires much less calculation time than the entire
shape optimization.
In case that the design restrictions are defined, they are also enforced during CHECK_INPUTS operation, and thus it can be checked if they are
defined correctly.
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Tosca Structure
1. Right click CHECK_INPUTS

TEST_SHAPE_CHECK.
If the CHECK_INPUTS item is
missing rightclick TOSCA
Structure Task | New |
CHECK_INPUTS.
2. Right click
TEST_SHAPE_CHECK item and
select New | TEST_SHAPE.
3. In the opened TEST_SHAPE

dialog, enter 3 in the field
DISPLACEMENT; this is the
maximal test displacement
value.
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4. Enter 3 in the field INCREMENT;

this is the number of iterations
in which the displacement is
increased from 0 to the
maximal value.
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5. Optionally, select SHRINK

instead of GROW in DIRECTION
field; this changes the direction
of displacements (towards the
inside or towards the outside).
Click OK.
6. Right click TEST_SHAPE_1

item and select Update.
Wait until Tosca Structure
finishes. Close the TOSCA Job
and the TOSCA_TEST window
to continue.
8. Right click
and select View.
Tosca Structure.view window
opens.
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7. Right click
TEST_SHAPE_CHECK item and
select New |
VTF_VISUALIZATION.
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pause and stop symbol in the task menu. You can change between
SHAPE_DISP and SHAPE_CTRL by doubleclicking on the corresponding case in the Table of Cases window or by selecting it in the
dropdown menu. Examine the model with test displacements and close
Tosca Structure.view window in order to proceed with Tosca ANSA environment.Please note: as no FE-Analysis is performed, there are no
CTRL_INPUT results available.
10. In the animation appearing after the test run it should be quite easy to
check:
Is the optimization direction (nodal movement) in the correct direction?
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Are the design nodes (moving nodes) correctly defined?
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1.3.7
Start Optimization

START_OPTIMIZATION and
select Update.
finishes and then close TOSCA
Job and OPTIMIZATION_RUN

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The results produced by the solver in the last iteration are saved in the directory SAVE.<ext>, where <ext> is the extension corresponding to the solver
(in this example, the directory are SAVE.f06 and SAVE.op2). Since the
model with the optimized geometry is used in the last iteration, a generation
of a new model for validation run (as in topology optimization) is not needed.
1.3.8
Postprocessing
Using Tosca Structure.report, the geometry after the shape optimization as
well as the values of controller input (von Mises stress in the example) can
be visualized. This subsection is optional.
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1. Right click SHAPE_CTRL item

under
GENERATE_REPORT_FILE and
3. Right click SHAPE_DISP item

under
select Update.
under
select View.
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2. In the opened CONTOUR_PLOT

PARAMETERS dialog, choose
NODAL DISPLACEMENTS
(SHAPE) from the dropdown
list in TYPE_PROPERTY field.
Alternatively, SHAPE CONTROLLER INPUT can be
chosen: then, the fringe plot
(i.e., the color of the surface)
will reflect the controller input
values (von Mises stress in the
example) and not the optimization displacement values.
Click OK.
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5. In Case Panel choose your result case, either a 3D animation of an optimization plot or a result plot. The animation starts and stops by clicking
on the start forward/backward, pause and stop symbol in the task menu.
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1.3.9
Report Generation
1. Open your VTFX file again by
clicking
VTF_VISUALIZATION and
select View.
2. View | Viewports allows to

select up to four viewports in
different positions. Choose two
viewports: You see the relative
material distribution of your
model on the left side of the
split window. The right side is
still empty.

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3. Select Case 2 in the Table

of Cases and drag it onto the
right part of the window.
Another possibility is to rightclick at case two and select
View 1.
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mouse).
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named GLview Report
chapter!

Repository as to save your
captured situations to a file. If
you close the Tosca Structure
Report Builder window, you can
continue by opening your saved
repository.
10. In Tosca Structure Report Builder window both model siutationsare

listed. By rightclicking at the situation you can delete it or change the
order.
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9. Switch back to Tosca Structure.view window. Repeat steps 6 and 7, but

select 3D model as situation type for capturing.
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12. The last setting is kept for capturing, thus, the original model is loaded
as 3D model into the Tosca Structure Report Builder.
13. Load the original model (right window in Tosca Structure.view) as image
into the Tosca Structure Report Builder. (Look at steps 6 and 7, if necessary, and do not forget to activate the window).
doubleclick at VARIABLE |
DRESP values in the Table
of Cases. This case cannot
be displayed with another viewport. By selecting Capture
Situation or Capture
active view load the plot as
Image into the Tosca Structure
Report Builder.
16. Repeat steps 13, 14 and 15

Cases).
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plot captured as Table.
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which is the original model as
3D model to deactivate this
situation for the transfer. The
same effect is given by rightclicking and selecting Deactivate.
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18. Transfer these situations into

a powerpoint document by
PowerPointReport.
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under <directory>\report\Templates. Select a file location and the media
type. Click OK.
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1.3.10 Result transfer (Smooth)

Tosca Structure.smooth is used in order to extract the surface of the optimized geometry and to save it in a desired format. IGES and STL output formats as well as the output of slices in IGES format are supported.
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RUN_SMOOTH.
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2. Make sure that TASK is set to SURFACE and choose the output formats
you need for CAD transfer (STL and IGES1 in this example); refer to
vol.2 chapter 9.1.9, Output parameters for the differences between
different IGES formats and the description of other formats.
If the output of slices is desired, check slices checkbox and then fill in
the fields SLICE_NUMBER (number of section planes), SLICE_NORMAL
(normal direction of section planes) and SLICE_FORMAT (choice
between polygon or spline slices). Refer to vol.2 chapter 9.1.10, Slices
through 3D models and border of 2D models for more information.
Click OK.
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Update.
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Besides the new geometry loaded into Tosca ANSA environment, the results
of Tosca Structure.smooth (by default saved in TOSCA_POST subdirectory of
your working directory (named Output by default)) might include:
VTFX file for visualization (SMOOTH_INSTANCE.vtfx);
STL file with the optimized geometry (SMOOTH_INSTANCE.stl);
IGES file with the optimized geometry (SMOOTH_INSTANCE.igs);
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4. Tosca Structure.smooth will

finished, close the TOSCA Job
and the TOSCA_SMOOTH
windows. The generated triangular surface is loaded and
model.
SIMULIA
Tosca Structure
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IGES file with slices in one direction (SMOOTH_INSTANCE_slices.igs):

see the next figure.
SIMULIA
Tosca Structure

The result, depending on the used solver, should be similar to Fig. 10.
Stress reduction in the design area from 197 MPa to 134 MPa in
5 iterations (see chapter 1.3.12.3 Redefine the global stop condition)
In Fig. 10 the stress reduction is clearly seen. The maximal stress has been
decreased about 32%. The remaining stress concentration in Fig. 10 can not
be removed because further nodal optimization displacement would lead to
inacceptable element quality. A solution would be to remesh the two areas or
the whole part and to restart the optimization.
1.3.12 Extensions
There may be different manufacturing constraints for the conrod. Assume that
it is produced by casting and therefore must comply to the following requirements:
1. be demoldable;
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Fig. 10
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2. be symmetric to x-z-plane.
These requirements can be realized in different ways in Tosca Structure.shape. In the following only one of these ways is described in detail,
some alternatives will be discussed at the end of the chapter.
Casting Constraint
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1. Add new definitions to your

optimization task: rightclick at
PRE-PROCESSING |
SHAPE_OPTIMIZATION_CONT
ROLLER | DESIGN_AREA |
DV_CONSTRAINTSand select
New | DEMOLD_CONTROL for
a new casting constraint.
SIMULIA
Tosca Structure
2. Define settings for the casting constraint. Set your demolding direction
(DEMOLD_DIR_1 to DEMOLD_DIR_3 fields) to (1, 0, 0). Define a new
group of solidfacets consisting the exterior of the positive half in x-axisdirection. Its important to avoid intersection! Set ND_GROUP and
CHECK_GROUP fields to your new node group (e.g. SURF_DEMOLD_POS).
Repeat this step with the negative part and the demolding direction
(-1,0,0).
Symmetry to x-z-plane
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3. Define symmetry (PREPROCESSING |

ROLLER | DV_CONSTRAINTS
| New |
SYMMETRY_CONTROL) for all
design nodes. The normal
vector for the symmetry plane
should be in y-direction and a
point in the plane defined by x
and y both being zero. Note,
mesh also has to be symmetric.
SIMULIA
Tosca Structure

By visual observation the FE-model seems to gain weight. This may not be
a desired effect. One way to prevent this is to define a volume constraint.
2. Set MAGNITUDE to REL (relative volume)and enter 1.0 in

VALUE field.
Click OK.
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1. In PRE-PROCESSING |
ROLLER |CONSTRAINTS item,
select New |
VOLUME_CONSTRAINT.
SIMULIA
Tosca Structure

Although the very efficient shape optimization often does a really good job
in only 5 iterations a few percent more may be gained by letting the optimizer run a little longer. The simplest way to do this is to change the maximum number of iterations.
1. In PRE-PROCESSING |
SHAPE_OPTIMIZATION |
GLOBAL_STOP_CONDITION
item, choose Edit or double
click
GLOBAL_STOP_CONDITION.
2. Set maximal number of iterations, ITER_MAX, to 10.
Click OK.
1. Try it out using Edit command

on
ROLLER | DESIGN_AREA |
MESH_SMOOTH item or double
click MESH_SMOOTH.
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Tosca Structure.shape has a built in function to select a number of layers of

elements away from the design nodes.
SIMULIA
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2. Select MS_LAYER in EL_GROUP field. In ND_GROUP field, choose the

design area group. Set the value of LAYERS field (the number of mesh
smooth layers) to 5 and click OK.
Observe the difference in the geometry after the optimization, especially
the inner surface of of the holes of the conrod.
Remark
2. The default if no MESH_SMOOTH command is defined is 6 layers from the

design nodes. For the current model and the design area in Fig. 8, the
mesh smooth group becomes too large and the optimization stops after
several iterations because of a bad mesh.
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1. Compared to the description in chapter 1.3.5.3 Selection of mesh

smoothing elements, the automatic definition of the mesh smoothing
elements is a quick but not always optimal option. The problems that can
occur are many especially. In real life applications, the automatic method
may lead to many problems. In this example, the nodes on the inner
surface of the the holes (where the connection elements are) are also
displaced, although this is not desired. Therefore, we emphasize that
selecting the mesh smoothing element group manually can often save time
in the long run.
SIMULIA
Tosca Structure
Fig. 11
Error message of optimization run. The solver run (Abaqus in this

example) was not successful.
1.3.13.1 Suggestions in case of mesh problems

The best solution is of course to remesh, but this may be a time consuming
task.
The second best solution is to check the solver log file and find out which elements are causing the problems. Look these elements up in your preprocessor. If you only have a few problematic elements at the edge of the mesh
smoothing area, try to remove these problematic elements from the mesh
smoothing area.
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In most cases, the problems during shape optimization are related to the
mesh problems, causing the optimization to stop.
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A good mesh for shape optimization does not always mean a high quality calculation mesh. Avoid using mesh refinement on the surface and instead
mesh a little coarser than usual and uniformly.
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1.4
Bead Optimization with Tosca ANSA

environment
Bead optimization is a way to enhance shell structures without adding more
mass to the structure. The beads can easily be added in the stamping process which makes bead a low weight and cost neutral alternative to enhance
a sheet-metal structure.
1.4.1
What is Bead Optimization?
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The easiest way to understand bead optimization is a simple example every

mechanical engineer will intuitively understand.
a)
Fig. 12
b)
Simple plate in bending with loading and supports (a) and an optimal bead (b). The maximal displacement of (a) is 6.6 mm and (b)
is 0.25 mm
SIMULIA
Tosca Structure
Bead Optimization with Tosca ANSA environment
In Fig. 12, a simple flat plate in bending is shown. It is evident that the solution in Fig. 12 (b) has a much greater stiffness than the original flat plate in
Fig. 12 (a).
Regarding the simple example in Fig. 12 a couple of comments must be
made:
bead height
bead width
Fig. 13
Bead height and bead width
The bead height (see Fig. 13) has the most significant effect on the stiffness of the plate structure. Usually, the greater the bead height the greater
the stiffness. But, the bead height is usually controlled by manufacturing
capabilities, i.e. how deep one can draw a bead with your available tools.
Increasing stiffness
Fig. 14
Bead layouts for simple geometries with a uniform pressure load.

From Oehler and Weber: "Steife Blech- und Kunststoffkonstruktionen", Springer-Verlag GmbH (1972)
For more complex loads or dynamic problems, i.e. eigenvalue or frequency

response, the optimal bead layout is not intuitive anymore (see Fig. 14).
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The bead width (see Fig. 13) has an effect on the possible designs. As
seen in Fig. 14 a small or a large bead width is not necessarily related to
the stiffness of the sheet structure. Tosca Structure.bead default values
usually suffice, but if an optimal solution is sought you must try more bead
widths.
SIMULIA
Tosca Structure
Thus, an easy way to find a good bead pattern is to use Tosca Structure.bead.

Tosca Structure.bead is the Tosca Structure module for bead optimization.
Two bead optimization algorithms have been implemented:
Controller based bead optimization (BEAD_CONTROLLER)
Sensitivity based bead optimization (BEAD_SENSITIVITY)
In general the controller algorithm is much faster than the sensitivity algorithm, but lacks handling of complex design responses such as frequency
response or combined responses. The controller algorithm leads to very easy
interpretable beads. The bead patterns of the sensitivity algorithm can be
more difficult to interpret, but the results are often superior to the controller
results, especially for dynamic problems.
stiffness (compliance and displacements*)
eigenfrequencies
* Only sensitivity based algorithm allows these constraints and objectives
The following presents a start guide for Tosca Structure.bead. The purpose is
to show how simple it is to set up a bead optimization problem in Tosca ANSA
environment. For more background knowledge about bead optimization, differences between the two algorithms and other advanced settings in Tosca
Structure.bead please consult the user manual. This guide is restricted to
showing the controller based bead algorithm.
The Model
Model information:
A model of an oilpan is found in the Tosca Structure installation directory
(<tosca>) according to your FE-solver (<solver>) :
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1.4.2
SIMULIA
Tosca Structure
<tosca>/<solver>/examples/bead/oil_pan
x
Fig. 15
FE-model of an oilpan: a typical automotive sheet metal part.
Dimensions:
Length (z-direction): ~ 500 mm
width (x-direction): ~ 305 mm,
depth (y-direction): ~42 mm,
thickness: 1.3 mm
Mesh: Average element edge length: ~ 7 mm, mostly linear quads and a
few trias.
Initial 1st eigenvalue: 179 Hz
Boundary conditions are for simplicity crude full supports on the edges of
the oilpan. Real life boundary condition could be obtained by using the full
body-in-white model of a car which would also run with Tosca Structure - of
course with unreasonable runtimes for this simple introduction.
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The element normals of the shell elements are in the negative y-direction.
y
x
Fig. 16
1.4.3
Design area
Optimization Task
Maximize the natural (1st) eigenfrequency of the oil pan using controller
based algorithm. The maximal bead height is 5 mm and the bead direction
must be in the positive y-direction, see Fig. 15.
Note that, with some minor modifications, the same task can be solved using
the sensitivity-based bead optimization. However, for this example, the controller-based algorithm is chosen because it leads to shorter optimization
time.
1.4.4

Preprocessing
BEAD_CONTROLLER command of Task Manager
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3. Design area: PRE_PROCESSING | BEAD_OPTIMIZATION_CONTROLLER
| DESIGN_AREA
4. Constraint on nodes with boundary conditions: PRE_PROCESSING |
BEAD_OPTIMIZATION_CONTROLLER | DESIGN_AREA |
DV_CONSTRAINTS | CHECK_BC
5. Objective function: PRE_PROCESSING |
BEAD_OPTIMIZATION_CONTROLLER | OBJ_FUNC_ITEM_1
6. Objective function term: PRE_PROCESSING |
BEAD_OPTIMIZATION_CONTROLLER | OBJ_FUNC_ITEM_1 | EIGENFREQUENCY
SIMULIA
Tosca Structure
7. Bead height constraint: PRE_PROCESSING |

BEAD_OPTIMIZATION_CONTROLLER | CONSTRAINT |
BEAD_HEIGHT_CONSTRAINT
BEAD_OPTIMIZATION_CONTROLLER | Output
Node displacement check (Check Inputs)
9. Using test displacements: CHECK_INPUTS | TEST_BEAD_CHECK |
TEST_BEAD
Start optimization
Postprocessing
11.Viewing the intermediate results:POST-PROCESSING |
Result transfer and validation run (Smooth)
12.Smooth surface: SMOOTH | SMOOTH_INSTANCE | RUN_SMOOTH
13.Modified surface: SMOOTH | SMOOTH_INSTANCE | VALIDATE |
BATCH_RECONSTRUCT
14.Saving the result: SMOOTH | SMOOTH_INSTANCE | VALIDATE |
VALIDATION_OUTPUT
1.4.5
Preprocessing

ANSA window.
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15.Running the solver: SMOOTH | SMOOTH_INSTANCE | VALIDATE |

VALIDATION_RUN
SIMULIA
Tosca Structure

TASK | BEAD_CONTROLLER.

Expand-button.

LINK, chooseas WORKING
MODEL_LINK.
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MODEL_LINK in Task
SIMULIA
Tosca Structure

double click FILE.

input file and click Open.
The items FILE and PREPROCESSING in Task
Manager get renamed: the file
name is used as the name of
FILE item, while the directory
of the file is appended to

In bead optimization, the design area denotes the set of nodes that may be
displaced during the optimization, in contrast to the frozen areas that
remain unchanged.
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and select Update. The input
file is loaded and the model is
shown in the main window.
SIMULIA
Tosca Structure

DESIGN_AREA in Task
2. In the appeared DV_BEAD

ND_GROUP.

screen.
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key.
SIMULIA
Tosca Structure
5. In this window, click GRID item

once in order to highlight it.
Now, the nodes of the model
can be chosen using the
mouse.
6. If needed, bring the model to the view shown in the figure by pressing F1
key. Then, enclose all nodes but those that belong to the outer rim in a
frame drawn with the mouse while holding the left mouse button. Make
sure that the nodes on the upper flat surface are not selected. Click with
the middle mouse button to confirm the selection and to proceed to SET
window.

will then close.
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OK.
SIMULIA
Tosca Structure
9. Click OK in DV_BEAD window.

In the example, the objective function that is to be maximized is the first
eigenvalue.

"(MODAL,All,1)". Alternatively, select the appropriate
values of APPROACH, LOADCASE and SUBSTEP fields of
the dialog LC_SET that opens
when "?" key is pressed in
LC_SET field and click OK.
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EIGENFREQUENCY.
SIMULIA
Tosca Structure

4. Select MAX as the value of


The constraint is necessary in order to put the limits for optimization displacements.
2. In CONSTRAINT_ITEM window,
select ABS in the dropdown list
MAGNITUDE and set the value
of VALUE field to 5.
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1. Right click CONSTRAINTS item

and select New |
BEAD_HEIGHT_CONSTRAINT.
SIMULIA
Tosca Structure
3. Select GROUP_DEF instead of

ALL_NODES in GROUP_DEF
dropdown list.

key. In this case, no new group
should be defined since the
design area group is already
selected. Therefore, the
window GROUP_DEF HELP that
appears when "?" key is
pressed is only needed for the
selection of the group name,
that may also be inserted
manually.
6. Click OK.
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5. Double click the name of the

design area group
example). The window SET
HELP then closes.
SIMULIA
Tosca Structure

1. Right click
BEAD_OPTIMIZATION_CONTR
OLLER itemabd select New |
SETTINGS.
2. In the opened OPT_PARAM

window, set the value of SCALE
field to -1. This changes the
displacement direction of nodes
in the design area.
Click OK.
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3. Right click Output item and

select Update. The parameter
file Output.par for Tosca
Structure is written at this point.
The file is saved in the same
directory where the input model
is located. The optimization
with Tosca Structure will also
start in this directory. Note that
you may change the parameter
file name (and, thus, the
working directory that is named
after it) by clicking twice on
Output item.
Node Displacement Check (Check Inputs)

Using CHECK_INPUTS item, the change of the geometry caused by sample
optimization displacements is examined. This test reveals possible problems with the definition of the design area as well as checks if the syntax of
the parameter file is correct. Also, by viewing the geometry after the test
displacements in VTFX format, the user is able to see if the real optimization displacements are likely to result in distorted elements or violate some
other requirements. This check is optional; it has no effect on further
actions. However, it is recommended in most cases since it usually requires
much less calculation time than the entire bead optimization.
In case that design restrictions are defined, they are also enforced during
CHECK_INPUTS operation, and thus it can be checked if they are defined
correctly.
1. Right click CHECK_INPUTS
TEST_BEAD_CHECK.
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SIMULIA
Tosca Structure
2. Right click TEST_BEAD_CHECK

TEST_BEAD.
3. In the opened TEST_SHAPE

dialog, enter 3 in the field
DISPLACEMENT; this is the
maximal test displacement
value.
5. Make sure that the value in

DIRECTION field is GROW and
click OK.
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4. Enter 3 in the field INCREMENT;

this is the number of iterations
in which the displacement is
increased from 0 to the
maximal value.
SIMULIA
Tosca Structure
6. Right click TEST_BEAD_1 item

and select Update.
Wait until Tosca Structure
finishes and close TOSCA Job
and TOSCA_TEST window to
continue.
7. Right click TEST_BEAD_CHECK

VTF_VISUALIZATION.
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8. Right click
and select View.
Tosca Structure.view window
opens.
SIMULIA
Tosca Structure
9. The animation starts and stops

by clicking on the start forward/
backward, pause and stop
symbol in the task menu.
Examine the model with test
displacements and close Tosca
Structure.view window in order
to proceed with Tosca ANSA
environment.
1.4.7
Start Optimization

START_OPTIMIZATION and
select Update.
finishes and then close TOSCA
Job and OPTIMIZATION_RUN
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Tosca Structure

The default bead width is proportional to the average element length; in this
example, the average element lengths equals 7 while the bead width is 45;
both values are found in TOSCA.OUT file.

The results produced by the solver in the last iteration are saved in the directory SAVE.<ext>, where <ext> is the extension corresponding to the solver
(in this example, the directory are SAVE.f06 and SAVE.op2). Since the
model with the optimized geometry is used in the last iteration, a generation
of a new model for validation run (as in topology optimization) is not needed.
1.4.8
Postprocessing
Using Tosca Structure.report, the geometry after the bead optimization as
well as the values of controller input can be visualized. This subsection is
optional.
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1. Right click BEAD_DISP item

under
BEAD_DISP.
SIMULIA
Tosca Structure
2. In the opened CONTOUR_PLOT

PARAMETERS dialog, choose
NODAL DISPLACEMENT
(BEAD) from the dropdown list
in TYPE_PROPERTY field. Alternatively, BEAD CONTROLLER
INPUT can be chosen: then,
the fringe plot (i.e., the color of
the surface) will reflect the
controller input values and not
the optimization displacement
values.
Click OK.

under
select View.
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3. Right click BEAD_DISP item

under
select Update.
SIMULIA
Tosca Structure

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6. Click POST-PROCESSING |
Update.
SIMULIA
Tosca Structure
1.4.9
Report Generation
1. Open your VTFX file:
VTF_VISUALIZATION >
View.
2. With View | Viewports you

can select up to four viewports
in different positions. Choose
two viewports: You see the relative material distribution of your
model in the left side of the split
window. The right part is still
empty.

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View 1.
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Tosca Structure

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mouse).
SIMULIA
Tosca Structure

named GLview Report
chapter!

situations to a file. If you close
the Tosca Structure Report
Builder window, you can go on
by opening your saved repository.
10. In the Tosca Structure Report Builder window now both siutations are
listed. By rightclicking at the situation you can delete it.
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9. Go back to Tosca Structure.view window. Repeat step 6 and 7, but select

3D model as Situation type for capturing.
SIMULIA
Tosca Structure
11. Now, in Tosca Structure.view

window select the right window
and click Quick Capture
active view in the quick
access toolbar or select File
| Quick Capture Situation.
12. The last settings are kept for capturing, thus the original model is
loaded as 3D model into the Tosca Structure Report Builder.
into the Tosca Structure Report Builder. (Look at step 6 and 7, if necessary, and do not forget to activate the window).
doubleclick at

Cases).
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15. Repeat step 13 to capture the

same plot as Table.
SIMULIA
Tosca Structure

situation name is shown without
number in italic. The same
effect is achieved by rightclicking and selecting Deactivate.
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18. Transfer the active situations

into a powerpoint document by
PowerPointReport.
SIMULIA
Tosca Structure
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in <tosca_directory>\report\Templates. Select your output file name and
the media type (3D plugin for interactive and animated 3D data, videos
and image for animations and image only for screenshots of all situations). Click OK.
SIMULIA
Tosca Structure
1.4.10 Result Transfer (Smooth)

Tosca Structure.smooth is used in order to extract the surface of the optimized geometry and to save it in a desired format. IGES and STL output
formats are supported.
RUN_SMOOTH.
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2. Make sure that TASK is set to

SURFACE.
SIMULIA
Tosca Structure
3. Choose the output formats you need for CAD transfer (STL and IGES in
this example); refer for the differences between different IGES formats
and the description of other formats and click OK.
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Update.
Tosca Structure.smooth will
finished, the generated triangular surface is loaded and
model; see next figure.
SIMULIA
Tosca Structure
5. Tosca Structure.smooth will

finished, close the TOSCA Job
and the TOSCA_SMOOTH
windows. The generated triangular surface is loaded and
model.
Besides the new geometry loaded into Tosca ANSA environment, the results
of Tosca Structure.smooth (by default saved in TOSCA_POST subdirectory of
your working directory (named Output by default)) might include:
VTFX file for visualization (SMOOTH_INSTANCE.vtfx);
STL file with the optimized geometry (SMOOTH_INSTANCE.stl);
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IGES file with the optimized geometry (SMOOTH_INSTANCE.igs).
SIMULIA
Tosca Structure

When the bead optimization with Tosca Structure is finished, the result
(depending on solver) should be similar to Fig. 17.
a)
Optimization displacement result plots from controller based

bead optimization where a) has default bead width and b) has
bead width 30.0 mm. The eigenvalues are (a) 356 Hz and (b) 385
Hz, which is an increase of 99% and 115%, respectively.
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Fig. 17
b)
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1.5
Sizing with Tosca ANSA environment

At the beginning of the conventional design process, the design engineer
often defines new components using the experience and the results gained
from existing designs. This results in an evolution process that might require
several manual design iterations and a long process development time.
Optimization tools provide the engineer with an automatic procedure to
develop fundamentally new designs and shorten the development process.
For sheet metal structures ideal sheet thicknesses according to the existing
load and boundary conditions have to be derived.
With Tosca Structure, it is possible to carry out sizing optimization in the existing CAE environment. Within this process shell thicknesses are calculated
automatically to obtain optimal sheet metal structures.
Fig. 18
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1.5.1
Sizing for chassis components

Sizing is a tool to optimize sheet metal components through modification of
sheet thicknesses. It is mostly applied at a later stage of the development
process when the general layout of a component (i.e. the topology) is more or
less fixed.
Starting with the design area (which represents the sheet structures to be
modified) and with the boundary conditions, such as loads, fixtures and manufacturing conditions, the optimization system will determine a new thickness
distribution by modification of the shell thicknesses in the design area. This
design proposal should fulfill all mechanical requirements and often represents a weight-optimal design proposal. Sizing with Tosca Structure allows
changes for each single shell element in the model as well as clustering of
thicknesses, i.e. simultaneous modification of shell thicknesses for specific
areas.
For the optimization, the following constraints and objectives can be applied:
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Tosca Structure
stiffness (compliance and displacements);

eigenfrequencies;
internal and reaction forces;
weight, volume;
center of gravity;
moment of inertia.
In addition, a number of manufacturing constraints can be applied ensuring
that the design proposal can be produced. Different constraints like, e.g.,
symmetry constraints can be defined.
As result, the optimization creates a design proposal with new shell thicknesses. This design proposal can then be transferred back to your CAD system.
1.5.2
Model
The component to be used within the tutorial represents a holder for a gear
shift control and is found in the Tosca Structure installation directory (<tosca>)
according to your FE-solver (<solver>) (available for Abaqus and ANSYS):
<tosca>/<solver>/examples/sizing/holder
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The model is meshed with linear homogenous shell elements with an initial
thickness of 3.5.
There are two loadcases defined. The first one is a bending loadcase with a
load Fx =-2500N at node 5 and the second one is a torsional moment Mx =
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80000 Nmm at node 5. Further, all drill holes are fixed in all directions (cf. Fig.
19).
Fig. 19
Original design of a holder with loads and design area (yellow)
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The design area consists of the elements in the interior of the structure, colored yellow in Fig. 19 . The elements of the design area are combined to a
group design_all which can later be used for the optimization. For further
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Fig. 20
1.5.3
Clustering groups (from left to right):

Horizontal clustering groups named DES_HOR1 (on the top) till
DES_HOR12, vertical clustering groups named DES_VER1 (left
group) till DES_VER6 and circular clustering groups named
DES_RING1 (outer ring) till DES_RING3.
Optimization Task
The optimization task is to find a structure with maximum stiffness for the
component for both static load cases. Additionally, a volume constraint of
maximum 100 % of the initial volume should be considered.
The value for the first constraint is calculated from the sum of the volumes of
all elements.The first eigenmode is derived from a modal analysis.
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tasks using clustering this design domain is split into several subgroups as
described below:
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The shell thicknesses should vary between an absolute value of 0.1 and 3.0.
Four variants of the optimization can be performed:
Free sizing (i.e. the shell thicknesses of all design elements can be modified independently)
Clustering with horizontal areas (the design area is split horizontally into
several areas in which the shell size will vary simultaneously)
Clustering with vertical areas (the design area is split vertically)
Clustering with "circular" areas (the design area is split into several "round"
areas) - this cluster variant is motivated by the result of the free sizing.
1.5.4

Preprocessing
SIZING command of Task Manager
3. Design area: PRE_PROCESSING | SIZING_OPTIMIZATION |
DESIGN_AREA
4. Constraint on shell thickness: PRE_PROCESSING |
SIZING_OPTIMIZATION | DESIGN_AREA | DV_CONSTRAINTS |
THICKNESS_BOUNDS
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6. Objective function: PRE_PROCESSING | SIZING_OPTIMIZATION |

OBJ_FUNC_ITEM_1
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5. Optional: Clustergroup definition: PRE_PROCESSING |

SIZING_OPTIMIZATION | DESIGN_AREA | DV_CONSTRAINTS |
CLUSTER_GROUPS
9. Volume constraint terms: PRE_PROCESSING | SIZING_OPTIMIZATION

| CONSTRAINTS | VOLUME_CONSTRAINT
7. Objective function terms: PRE_PROCESSING | SIZING_OPTIMIZATION

| OBJ_FUNC_ITEM_1 | COMPLIANCE
8. Volume constraint: PRE_PROCESSING | SIZING_OPTIMIZATION |
CONSTRAINTS
10.Saving Tosca Structure parameter file: PRE_PROCESSING |

SIZING_OPTIMIZATION | Output
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Start optimization
Postprocessing
12.Viewing the intermediate results:POST-PROCESSING |
Please note that Tosca Structure 8.0 or higher is required in order to complete the optimization task.
1.5.5
Preprocessing
In the following detailed description the setup of a typical sizing optimization
task with Tosca ANSA environment is shown.

ANSA window.

Expand-button.
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TASK | SIZING.
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MODEL_LINK in Task

your input file (Abaqus in this
example) and click OK.
MODEL_LINK.

input file holder.<ext> and
click Open.
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double click FILE.
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(holder.<ext>) and select
Update. The input file is loaded
and the model is shown in the
main window.

In sizing optimization, the design area denotes the set of elements that may
be changed (whose thicknesses are modified) during the optimization. A
subset can be defined as frozen areas which will remain unchanged.
DESIGN_AREA in Task
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2. In the DV_SIZING window,

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key.

Choose your predefined group
DESIGN_ALL from the list of
predefined groups.
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5. Double click to assign this

group to your design area definition. Click OK.
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6. FE model with the highlighted

DESIGN_AREA.
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1.5.5.4 Choice of thickness bounds (design variable constraint)

Design variable constraints introduce restrictions on the shape of the optimized model. Besides the shell thickness constraint discussed below, other
types of design constraints such as symmetry and minimum member size
restrictions are supported by Tosca Structure.
Select New |
THICKNESS_BOUNDS.
2. In THICKNESS_BOUNDS
EL_GROUP
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key.
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4. In the SET HELP window,

double click DESIGN_ALL item.
The window will then close and
assign the chosen group to the
design variable constraint.
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5. For defining a thickness restriction for the selected element

group define a lower and upper
bound of 0.1 and 3.0 respectively in the corresponding
fields. Select Magnitude = ABS
for absolute magnitude.
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Tosca Structure

It is always recommended to perform a first sizing optimization without too
much additional constraints to use the maximum design flexibility for the
optimization. Influenced by a first design proposal, clustering may be introduced. With Clustering, certain areas of the model are grouped such that
they get a common shell thickness during the optimization. Clustered areas
may later be manufactured by sheets of constant thickness. An example is
the optimization of an assembled sheet structure like a car body, where
each sheet has one thickness.
Select New |
CLUSTER_GROUPS.
3. For horizontal clustering choose the groups DES_HOR1 till DES_HOR12,

for vertical clustering choose the groups DES_VER1 till DES_VER6 and
for circular clustering choose the groupsDES_RING1 till DES_RING3 as
shown in Fig. 20. Please note: for each cluster group one single
DV_CONSTRAINT definition is required.

In the example, the maximum compliance of both loadcases is to be minimized.
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2. In CLUSTER_GROUPS window,
dropdown list below
EL_GROUP. Type "?" to
access the list of predefined
groups.
SIMULIA
Tosca Structure

COMPLIANCE.

"(STATIC,1,,)". Alternatively, select the appropriate
values of APPROACH, LOADCASE and SUBSTEP fields of
the dialog LC_SET that opens
when "?" key is pressed in
LC_SET field and click OK.
3. Repeat steps 1-2 for the second load case.
5. Select MIN as the value of

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1. Right click CONSTRAINT item
and select NEW, then select
VOLUME_CONSTRAINT.

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2. Enter 1.0 in the field VALUE

and click OK.
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1. Right click Output item. Select

Update.
The parameter file
this directory.
1.5.6
Start Optimization
The following chapters describe how to start the optimization with an illustrated step-by-step instruction.

START_OPTIMIZATION.
Select Update.
finishes. Then close the TOSCA
Job and the
OPTIMIZATION_RUN window
to continue.

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1.5.7
Postprocessing
Using Tosca Structure.report, the intermediate results of sizing optimization, namely the thicknesses of element shells, can be visualized. This subsection is optional.
1. Right click
SIZING_THICKNESS item
under
Select Update.
A VTFX file containing the optimization results will be generated.
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2. To view the VTFX file right click

under GENERATE_POST_FILE
and select View.
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1.5.8
Report Generation
1. Open your VTFX file:
VTF_VISUALIZATION >
View.

View 1.
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the element thickness distribution of your model on the left
side of the split window. The
right side is still empty.
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mouse).

Image as Situation type for
capturing and press OK. A new
window named GLview
Report Builder opens.
Keep this window open till the
end of this chapter!
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Tosca Structure

chosen situations to a file. If
repository.

12. The last setting is used for capturing, thus, the smoothed optimization
13. Load the optimization result ELEMENT_DELTA_THICKNESS (right
window in Tosca Structure.view) as image into the Tosca Structure
Report Builder. (Look at step 6 and 7, if necessary, and do not forget to
activate the window).
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10. In Tosca Structure Report Builder window both model situations are
now listed. By rightclicking at the situation you can delete it or change the
order.
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Tosca Structure

doubleclick at
plot as Table.
16. Repeat step 12,13 and 14 with
the objective function
Cases).
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17. Now there should be 8 entries

Doubleclick at one entry to
transfer. The same effect is
given by rightclicking and
selecting Deactivate.
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type. Click OK.
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PowerPointReport.
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21. For transferring into a word file use Create WordReport and the
As the vtfx plug-in only works in combination with Internet Eplorer, you
can choose Video and image as Media type for other browsers.
1.5.9
Result Discussion
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A free sizing optimization without additional restrictions leads (naturally) to

the best results, in this case a reduction of the maximum displacement by
45%. An optimization with clustering (circular in this case), required by manufacturing, still leads to an improvement of 30%. In the figure below (Fig. 21)
the displacement results are shown:
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Tosca Structure
Displacement magnitude: initial model, optimization result without

clustering and with circular clustering (top to bottom)
Fig. 22 and Fig. 23 show the shell thickness in the design area for different
cases: The differences in the results of the optimization without clustering and
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Fig. 21
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with the several kinds of clustering are obvious. Furthermore, the result of
optimization with vertical clustering indicates the unsymmetric load.
Fig. 22
Optimization results: Final shell thickness in the design area without clustering (left) and with horizontal clustering (right)
Fig. 23
Optimization results: Final shell thickness in the design area with

vertical clustering (left) and with circular clustering (right)
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Getting Started with Tosca

Structure.gui
Tosca Structure.gui simplifies the work process of Tosca Structure for the
user. The graphical user interface supports the user with defining the optimization task (Tosca Structure.pre), starting the optimization in Tosca Structure,
calculating iso surfaces, data smoothing and reduction (Tosca Structure.smooth) and preparing results for FE postprocessors (Tosca Structure.report).
Fig. 24
2.1
Tosca Structure.gui: graphical user interface of Tosca Structure
User interface
2.1.1
Requirements, Settings and Program Start

Tosca Structure.gui is a platform-independent Jar archive. An html browser
and Adobe Acrobat Reader to view the documentation should be installed to
simplify the handling of the program. Further, a vrml plugin (not provided with
Tosca Structure) or a vtfx plugin (for download see http://www.fe-design.de/
tosca/toscaview.html) must be installed to visualize vrml or vtfx files in html
pages.
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Tosca Structure.gui is the classical user interface for the definition, start and
postprocessing of Tosca Structure optimization tasks.
SIMULIA
Tosca Structure
User interface
Tosca Structure.gui is started by calling the jar files tosca_gui.jar. When using
Unix, type tosca_gui in a command line. For Windows, Tosca Structure.gui
can be found in the Start Menu.
Tosca Structure.gui: Settings
In order to gain the most from all program functionalities a few default settings
may need to be made. The window Edit Configuration shows the paths of
the external programs used by Tosca Structure.gui, the Tosca Structure
installation directory (Tosca StructureHome) and extensions of the solver
files. The paths are set to standard paths during installation. Using the button
"Reset to Defaults" the paths are read from the Tosca Structure configuration
and entered on the screen.
The settings are saved (button Save) in a file toscagui##.ini (## = current
Tosca Structure version) in the user directory (and in the user profile). This file
also serves as a configuration file for Tosca Structure.pre. Should there be
deviations in the paths from standard during installation of the modules, some
paths may need to be set individually.
2.1.2
Tosca Structure.pre
The optimization task is defined using Tosca Structure.pre and the settings
are stored in a parameter file. A predefined parameter file can be loaded into
Tosca Structure.pre (File -> open) and is then available for any desired modifications or the optimization task can be defined from scratch. The optimiza-
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Fig. 25
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tion task can either be created by a wizard or by defining the individual

commands.
Fig. 26
Tosca Structure.pre: Defining the optimization task
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2.1.2.1 Overview
The graphical user interface of Tosca Structure.pre consists of a menu, a toolbar, a status line and a split inner frame.
The left frame shows the entire parameter file in text format, compact format
or tree format. The compact format only shows command types and the ID
name of each command. By "Opening" the command the complete definition
is shown. Using the text view (text format in left frame) of the parameter file, a
double click on a command opens the corresponding command template in
the right frame. In the tree format, commands can be edited by simply clicking
on an entry in the tree. Commands of the same type are grouped in the tree
view. The order of the commands corresponds to the best sequence for creating a new parameter file.
In the right frame, a selected command can be created or modified in a command template.
SIMULIA
Tosca Structure
User interface
The toolbar provides buttons to move commands, save and open parameter
files, undo and redo buttons and a help button that opens the Tosca Structure
help file.
Fig. 27
Interface of Tosca Structure.pre
2.1.2.2 Creating, modifying and saving parameter files

Creating a new parameter file
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The menu item File/New File creates a new (empty) parameter file.
There is no difference between the creation of a parameter file for a bead,
topo or shape optimization task.
SIMULIA
Tosca Structure
The new parameter file contains only a standard header and the final EXIT
command.
Fig. 28
Creating or opening a parameter file
The menu item File/Open can open an existing parameter file. The parameter file can be selected in a file dialog. If the parameter file contains
FEM_INPUT or GROUP_IMPORT definitions, the corresponding files will
automatically be scanned for group definitions. These groups are available
whenever a group can be selected by a command. The content of these
groups can not be modified. Nastran bdf files do not contain any group definitions, therefore this feature is not available for Nastran files.
Saving a parameter file
The parameter file can be saved by pressing the save button in the toolbar or
in the file menu.
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Reading an existing parameter file
SIMULIA
Tosca Structure
User interface
Switching between text, tree and compact view

The buttons in the lower left corner of the interface allow the user to switch
between text view, compact view and tree view of the parameter file (similar
to the tree structure in previous Tosca Structure versions)
Fig. 29
Different views of the parameterfile
Quitting the program

If the parameter file has been modified, and the application is ended by
File/Exit or if a new file is opened or created the user will be warned by a
message box:
Fig. 30
Message box when leaving the application
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The text version is editable when no command is opened in the command

editor in the right frame. All copy & paste functionalities that are available in
Windows or Unix are accessible.
The tree view gives the best overview over the commands of the groups. For
each type of commands a folder is shown. Any new defined command is
added to the folder of its type in the tree structure. The tree view is not directly
editable, therefore commands have to be edited in the corresponding command templates.
The compact view allows the user to "open" commands to display the complete definition of a single command. This view is not editable, therefore commands have to be edited in the command editor.
SIMULIA
Tosca Structure
2.1.2.3 Defining optimization tasks

Procedure
A right-click in the left frame (parameter file) opens a context menu with the
most common commands:
This context menu also represents a guideline for defining an optimization
task that sequentially can be processed. Specific commands are labeled
according to the optimization type (bead (B), shape (S), topology (T)).
Add commands
A new command can be created either by selecting the corresponding item in
the context menu or using the command menu:
Adding a new command using the command menu
A template will open in the right frame where parameters for the commands
can be set. A basic syntax check is performed when creating a new command. By pressing the button "Create" the command is inserted into the
parameter file. The position of the command in the parameter file is deter-
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Fig. 31
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User interface
mined by Tosca Structure.pre. Afterwards, the commands can be modified in

the parameter file.
Referencing previously defined commands
Objects defined by previous commands can be referenced in other commands by choosing them in the selection boxes (see Fig. 32). The solver
input files that are specified in the READ or GROUP_IMPORT commands will
be scanned for definitions of element and node groups. These groups can be
referenced by various commands too (see vol.1 chapter 2.1.2.4).
Modifying commands
If an existing command should be changed, it has to be selected in the
parameter file. The command is opened with an appropriate template in the
right frame where the parameters can be changed. The changes are
accepted by pressing the button "Modify".
To copy a command it first has to be selected in the parameter file view (left
frame). The id name of the command must now be changed in the command
editor. By pressing "Create" the command is inserted as a copy of the original
command. It is essential to change the id name of the command, because
two commands of the same type must not have identical id names.
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Fig. 32
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When using the text view for editing the parameter file, commands can be
copied with copy & paste, but the id name has to be modified manually afterwards!
Fig. 33
Modify and copy commands
Some commands are only allowed once in the parameter file (e.g.
FEM_INPUT) and can not be copied.
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Deleting commands
The button "Delete" removes the selected command from the parameter file.
Arrangement of the commands
The arrangement of the individual commands in the parameter file is arbitrary.
Only if a command references another command, the referenced command
has to be defined before.
New commands will be added automatically to the parameter file in a suitable
position.
Comments
Comments can be added anywhere in the parameter file (even inside of commands). Commands are not available as a command, but have to be inserted
SIMULIA
Tosca Structure
User interface
manually in the text view of the parameter file. Comment lines always start
with an !.
Existing comments can be loaded and edited in a command template.
INCLUDE commands
An INCLUDE statement inserts Tosca Structure commands from another file
into the current parameter file. A file can be selected in a file selection box by
Add Include from the menu "Edit" and from the context menu, respectfully. INCLUDE-commands are always by default inserted at the end of the
parameter file. Therefore, it has to be moved manually to the desired position.
Adding free text
Tosca Structure.pre does not support all available commands (e.g. SELECT).
These commands can be added as free text. There is no command item for
free text. However, free text can just be added into the text view of the parameter file.
2.1.2.4 Simplifications for the user

Tosca Structure.pre offers some direct possibilities to select common features
or to reference previously defined objects.
If other objects have to be referenced in a command (e.g. when combining

constraint, objective function and design variables to a complete optimization
task with the command "OPTIMIZE") the appropriate objects are supplied in a
selection list.
Groups that are defined in the solver input files are extracted and can be referenced by other commands (this feature is only available for Abaqus, Marc,
ANSYS and PERMAS). The format of the input file is detected automatically
by the file extension. Tosca Structure uses by default the common file extensions of the solvers. Default values can be changed in the preferences menu
of Tosca Structure.gui.
Extensions of default solvers in Tosca Structure.gui:
NastranSuffix = nas; bdf
AbaqusSuffix = inp
ANSYSSuffix = ans; cdb
PERMASSuffix = uci
MarcSuffix = dat
Standard Design Responses
The compilation of design responses is needed for defining the objective
function and the constraint. The compilation is quite simple when using one of
the following standard design responses:
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Selection lists of predefined objects
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First natural frequency: used for defining the objective function in shape
and topology optimization
Maximum absolute displacement: can be used as a constraint in topology
optimization
Maximum von Mises stress: used to define the objective function in shape
optimization
Sum of Strain Energy: can be used to define the objective function in topology optimization
Volume (Shape): total volume of the model; which can be used to define
constraints in shape optimization
Volume (Topology): relative volume of the model; which defines volume
constraints in topology optimization
Bead height: used for defining the constraint in bead optimization.
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By selecting one of these standards all parameters in the design response

template will automatically be set. Eventually, the group chosen for the calculation of the design response has to be changed. Afterwards, the command
just has to be inserted into the parameter file.
Fig. 34
Standard Design Response
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Tosca Structure
User interface
Wizard
New parameter files can be generated using a wizard. The wizard is available
in the menu File/TOSCA.wizard or by pressing the "New" button in the
toolbar.
Fig. 35
Tosca Structure.wizard
When finishing the wizard, a parameter file with all absolutely required definitions is created. Afterwards, the parameter file can be modified as usual.
The wizard is limited to the following topics:
selection of optimization type (Topo, Shape, Bead)
definition of design area

geometrical restrictions (frozen area, casting restrictions)
definition of an objective function
specification of a constraint (if available)
optimization parameters (speed)
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choice of model file (solver input file)
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output requests
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Fig. 36
Tosca Structure.wizard: some steps
Design nodes and elements are defined by an element or a node group. If the
groups are available in the solver input file, they can be selected in the wizard. Alternatively, a new group can be defined as an element or node list.
After completing the wizard, the commands can be modified or new commands can be added as usual.
2.1.3
Starting the Optimization

Optimization with Tosca Structure.bead, Tosca Structure.shape or Tosca
Structure.topology can be started on the "Start Tosca Structure" screen in
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User interface
Fig. 37
Tosca Structure: Starting optimization from Tosca Structure.gui
When pressing the button "Abort", the current optimization aborts. To resume
the optimization has to be started again with the option "-restart".
A small queueing system is available in the template "Start Tosca Structure".
It can be used to start multiple Tosca Structure jobs successively on your
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Tosca Structure.gui. The job name of the optimization job (chosen by a

parameter file), the start directory and if necessary the name of the FE solver
are defined here. Further (optional) settings can be made using the menu
"additional Parameters".
After starting the optimization, information about the optimization process is
given in the output window. When calling tosca using a command line vol.2
chapter 2.4, Working with Tosca Structure in the Command Shell, this control
information is transferred directly into the command window. More detailed
information regarding the output information for the optimization process can
be found in the Tosca Structure User Manual (vol.2 chapter 12, Tosca Structure Control).
SIMULIA
Tosca Structure
local computer. If a Tosca Structure job is already running and a new job is
started, the new job will automatically be added to the queue.
Fig. 38
Add a job to the queue
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By the button "Edit queue" it is possible to display the status of the queue. All
optimization jobs that will be started after the current job are listed here. Each
individual job can be moved or deleted.
If the current optimization is aborted, the optimization stops and the queue is
paused. Meaning that no new optimization is started until the pause mode is
ended.
Fig. 39
2.1.4
Editing the queue
Tosca Structure.smooth prepares the optimization result for transfer into a
CAD-system or FE-preprocessor. The Tosca Structure.gui window Tosca
Structure.smooth enables you to enter parameters to perform and control sur-
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Tosca Structure
User interface
face or isosurface calculation for an optimization result, smoothing and data

reduction. The results from Tosca Structure.smooth can be displayed by
Tosca Structure.view.
Fig. 40
2.1.5
Tosca Structure.smooth: Input parameters via Tosca Structure.gui
Visualization with Tosca Structure.view
2.1.6
Postprocessing (Tosca Structure.report)

The module Tosca Structure.report allows a preparation for postprocessing of
the optimization results. Animation sequences for Tosca Structure.view
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Tosca Structure.view can display animations of the optimization results. Start

Tosca Structure.gui using the button View Report of Tosca Structure.smooth or Tosca Structure.report screen in Tosca Structure.gui.
Besides Tosca Structure.view a plug-in for MS Internet explorer, MS PowerPoint and MS Word is available. Thus, it is possible to create interactive presentations inside MS Office documents.
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Tosca Structure
including plots of optimization relevant values (objective, constraint) can be

created.
Tosca Structure.report: Preparation of the optimization results for

postprocessing
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Fig. 41
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User interface
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2.2
Topology Optimization with Tosca

Structure.gui
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At the beginning of the conventional design process the design engineer

defines the shape and the topology of new components using the experience
and the results gained from the forerunner. These results in an evolution process which might lead to an optimum design after some iterations and a long
period of time.
Nowadays it is necessary to shorten the development process of new components. Therefore tools are necessary that replace the natural evolution process by an automatic procedure.
With Tosca Structure it is possible to carry out topology and shape optimization in the CAE environment.
2.2.1

Topology optimization is a tool to generate a design proposal and is often
used within the concept finding for a new component. Starting with the design
area which is the maximum allowed area for the component and with the
boundary conditions, such as loads, fixtures and manufacturing conditions
the optimization system will determine a new material distribution by removing material from the design area. This design proposal fulfills all mechanical
requirements and represents a weight-optimal design proposal.
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Topology Optimization with Tosca Structure.gui
stiffness (compliance and displacements)

eigenfrequencies
internal and reaction forces
weight, volume
center of gravity
moment of inertia
In addition a number of manufacturing constraints can be applied so that the
design proposal can be produced with casting, stamping. For this casting
constraints, member size constraints, freezing and symmetry and coupling
constraints can be defined.
As result the optimization system creates a design proposal with the information where the material has to be positioned. This design proposal has to be
interpreted and has to be used for the more detailed analysis.
For supporting this step the Tosca Structure system supports the generation
of a verification model within Tosca ANSA environment. This means a new
model based on the results of the topology optimization can be created easily
without the necessity of applying the loads and boundary conditions to the
verification model. All loadcases and boundary conditions of the optimization
model are transferred automatically to the verification model.
With the results of the verification run it is possible to perform a normal FE
postprocessing step within the postprocessing environment suitable for your
solver or a CAD model can be generated which then can be transferred back
to your CAD system.
The Model
The component to be used within the tutorial represents a control arm for a
car and is found in the Tosca Structure installation directory (<tosca>) according to your FE-solver (<solver>) :
<tosca>/<solver>/examples/topo/control_arm
The model is loaded with one loadcase consisting of two fixtures in the upper
left and right areas and is loaded with one load in the lower bearing area. The
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2.2.2
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original design is the realized design which has to be strengthened by the

optimization.
Design Area
Existing design of a control arm with the design area
The model for the topology optimization was modified in such a way that the
inner areas of the component are filled with elements to create a design area
where the optimization system can remove or rearrange elements for getting
a better mechanical behavior of a component with a lower weight.
The start model for the optimization represents a design of a control arm for a
car. The component has to be manufactured by forging and consists of aluminum. The red areas of the component are not free for the optimization
because they are used for the fixtures and for the load application. One red
area is used for the mounting of a sensor for the headlight range adjustment.
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Fig. 42
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Fig. 43
Loads of the model
The fixture is realized with spring elements on the right upper red area. The
springs represent a rubber bearing. The left bearing is fixed in all three translation degrees of freedom, but is able to rotate about the x-axis. As loading a
force is applied in the center of the lower bearing.
Due to symmetry reasons only one half of the model is meshed so the symmetry plane is fixed in z-direction for ensuring the symmetry condition.
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2.2.3
Optimization Task
The optimization task is to find a structure with the maximum stiffness for the
component with a volume or weight restriction. This represents the most common standard optimization task for the topology optimization.
The constraint is the weight or volume constraint which is defined to be 70%
of the initial volume/weight of the structure.
As manufacturing constraint a casting/forging constraint has to be defined.
The idea of the constraint is to ensure that the created structure of the topology optimization has no undercuts and can be demolded (or removed from
the forging die).
2.2.4

If you have never worked with Tosca Structure.gui before you should skip this
summary and go directly to the detailed description. If you do have some
experience with Tosca Structure.gui you can try to generate your parameter
file just using the recipe summary. Did you get it all right?
Preprocessing
1. Starting Tosca Structure preprocessor: Tosca Structure.pre | Tree
2. Input file: Tosca Structure.pre | FEM_INPUT
3. Define Group (Nastran users only): Tosca Structure.pre | GROUP_DEF |
Read Nastran Set
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4. Design area: Tosca Structure.pre | DV_TOPO

5. Design constraints: Tosca Structure.pre | DVCON_TOPO | Cast
6. Design Responses: Tosca Structure.pre | DRESP
7. Objective function: Tosca Structure.pre | OBJ_FUNC | Minimize
8. Constraints: Tosca Structure.pre | CONSTRAINT
9. Define optimization task: Tosca Structure.pre | OPTIMIZE
10.Saving Tosca Structure parameter file: Tosca Structure.pre | FILE |
Save As
Start Optimization
11.Running Tosca Structure: Start Tosca Structure | Start
TOSCA
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Postprocessing
12.Generating material distibution file: Tosca Structure.report | Generate
Report
13.Generating smooth surfaces: Tosca Structure.smooth |
Start Smoothing
Performing a complete validation run as well as generating the whole setup
for a validation run is not possible automatically using Tosca Structure.gui.
Nevertheless, different output formats for the optimized structure are supported as basis for validation models. However, further preprocessing (manual addition of loads and boundary conditions) is required by the user in order
to generate a FE model using the optimized structure.
2.2.5
Preprocessing
1. Tosca Structure.gui starts and the Tosca Structure.pre module is

displayed. Left click on the Tree button to change the view of the optimization task structure on the left side to tree mode.
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1. Select the item FEM_INPUT
from the optimization task tree.
The FEM_INPUT menu appears
on the right.
2. In the Input Files area,

click Add to select the model for
the optimization. The Open
dialog appears.
4. Left click on Create to add the

item MY_INPUT_FILES to the
optimization task tree.
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FE model for your solver
(control_arm.<ext> where
<ext> is the extension your FEsolver uses.) and press Open.
The model name with its full
path appears in the The
finite element input
files field.
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Tosca Structure

The following part is important only for Nastran users. If your input file
matches any other solver supported by Tosca Structure please skip this
chapter and continue with the definition of the design area. For any other
solver the groups for topology optimization are included in the solver input
files and transferred in Tosca Structure via the FEM_INPUT command.
1. Select the item GROUP_DEF
The GROUP_DEF menu appears
to the right.
2. Type a proper name for the

group in the field ID_NAME,
DESIGN_ELEMENTS for
example, and activate the
radio button Element next to
Type to specify the group type.

file
control_arm_groups.bdf
which contains the element set
needed for the topology optimization and press Open. The
Select Nastran Set dialog
appears where the content of
the file
control_arm_groups.bdf
is listed.
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3. Click Read Nastran Set to

select the existing group. The
Open dialog appears.
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5. In the Select Nastran Set

dialog, select 1 from the Set
Number dropdown list if not
already selected and press Ok.
The selected Nastran set transferred to the Data field in the
GROUP_DEF menu.
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6. Click Create to add the item

DESIGN_ELEMENTS to the
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In topology optimization, the design area denotes the set of elements that
may be removed during the optimization, in contrast to the frozen areas
that remain unchanged.
1. Select the item DV_TOPO from
the optimization task tree. The
DV_TOPO menu appears on the
right.
2. Choose the group

DESIGN_ELEMENTS from the
dropdown list next to
EL_GROUP and click Create to
add the item MY_DV_TOPO to
the optimization task tree.
2.2.5.5 Choice of the design variable constraints
1. Select the item DVCON_TOPO

The DVCON_TOPO menu
appears on the right.
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Design variable constraints introduce restrictions on the shape of the optimized model. Besides the demolding constraint discussed below, other
types of design constraints such as symmetry and member size restrictions
are supported by Tosca Structure.
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Tosca Structure
2. Type a proper name in the field

ID_NAME, for example
DVCON_CAST, and select
DESIGN_ELEMENTS from the
dropdown list next to Element
Group. The constraint will now
be applied to all elements of the
selected group.
Please note that the ID_NAME is a special mark of any component of the
optimization task. The ID_NAME must be unique for each component.
Using the ID_NAME you can select between different components of the
same type during the optimization setup. If no other component of the same
type appear in the optimization task, the change of the ID_NAME is optional
and the Tosca Structure default ID_NAME can be used.
4. Choose DESIGN_ELEMENTS
from the Check Group dropdown list to define the check
group for the cast restriction
and click Create to add the
item DVCON_CAST to the optimization task tree.
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3. For defining a cast restriction

for the selected element group
activate the radio button Cast
and define the pull direction
vector by typing in the values
0,0,1 in the fields next to Pull
Direction. Make sure the
global coordinate system CS_0
is selected in the field next to
Pull_CS.
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Tosca Structure

In order to specify optimization target and constraints you must first define
design responses. The design responses are assigned to output parameters from the FE analysis. In this example design responses for the volume
and the strain energy will be needed.
1. Select the item DRESP from the
optimization task tree. The
DRESP menu appears on the
right.
3. Choose ALL_ELEMENTS from

the Element/Elementgroup dropdown list and set
the Group Operator to Sum
to build the sum of the volumes
of each element in the model.
Thus the whole volume of the
structure is determined.
Click Create to add the design
response DRESP_VOLUME to
4. Repeat step 1 to define another design response.
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DRESP_VOLUME, and choose
the type VOLUME in the field
Type of the Base category.
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5. Type a ID_NAME for the new

design response, for example
DRESP_STRAIN_ENERGY, in
the corresponding field and
choose Stress/Strain from
the Category dropdown list
and in the Type field choose
the type STRAIN_ENERGY.
6. Activate the Element/Elementgroup radio button and

select ALL_ELEMENTS from
the Element/Elemtgroup
dropdown list.
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7. Set the Group Operator to

Sum and click Create to add
the design response
DRESP_STRAIN_ENERGY to
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Tosca Structure

1. Select the item OBJ_FUNC from
OBJ_FUNC menu appears on
the right.
2. Click Add Dresp to select a

design response for the objective function. The Select
Design Responses dialog
appears.
4. Select the radio button Minimize next to Target and click

Create to add the item
MY_OBJ_FUNC to the optimization task tree.
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3. In the Select Design

Responses dialog, activate the
design response
DRESP_STRAIN_ENERGY and
press Ok. The window closes
and the selected design
response appears in the field.
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Tosca Structure

1. Select the item CONSTRAINT
The CONSTRAINT menu

VOLUME_CONSTRAINT, and
choose the design response
DRESP_VOLUME from the
Design Response dropdown
list.
4. Select the equality radio

button next to Constraint
Type, thus the target volume
for the optimization is set to
exactly 70 percent of the original volume, and click Create
to add the item
VOLUME_CONSTRAINT to the
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3. Select the radio button Relative next to Type to set the

constraint type and push the
slider to 70 or type the value in
the field manually.
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Tosca Structure

1. Select the item OPTIMIZE from
OPTIMIZE menu appears on
the right.
2. Select TOPO_CONTROLLER
from the Strategy dropdown
list to choose the optimization
strategy. Design area and
objective function are selected
automatically.

Variable Constraints
dialog, activate the design variable constraint DVCON_CAST
and press Ok. The
DVCON_CAST item appears in
the DV Constraints field.
5. Click Add next to the Constraints field to add the
constraints to the optimization
task. The Select Constraints dialog appears.
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3. Click Add next to the DV

Constraints field to add the
design variable constraints to
the optimization task. The
Select Design Variable
Constraints dialog appears.
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Tosca Structure
6. Activate the constraint

VOLUME_CONSTRAINT and
press Ok. The
appears in the Constraints
field.
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MY_OPTIMIZATION_TASK to
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Tosca Structure

The Tosca Structure parameter file contains ASCII commands which define
all settings for the optimization task.
1. Select File from the main
menu and pick Save As from
the File dropdown list. The
Save As dialog appears.
2. In the Save As dialog choose

a name for the optimization
task, enter the filename in the
field below and press Save As.
The file automatically receives
the extension .par and
becomes the parameter file for
Tosca Structure.
Start Optimization
1. Switch to the Start TOSCA
Structure module from the
Module dropdown list in the
upper right corner.
2. Choose all from the Type

dropdown list . This option
includes a preprocessing test
and the optimization run.
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2.2.6
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3. Select the solver of your choice

from the Solver dropdown list.
4. Click Start TOSCA to start the

optimization. Status information about the optimization run
is displayed in the field below.
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5. After approx. 15 design cycles

the optimization run is finished
and the status TOSCA job
finished is displayed.
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Tosca Structure
2.2.7
Postprocessing
Viewing the intermediate results using Tosca Structure.report.
Using Tosca Structure.report, the intermediate results of topology optimization, namely the densities of individual elements, can be visualized.
1. Switch to the Tosca Structure.report module from the
upper right corner.
3. To see every design cycle click

in the field below Iter
(concerning the result Controller Input) and select
All from the Iter dropdown
menu (default). Repeat this for
the result Material Distribution
(second field below Iter).
4. Click Generate Report to
start the generation of the result
file. Status information about
the file generation is displayed
in the field below.
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2. Select the results by activating

the buttons to the left of the
Results Controller Input
and Material Distribution. A standard report is
available in the directory
<jobname> | TOSCA_POST
after each optimization which
can be visualized using Tosca
Structure.view.
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Tosca Structure
5. When the file generation is

completed a message about
the successful job ending is
displayed in the status field.
6. Click View Report to view the

material distribution in the optimized structure. The Open
dialog appears.
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7. In the open dialog select the

generated .vtfx file and press
Open. Tosca Structure.view
starts.
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Tosca Structure
8. The Animation starts and stops by clicking on the start forward/backward, pause and stop symbol in the task menu.
The described example is generated using the FE solver MSC Nastran.
Please note that slight differencies in the optimized design are possible
for the different solvers. However the design conception remains the
same.
2.2.8
Report Generation
dialog appears. Open your vtfx
file.

View 1.
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the relative material distribution
of your model on the left side of
the split window. The right side
is still empty.
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mouse).

window named GLview
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repository.

13. Load the smoothed optimization result (right window in Tosca Structure.view) as image into the Tosca Structure Report Builder. (Look at step
6 and 7, if necessary, and do not forget to activate the window).
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10. In Tosca Structure Report Builder window both model siutations are
order.
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doubleclick at
plot as Table.
Cases).
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which is the smoothed optimization result as 3D model to
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type. Click OK.
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PowerPointReport.
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2.2.9
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After the optimization an automatic validation run enables quality checks of

the result. An approved result must then be transferred into the product
development process. To this end, the new design proposal must be available
for import and further processing in CAD systems.
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Tosca Structure
2.2.9.1 Surface generation using Tosca Structure.smooth.

Tosca Structure.smooth generates the surface of the material remaining
after the topology optimization and improves the surface quality.
1. Switch to the Tosca Structure.smooth module from the
upper right corner.
2. In the Tosca Structure.smooth
module click Select Job. The
3. In the Open dialog, select the

Tosca Structure parameter file
and press Open.

completed the message
Program finished is
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4. Click Start Smoothing

(keep the default configuration).
Status information about the file
generation is displayed in the
field below.
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6. Click View Result to view the

dialog appears.
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corresponding .vtfx file and
press Open. Tosca Structure.view starts.
2.2.9.2 Processing the optimized structure

Using Tosca Structure.gui a complete reconstruction of the model with the
new design is not possible. Therefore some additional steps are required
which should be performed manually by the user. However Tosca Struc-
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Tosca Structure
ture.gui offers several opportunities to generate a design model using Tosca

Structure.smooth as a base for further processing by the user. Different output formats for the smooth surface can be chosen. For example geometry
surfaces can be created using the stl or igs format. In this case the geometry can be loaded in a CAD tool for further handling or in a FE preprocessor
for generating a new mesh. Using solver output format (bdf, inp, cdb, etc.)
Tosca Structure.smooth automatically generates a mesh on the smooth structure in the corresponding solver format. However the boundary conditions for
the FE analysis must be generated manually by the user.
The topology optimization created a new design proposal for the control arm
component. The result of the topology optimization has to be discussed in
several ways.
First of all the optimization result has to be checked. This can be done with
viewing the convergence plot and with checking the TOSCA.OUT file for
warnings and errors. If there is a critical error during the optimization the optimization loop will be stopped. In other cases (if some results are missing) the
optimization system will continue but the result may be not sufficient.
Second the resulting model and the finite element analysis of the model has
to be checked if the displacements, the stresses and all other finite element
related information are suitable.
Initial model (complete
model with 70% of
material homogeneously
distributed)
Result
Strain Energy
Table 2
1645850
Result comparison
Final model
425093.5
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Fig. 44
von Mises stresses of optimized structure
After checking the results the remaining structure can be passed to the
design department as a CAD model to be used as design proposal for the
fine tuning of the design. If the stresses within the component are not below
the allowed range the shape optimization of Tosca Structure (Tosca Struc-
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For this optimization task the stresses are in the same range compared to the
initial model but the stiffness of the structure is higher and the material
amount necessary for the structure is lower. The values to be compared are
the volume or weight of the structure and the sum of the strain energy. The
strain energy is the measure for the compliance which is the reciprocal value
of the stiffness
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Fig. 45
Optimization result represented after data reduction: IGES surfaces for CAD transfer
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ture.shape) will be able to remove the stress peaks so that the component will
be suitable from the mechanical point of view.
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The results can be transferred as surfaces in STL format or IGES format.

Another way to transfer less data is to export the results as slices.
Optimization result represented as slices
For sharing the result and the animation with colleagues or partners the VTFX
format is comfatable way. This result format is able to contain a full 3D animated model with the optimization history. The model can be rotated and
zoomed during the animation. The viewer is available for free for different
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Fig. 46
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platforms and there is also a possibility to include the files into HTML-pages
and into Powerpoint presentations.
Material distribution after topology optimization
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2.3
Shape Optimization with Tosca Structure.gui

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2.3.1

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Specification of design domain restrictions by FE-meshes
2.3.2
The Model
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The component optimized in this tutorial is a connecting rod (conrod) and is

found in the Tosca Structure installation directory (<tosca_install_dir>):
<tosca_install_dir>/<solver>/examples/shape/conrod
The model is built with an autogenerated tetrahedron mesh symmetric to the
xz and yz plane. The mesh quality is medium/poor with average element
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De
sig
n
are
a
edge of ~ 2 mm. Outer dimensions: 180 x 84 x 24 mm.

Allowed design and mesh smooth area are shown in Fig. 48.
Mesh smooth area
Fig. 48
Connecting rod (conrod) with design and mesh smooth area
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Loaded nodes are connected with MPCs to the inner side of the conrod
mounts. Nodes in the big eye nodes on the inner radius (crankshaft bearing)
are fixed in all three coordinate directions.
Loadcase 1:
Screw fixation
Loadcase 2:
Loadcase 3:
Bending about the x-axis
SIMULIA
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Loadcase 4:
Bending moment about the y-axis
Loadcase 5:
Torsion about the z-axis.
Fig. 49
2.3.3
Loads and boundary conditions of the model conrod: (a) centrifugal force,
right: force caused by gas pressure (b), bending and torsion
about x-, y- and z-axis.
Optimization Task
The goal is to reduce stress peaks on the surface of the component with
small changes at the surface of the component. Thus the optimization task is
to minimize the maximum stresses of the loadcases on the connecting rod,
see Fig. 49. The design area is shown in Fig. 48 and consists of the surface
nodes of the area in the inner rectangle.
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2.3.4

Preprocessing
3. Define group (Nastran users only): Tosca Structure.pre | GROUP_DEF |
Read Nastran Set
4. Design area: Tosca Structure.pre | DV_SHAPE
5. Design variable constraint: Tosca Structure.pre | DVCON_SHAPE |
Check_DOF
6. Design responses: Tosca Structure.pre | DRESP | Add LC
7. Objective function: Tosca Structure.pre | OBJ_FUNC | Minmax
8. Mesh smooth: Tosca Structure.pre | MESH_SMOOTH
9. Define optimization task: Tosca Structure.pre | OPTIMIZE
10.Global stop condition: Tosca Structure.pre | STOP
11.Saving Tosca Structure parameter file: Tosca Structure.pre | FILE |
Save As
Check Inputs
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12.Setting up test optimization: Tosca Structure.pre | TEST_SHAPE

13.Running test optimization: Start Tosca Structure | test1 |
Start TOSCA
14.Viewing test results: Tosca Structure.report | Generate Report
Start Optimization
15.Running Tosca Structure: Start Tosca Structure | all |
Start TOSCA
Postprocessing
16.Generating result displacement file: Tosca Structure.report | Generate
Report
SIMULIA
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Result Transfer
17.Generating CAD output: Tosca Structure.smooth | igs |
Start Smoothing
Extensions
18.Link Conditions: Tosca Structure.pre | LINK_SHAPE |
SURFACE_DEMOLD
19.Design Variable Constraints: Tosca Structure.pre | DVCON_SHAPE |
Link Condition
20.Design Responses: Tosca Structure.pre | DRESP
21.Constraints: Tosca Structure.pre | CONSTRAINT
22.Mesh Smooth: Tosca Structure.pre | MESH_SMOOTH
23.Global Stop Condition: Tosca Structure.pre | STOP
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2.3.5
Preprocessing


on the right.
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dialog appears.

(conrod.<ext> where <ext> is
the extension your FE-solver
uses.) and press Open. The
model name with its full path
appears in the field The
files.
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solver the groups for shape optimization are included in the solver input
on the right.

group in the field ID_NAME, for
example DESIGN_NODES, and
activate the radio button Node
next to Type to specify the
group type.
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SIMULIA
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file conrod_groups.bdf
which contains the sets needed
for the shape optimization and
press Open. The Select
Nastran Set dialog appears
where the content of the file
groups.bdf is listed.

Number dropdown list and
press Ok. The selected Nastran
set is transferred to the Data
field in the GROUP_DEF menu.
6. Click Create to add the group

DESIGN_NODES to the optimization task tree.

group in the field ID_NAME, for
example
MESH_SMOOTH_ELEMENTS,
and activate the radio button
Element next to Type.
9. Repeat step 3 and 4 selecting once again the file groups.bdf.
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7. Now repeat step 1 in order to create another group.
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press Ok. The selected
NASTRAN set is transferred to
the Data field in the
GROUP_DEF menu.
11. Click Create to add the group

MESH_SMOOTH_ELEMENTS to
12. Repeat these steps from 1 to 6 with set number 3 to create a group
FIXED_NODES.
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13. Still two groups are necessary for a further step in this example (see
chapter 2.3.12 Extensions). So repeat all steps from 1 to 6 twice again to
create two more node groups. Name the first group SURF_DEMOLD_POS
and select the NASTRAN set number 4 in the Select Nastran Set
dialog. Choose the name SURF_DEMOLD_NEG for the second node group
and select the Nastran set number 5 in the Select Nastran Set
dialog.
SIMULIA
Tosca Structure

1. Select the item DV_SHAPE from
DV_SHAPE menu appears on
the right.
2. Select the group

DESIGN_NODES from the
ND_GROUP dropdown list.

MY_DV_SHAPE to the optimization task tree.
design responses. The design responses are assigned to output parameters from the FE analysis. In this example design responses for the von
Mises stress for both loadcases will be needed.
right.
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DRESP_MISES_LC1.
3. Select Stress/Strain from

and select in the Type field the
type SIG_MISES
4. Select the group

Node/Nodegroup dropdown
list and set the Group
operator to Max.
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5. Click Add LC to select the load

case for the design response.
The Select Loadcase dialog
appears.
6. In the Select Loadcase

dialog, enter 1 instead of All
in the Loadcase Number field
and press Ok. The new entry
appears in the Loadcase
Selection field.

DRESP_MISES_LC1 to the optimization task tree.
SIMULIA
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8. Repeat all steps from 1 to 7 four times again to create four other design
responses for von Mises stress. Name the design response
DRESP_MISES_LC2, DRESP_MISES_LC3 and so on and select the
loadcase number 2, 3, 4 and 5 in the Select Loadcase dialog.
2.3.5.6 Choice of the design variable constraint

As the mesh smooth area also contains elements which should not be
changed a DOF control has to be implemented which fixes the nodes of
this area in all directions.
1. Select the item DVCON_SHAPE
The DVCON_SHAPE menu
2. Enter an appropriate name and
select FIXED_NODES as
ND_GROUP.
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3. Activate the CHECK DOF field

and DOF 1, DOF 2 and DOF 3.
Click OK.
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the right.

appears.
4. Activate the radio button

MinMax next to Target to
minimize the maximal von
Mises stress and click Create
to add the item MY_OBJ_FUNC
to the optimization task tree.
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Responses dialog, activate
both design responses and
press Ok. The window closes
and the selected design
responses appear in the field.
SIMULIA
Tosca Structure
2.3.5.8 Select mesh smoothing elements

1. From the Command menu
select MESH_SMOOTH. The
MESH_SMOOTH menu appears
on the right.

EL_GROUP and select the
element group
MESH_SMOOTH_ELEMENTS
from the dropdown list.
3. Leave all default settings

unchanged and click Create to
add the item
MY_MESH_SMOOTH to the optimization task tree.

the right.
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2. Select SHAPE_CONTROLLER
automatically.
3. Click Add next to DV

Constraints.
4. Activate the
DVCON_DOF_CONTROL button
and press Ok.
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5. Select MY_MESH_SMOOTH from

the Mesh Smooth dropdown
list and click Create to add the
item
SIMULIA
Tosca Structure
2.3.5.10 Define a stop condition

1. Select the item STOP from the
STOP menu appears on the
right.
2. Activate the Maximum number

of iterations radio button
and change the iteration
number to 5.
Click Create to add the item
MY_STOP to the optimization
task tree.

2. In the Save As dialog enter the

filename and press Save As.
The file automatic receives the
extension .par and becomes
the parameter file for Tosca
Structure.
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2.3.6
Check Inputs
Before starting an eventually long running optimization task you should
always check if your definitions make sense and are complete. Missing settings may require a complete rerun of your optimization.
2.3.6.1 TEST_SHAPE
The command TEST_SHAPE creates a simple optimization displacement
on all your design nodes. Then you can see if everything works as you
imagined it.
select TEST_SHAPE. The
TEST_SHAPE menu appears on
the right.
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2. Select the direction entry GROW,

set the displacement amount to
3 (mm) and enter 3 to specify
the number of increments for
the test displacement.

TEST_SHAPE to the optimization task tree.
4. Click Save to save the changes

in the parameter file.
SIMULIA
Tosca Structure

upper right corner.
2. Select the optimization type

test1 from the Type dropdown list (this option includes a
preprocessing test and the test
optimization run) and select the
solver of your choice from the
Solver dropdown list
test optimization. Status information about the optimization
run is displayed in the field
below.
2.3.6.3 Viewing the test results

upper right corner.
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4. After 3 increments the test optimization run is finished and the

status TOSCA job finished
is displayed.
SIMULIA
Tosca Structure

Results Optimization
Displacements and Opt.
Displacement Values. A
standard report is available in
the directory <jobname> |
TOSCA_POST after each optimization which can be visualized using Tosca
Structure.view.
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3. To see the Optimization

Displacements and the Opt.
Displacement Values for every
design cycle click in the field
below Iter (concerning the
result Optimization
Displacements) and select
the result Opt. Displacement
Values (second field below
Iter).
in the field below.

SIMULIA
Tosca Structure

test displacements. The Open
dialog appears.

pause and stop symbol in the task menu. You can change between
SHAPE_DISP and SHAPE_CTRL by doubleclicking on the corresponding case in the Table of Cases window or by selecting it in the
dropdown menu. Examine the model with test displacements and close
Tosca Structure.view window in order to proceed with Tosca ANSA environment. Please note: as no FE-Analysis is performed, there are no
CTRL_INPUT results available.
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starts.
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9. In the animation appearing after the test run it should be quite easy to
check:
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Is the optimization direction (nodal movement) in the correct direction?
SIMULIA
Tosca Structure
2.3.7
Start Optimization
1. Switch back to the Start
TOSCA Structure module
from the Module dropdown list
in the upper right corner.
2. Change the optimization type to

all from the dropdown list next
to Type.
This will cause the sequential start of both the test run and the real optimization. In order to skip the test run you can go to the Tosca Structure.pre
module and delete the TEST_SHAPE item from the optimization task.
4. After 5 design cycles the optimization run is finished and the

is displayed.
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2.3.8
Postprocessing
1. Switch again to the Tosca
Structure.report module from
the Module dropdown list in the
upper right corner.
2. Activate the button next to

Controller Input and
deactivate all other buttons to
view only the optimization
results under consideration of
the optimized parameters (in
this case von Mises stress).
To view also the changes in the shape of the structure with the amounts of
the nodal displacements of the design nodes, activate also the button next
to Optimization Displacements or next to Opt. Displacements
Value.
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3. Click in the field of column

Iter and row Controller
Input and select in the Iter
drop-down menu All to view
all cycles of the optimization.
4. In the row of Controller
Input you can optionally enter
0 in the column Fringe(min)
and 150 in the column
Fringe(max). (Doubleclick in
the corresponding field for
editation.)
in the field below.
SIMULIA
Tosca Structure


dialog appears.
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starts.
SIMULIA
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same.
2.3.9
Report Generation
file.
SIMULIA
Tosca Structure
2. View | Viewports allows to

select up to four viewports in
different positions. Choose two
viewports: You see the relative
material distribution of your
model on the left side of the
split window. The right side is
still empty.
View 1.
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mouse).
SIMULIA
Tosca Structure

named GLview Report
chapter!

Repository as to save your
captured situations to a file. If
repository.
10. In Tosca Structure Report Builder window both model siutationsare

listed. By rightclicking at the situation you can delete it or change the
order.
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12. The last setting is kept for capturing, thus, the original model is loaded
as 3D model into the Tosca Structure Report Builder.
into the Tosca Structure Report Builder. (Look at steps 6 and 7, if necessary, and do not forget to activate the window).
doubleclick at VARIABLE |
DRESP values in the Table
of Cases. This case cannot
be displayed with another viewport. By selecting Capture
Situation or Capture
active view load the plot as
Image into the Tosca Structure
Report Builder.
16. Repeat steps 13, 14 and 15

Cases).
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plot captured as Table.
SIMULIA
Tosca Structure

same effect is given by rightclicking and selecting Deactivate.
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PowerPointReport.
SIMULIA
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type. Click OK.
SIMULIA
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21. For transfer into a word file use Create WordReport and the
SIMULIA
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2.3.10 Result Transfer

Valid optimization results need to be transferred back into the design process. To this end the modified model has to be written in a format which can
be read by CAD programs to be used as draft for modifications of the existing design. To this end a Tosca Structure.smooth run will write the modified
surface of the optimized model to STL or iges, for example.
upper right corner.
2. Click Select Job. The Open

dialog appears.
4. Click the button with the three

dots at the right of Optimization
results to load them. The Open
dialog appears.
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and press Open.
SIMULIA
Tosca Structure
5. In the Open dialog, go to the

SAVE.onf directory and select
the the file SHAPE_00x.onf,
where x represents the last
design cycle of the bead optimization. In this case, select the
file SHAPE_005.onf and press
Open. The selected file with its
whole path appears in the field
next to Optimization
Results.
6. Select the option Create
Surface + Optimization
displacements (Shape
and Bead optimization)
from the Task dropdown list.
7. Select a CAD output format, for
example .igs or .stl and
deactivate the format .vtf.

completed the message
Program finished is
Click View Result and navigate in the Open window to
your smooth results in your job
directory in the subdirectory
TOSCA_POST.
For CAD transfer IGES-SLICES can be used. Continue with the following
steps to create IGES-SLICES using Tosca Structure.smooth:
10. Activate the checkbox Additional Parameters. Additional fields are displayed.
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8. Click Start Smoothing.

Status information about the file
generation is displayed in the
field below.
SIMULIA
Tosca Structure
11. Select Slices (3D) from

dropdown list next to Slices.
12. Select igs_curves from the

Format dropdown list.
13. Change the number of slices

to 60 and enter the normal
vector 0,0,1 to specify the
slices orientation.
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14. Click Start Tosca Structure.smooth. After Tosca Structure is finished click View
Result and navigate in the
Open window to your smooth
results in your job directory in
the subdirectory
TOSCA_POST.
SIMULIA
Tosca Structure

The result, depending on the used solver, should be similar to Fig. 50.
Stress reduction in the design area from 197 MPa to 134 MPa in
5 iterations (see chapter 2.3.12.4 Redefine the global stop condition)
In Fig. 50 the stress reduction is clearly seen. The maximal stress is minimized with around 32%. The staying stress concentrations in Fig. 50 can not
be removed because of the element quality prohibits futher nodal optimization
displacement. A solution would be to remesh the two areas or the whole part
and restart the optimization.
2.3.12 Extensions
There may be different manufacturing constraints for the conrod. Lets
assume that in the production it is cast and must therefore:
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Fig. 50
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Tosca Structure
1. be demoldable;
2. be symmetric to x-z-plane.
These requirements can be realized in different ways in Tosca Structure.shape. In the following only one of these ways is described in detail,
some alternatives will be discussed at the end of the chapter.
Casting Constraint
1. Go back to the Tosca Structure.pre module. If neccessary
load again your parameter file.
From the Command menu select
LINK_SHAPE. The
LINK_SHAPE menu appears on
the right.
3. Select the global carthesian

coordinate system CS_0 from
the Coordinate System
dropdown list and enter the
vector 1,0,0 in the fields next
to DEMOLD_DIR to set the
demold direction.
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LINK_CAST_POS, and select
SURF_DEMOLD from the
Client dropdown list to
specify a cast restriction.
SIMULIA
Tosca Structure
4. Select the group

SURF_DEMOLD_POS as check
group for the link condition and
click Create to add the item
LINK_CAST to the optimization
task tree. How to create the
groups for Nastran is explained
in chapter 2.3.5.3 Group
creation (Nastran users only).
5. Select the item DVCON_SHAPE
from the optimization task structure tree. The DVCON_SHAPE
menu appears on the right.
7. Select the link condition

LINK_CAST_POS from the
Link Condition dropdown
list and click Create to add the
item DVCON_CAST_POS to the
Now the setup has to be repeated to create a casting constraint for the
other half of the design area in the negative direction. Repeat all steps from
1 to 12 to create the new casting constraint. Name the link condition
LINK_CAST_NEG, enter the vector -1,0,0 for the opposite pull direction
and select the group SURF_DEMOLD_NEG as check group. Choose the
name DVCON_CAST_NEG for the new DVCON_SHAPE definition. Select the
node group SURF_DEMOLD_NEG in the ND_GROUP field and coose the new
link condition LINK_CAST_NEG in the Link Condition field. Leave all
other settings from the described steps unchanged.
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DVCON_CAST_POS, and select
the node group
SURF_DEMOLD_POS from the
ND_GROUP dropdown list.
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Symmetry to x-z-plane
SIMULIA
Tosca Structure
8. Define symmetry for all design nodes with a symmetry plane normal to
the y-axis through the point (0,0,100). First define a Cartesian coordinate
system with origin in point (0,0,100). Then define plane symmetry using
LINK_SHAPE: The symmetry plane contains the origin of the referenced
coordinate system and the normal vector is defined by CLIENT_DIR.
Third, reference LINK_SHAPE in DVCON_SHAPE for all design nodes.

By visual observation the FE-model seems to gain weight. This may not be a
desired effect. One way to prevent this is to define a volume constraint.Define
a design response for the volume
optimization task stree. The
right.
3. Select ALL_ELEMENTS from

the dropdown list next to
Element/Elementgroup and
choose Sum from the Group
Operator dropdown list.
Thus the sum of the volumes of each element in the model is built and the
whole volume of the structure is determined.
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DRESP_VOLUME, and select in
the Type field of the Base category the type VOLUME.
SIMULIA
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4. Click Create to add the design

Define the volume constraint

The CONSTRAINT menu
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select the design response
DRESP_VOLUME at the Design
Response dropdown list.

slider to 100 or type the value
in the field manually.
4. Activate the equality radio
button next to Constraint
Type, thus the original volume
will remain unchanged, and
SIMULIA
Tosca Structure
2.3.12.3 Updating the optimization task

1. Select the item
MY_OPTIMIZATION_TASK
The OPTIMIZE menu appears
on the right.


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dialog, activate all design variable constraints and press Ok.
The items appear in the DV
Constraints field.
SIMULIA
Tosca Structure
5. In the Select Constraints

dialog, activate the only defined
constraint
press Ok. The
appears in the Constraints
field.
6. Click Modify to activate the
changes and to exit the OPTIMIZE menu.
Although the very efficient shape optimization often does a really good job in
only 5 iterations a few percent more may be gained by letting the optimizer
run a little longer. The simplest way to do this is to change the maximum number of iterations. The change of the global stop condition is described in vol.2
chapter 6.11.1, Global Stop Condition. Modify the item MY_STOP and change
the iteration number to 10.
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SIMULIA
Tosca Structure

1. Select the item
MY_MESH_SMOOTH from the
MESH_SMOOTH menu appears
on the right.

ND_GROUP, Layer, select the
group DESIGN_NODES from the
ND_GROUP, Layer dropdown
list and change the number of
layers for mesh smooth to 5.
3. Click Modify to activate the

changes and to exit the
MESH_SMOOTH menu.
Run the optimization. What happens? Check the inside of the holes of the
conrod. Have nodes moved there? Why?
1. This automatic definition of the mesh smoothing elements should only be

used as the lazy option compared to the description in chapter 2.3.5.8
Select mesh smoothing elements. The problems that can occur are many
especially for real life applications. In this case the nodes on the inner
surface of the holes (where the connection elements are) are also moved,
which is not wanted. Therefore, we emphasize that selecting the
MESH_SMOOTH element group manually can often save time in the long
run.
2. If no MESH_SMOOTH command is defined per default 6 adjacent layers of
elements are added to the MESH_SMOOTH group starting from the design
nodes. For the current model and the design area in Fig. 48 the mesh
smooth group becomes too large - and optimization stops within a couple
of iterations because of a bad mesh.
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Remark:
SIMULIA
Tosca Structure
Shape optimization is often seen as a difficult optimization type which is in
most cases related to the mesh problems that may arise during optimization.
This can cause the optimization to stop.
2.3.13.1 How to workaround mesh problems?
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The best solution is of course to remesh, but this may be a time consuming
task.
The second best solution is to check the solver log file and find out which elements are causing the problems. Look these elements up in your preprocessor. If you only have a few problematic elements at the edge of the
MESH_SMOOTH area, try to remove these problematic elements from the
MESH_SMOOTH area.
A good mesh for shape optimization is not always equal to a high quality calculation mesh. Avoid using mesh refinement on the surface and rather mesh
a little coarser than usual and uniformly.
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Tosca Structure
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Tosca Structure
2.4
Bead Optimization with Tosca Structure.gui

mass to the structure. The beads can easily be added in the stamping process which makes bead a low weight and cost neutral alternative to enhance
a sheet-metal structure.
2.4.1
What is Bead Optimization?
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a)
Fig. 51
b)
Simple plate in bending with loading and supports (a) and an

optimalbead (b). The maximal displacement of (a) is 6.6 mm and
(b) is 0.25 mm
SIMULIA
Tosca Structure
In Fig. 51 is a simple flat plate in bending shown. It is evident that the solution
in Fig. 51 (b) has a much greater stiffness than the original flat plate in Fig. 51
(a).
made:
bead height
Fig. 52
bead width
Bead height and bead width
The bead height (see Fig. 52) has the most significant effect on the stiffness of the plate structure. Usually, the greater the bead height the greater
the stiffness. But, the bead height is usually controlled by manufactoring
capabilities i.e. how deep can you draw a bead with your available tools.
Fig. 53
Bead layouts for simple geometries with a uniform pressure load.

For more complex loads or dynamic problems i.e. eigenvalue or frequency

response, the optimal bead layout is not intuitive anymore (see Fig. 53).
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the stiffness of the sheet structure. The Tosca Structure.bead default values usually suffice, but if an optimal solution is saught you must try more
bead widths.
SIMULIA
Tosca Structure

Tosca Structure.bead is the Tosca Structure module for bead optimization.
Two bead optimization algorithms has been implemented:
Sensitivity based bead optimization (BEAD_SENSITITY)
In general the controller algorithm is much faster than the sensitivity algorithm, but lacks handling of complex design responses such as frequency
response or combined responses. The controller algorithm leads to very easy
interpretable beads. The bead patterns of the sensitivity algorithm can be
more difficult to interpret, but the results are often superior to the controller
results, especially for dynamic problems.
stiffness (compliance and displacements*)
eigenfrequencies
* Only sensitivity based algorithm allows these constraints and objectives
The following presents a start guide for Tosca Structure.bead. The purpose is
to show how simple it is to set up a bead optimization problem in Tosca ANSA
environment. For more background knowledge about bead optimization, differences between the two algorithms and other advanced settings in Tosca
Structure.bead please consult the users manual. This guide is restricted to
showing the controller based bead algorithm.
Model
Model information:
A model of an oilpan is found in the Tosca Structure installation directory
(<tosca>) according to your FE-solver (<solver>) :
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2.4.2
SIMULIA
Tosca Structure
<tosca>/<solver>/examples/bead/oil_pan
x
Fig. 54
FE-model of an oilpan - a typical automotive sheet metal part.
Dimensions:
length (z-direction): ~ 500 mm
width (x-direction): ~ 305 mm,
depth (y-direction): ~42 mm,
thickness: 1.3 mm.
Mesh: Average element edge lenght: ~ 7 mm, mostly linear quads and a
few trias.
Initial 1st eigenvalue: 179 Hz
Boundary conditions are for simplicity crude full supports on the edges of
the oilpan. Real life boundary condition could be obtained by using the full
body-in-white model of a car which would also run with Tosca Structure - of
course with unreasonable runtimes for this simple introduction.
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The element normals of the shell elements are in the negative y-direction
y
x
Fig. 55
2.4.3
Design area
Optimization Task
Task 1:
Maximize the natural (1st) eigenfrequency of the oil pan using controller
based algorithm.
The maximum bead height is 5 mm and the bead direction must be in the
positive y-direction, see Fig. 54.
Prerequisites
Tosca ANSA environment Basics - read and understood
FE-model oil_pan_tosca_env.<ext> for your solver
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2.4.4

Preprocessing
3. Define Group (Nastran users only): Tosca Structure.pre | GROUP_DEF |
Read Nastran Set
4. Design area: Tosca Structure.pre | DV_BEAD
6. Objective function: Tosca Structure.pre | OBJ_FUNC | Maximize
SIMULIA
Tosca Structure

8. Define optimization Task: Tosca Structure.pre | OPTIMIZE
9. Saving Tosca Structure parameter file: Tosca Structure.pre | FILE |
Save As
Check Inputs
10.Setting up test optimization: Tosca Structure.pre | TEST_BEAD
11.Running test optimization: Start Tosca Structure | test1 |
Start TOSCA
12.Viewing test results: Tosca Structure.report | Generate Report
Start Optimization
Start TOSCA
Postprocessing
Report
Result Transfer
15.Generating CAD output: Tosca Structure.smooth | igs | Start
Smoothing
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Please note that Tosca Structure 7.0or higher is required in order to complete the optimization task. With previous versions of Tosca Structure
SIMULIA
Tosca Structure
2.4.5
Preprocessing

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on the right.
3. In the area Input Files, click

Add to select the model for the
optimization. The Open dialog
appears.
SIMULIA
Tosca Structure

(oil_pan.<ext> where <ext> is
appears in the field The
files.
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solver the groups for topology optimization are included in the solver input
on the right.

group in the field ID_NAME,
DESIGN_NODES for example,
and click the radio button Node
next to Type to specify the
group type.

file groups.bdf which
contains the sets needed for
the bead optimization and
press Open. The Select
Nastran Set dialog appears
where the content of the file
groups.bdf is listed.
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Tosca Structure

press Ok. The selected Nastran
set is transferred to the Data
field in the GROUP_DEF menu.
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DESIGN_NODES to the optimization task tree.
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1. Select the item DV_BEAD from
DV_BEAD menu appears on the
right.
2. Choose the group

DESIGN_NODES from the dropdown list next to ND_GROUP
item MY_DV_BEAD to the optimization task tree.

design responses. The design responses are assigned to output parameters from the FE analysis. In this example design responses for the bead
height and the first eigenfrequency will be needed.
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right.

DRESP_BEAD_HEIGHT, and
choose the type BEAD_HEIGHT
in the field Type of the
category Base.
SIMULIA
Tosca Structure
3. Select the group

Node/Nodegroup dropdown
list, make sure the Group
Operator is set to Max and
DRESP_BEAD_HEIGHT to the
4. Repeat step 1 to create a new design response and name it
DRESP_EIGEN_1.

dialog, select MODAL as
Analysis Type and enter the
value 1 instead of All in the
Eigenmode/Substep field
and click Ok. The new entry
appears in the Loadcase
Selection field.

DRESP_EIGEN_1 to the optimization task tree.
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5. Select DYN_FREQ instead of

BEAD_HEIGHT in the Type
field of the category Base and
click Add LC to assign the
design response to the first
eigenfrequency. The Select
Loadcase dialog appears.
SIMULIA
Tosca Structure

the right.

appears.
4. Select the radio button Maximize in the Target area to

maximize the first eigenvalue
item MY_OBJ_FUNC to the optimization task tree.
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design response
DRESP_EIGEN_1 and press
Ok. The dialog closes and the
selected design response
appears in the field.
SIMULIA
Tosca Structure
2.4.5.7 Create bead height constraint

The CONSTRAINT menu
appears to the right.

BEAD_HEIGHT_CONSTRAINT,
and choose the design
response
DRESP_BEAD_HEIGHT from
the Design Response dropdown list.
3. Select the radio button Absolute in the Type area to set
the constraint type, enter the
value 5 in the Absolute field
to set the maximum height for
the beads and make sure the
Constraint Type is set to
equality

OPTIMIZE menu appears to
the right.
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to the optimization task tree.
SIMULIA
Tosca Structure
2. Select BEAD_CONTROLLER
automatically.
3. Click Add next to the Constraints field to add

4. In the Select Constraints

dialog, activate the constraint
and press Ok. The
item appears in the Constraints field.
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SIMULIA
Tosca Structure

The optimization direction of the controller algorithm can be changed in the
optimization settings.
1. Select OPT_PARAM in the
Command menu to open the
optimization settings. The
OPT_PARAM menu appears on
the right.
2. Enter the value -1 in the

Scale field to reverse the optimization direction. For bead
optimizations the numeric value
has no influence, only the sign
of the value.
3. Optionally you can change the bead width by typing a new value in the
BEAD_WIDTH field. For now use the default value by leaving the field
empty. The default value will be written in the file TOSCA.OUT in the
TOSCA_POST directory after the optimization is finished.

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MY_PARAMETERS to the optimization task tree.
SIMULIA
Tosca Structure

2. In the Save As dialog, choose

The file automatic receives the
extension .par and becomes
the parameter file for Tosca
Structure.
2.4.6
Check Inputs
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Before starting an eventually long running optimization task you should

always check if your definitions make sense and are complete. Missing settings may require a complete rerun of your optimization.
SIMULIA
Tosca Structure
2.4.6.1 TEST_BEAD
The command TEST_BEAD creates a simple optimization displacement on
all your design nodes. Then you can see if everything works as you imagined it.
select TEST_BEAD. The
TEST_BEAD menu appears on
the right.
2. Leave the default Direction

entry GROW, set the displacement amount to 5 (mm) and
enter 5 to specify the number of
increments for the test displacement.

TEST_SHAPE to the optimization task tree.

upper right corner.
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4. Click Save to save the changes

in the parameter file.
SIMULIA
Tosca Structure
2. Switch the optimization type to

test1 from the Type dropdown list (this option includes a
preprocessing test and the test
optimization run) and select the
solver of your choice from the
Solver dropdown list.
test optimization. Status information about the optimization
run is displayed in the field
below.
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4. After 5 increments the test optimization run is finished and the

is displayed.
SIMULIA
Tosca Structure
2.4.6.3 Viewing test results

upper right corner of the Tosca
Structure.gui
2. Activate the two buttons under
Result Name at Result
Selection. A standard report
is available in the directory
Structure.view.

in the field below.

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3. To see the Optimization

Displacements and the Opt.
Displacement Values for every
design cycle click in the field
below Iter (concerning the
result Optimization
Displacements) and select
the result Opt. Displacement
Values (second field below
Iter).
SIMULIA
Tosca Structure

dialog appears.
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starts.
8. Click to the start and stop button to animate the test result.
SIMULIA
Tosca Structure
In the animation appearing after the test run it should be quite easy to
check:
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Is the optimization direction (nodal movement) in the correct direction i.e.

positive y-direction?
SIMULIA
Tosca Structure
2.4.7
Start Optimization
1. Close Tosca Structure.view and
switch back to the Start
TOSCA Structure module
from the Module dropdown list
in the upper right corner.
2. Change the optimization type to
all from the dropdown list next
to Type. This will cause the
sequential start of both the test
run and the real optimization.
In order to skip the test run you can go to the Tosca Structure.pre module
and delete the TEST_BEAD item from the optimization task.
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4. After 3 design cycles the optimization run is finished and the

is displayed.
2.4.8
Postprocessing
1. Switch again to the Tosca
Structure.report module from
the Module dropdown list in the
upper right corner.
SIMULIA
Tosca Structure
2. Activate the buttons next to

Optimization Displacements and Opt.
Displacement Values and
deactivate all other buttons.

in the field below.
dialog appears.
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starts.
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Tosca Structure
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same.
SIMULIA
Tosca Structure
2.4.8.1 Result Transfer

Valid optimization results need to be transferred back into the design process. To this end the modified model has to be written in a format which can
be read by CAD programs to be used as draft for modifications of the existing design. To this end a Tosca Structure.smooth run will write the modified
surface of the optimized model to e.g. - STL or iges.
upper right corner.
2. Click Select Job. The Open
dialog appears.
4. Click the button with the three

dots at the right of Optimization
results to load them. The Open
dialog appears.
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and press Open.
SIMULIA
Tosca Structure
5. In the Open dialog, go to the

SAVE.onf directory and select
the the file BEAD_00x.onf,
where x represents the last
design cycle of the bead optimization. In this case, select the
file BEAD_003.onf and press
Open. The selected file with its
whole path appears in the field
next to Optimization
Results.
6. Select the task Create
Surface + Optimization
displacements (Shape
and Bead optimization)
from the Task dropdown list.
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7. Activate a button with a CAD

output format, for example
.igs or .stl and deactivate
all other buttons.
8. Click Start Smoothing. After
Tosca Structure is finished click
View Result and navigate in
the Open window to your
smooth results in your job directory in the subdirectory
TOSCA_POST.
2.4.9
Report Generation
1. Open your VTFX file by
clicking View Result.
SIMULIA
Tosca Structure
2. With View | Viewports you

can select up to four viewports
in different positions. Choose
two viewports: You see the relative material distribution of your
model in the left side of the split
window. The right part is still
empty.
View 1.
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mouse).
SIMULIA
Tosca Structure

named GLview Report
chapter!

situations to a file. If you close
the Tosca Structure Report
Builder window, you can go on
by opening your saved repository.
10. In the Tosca Structure Report Builder window now both siutations are
listed. By rightclicking at the situation you can delete it.
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9. Go back to Tosca Structure.view window. Repeat step 6 and 7, but select

3D model as Situation type for capturing.
SIMULIA
Tosca Structure
11. Now, in Tosca Structure.view

window select the right window
and click Quick Capture
active view in the quick
access toolbar or select File
| Quick Capture Situation.
12. The last settings are kept for capturing, thus the original model is
loaded as 3D model into the Tosca Structure Report Builder.
into the Tosca Structure Report Builder. (Look at step 6 and 7, if necessary, and do not forget to activate the window).
doubleclick at

Cases).
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15. Repeat step 13 to capture the

same plot as Table.
SIMULIA
Tosca Structure

situation name is shown without
number in italic. The same
effect is achieved by rightclicking and selecting Deactivate.
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18. Transfer the active situations

into a powerpoint document by
PowerPointReport.
SIMULIA
Tosca Structure
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in <tosca_directory>\report\Templates. Select your output file name and
the media type (3D plugin for interactive and animated 3D data, videos
and image for animations and image only for screenshots of all situations). Click OK.
SIMULIA
Tosca Structure

When Tosca Structure is done the result (depending on solver) should be
similar to Fig. 56.
a)
Optimization displacement result plots from controller based

bead optimization where a) has default bead width and b) has
bead width 30.0 mm. The eigenvalues are (a) 356 Hz and (b) 385
Hz, which is an increase of 99% and 115%, respectively.

The history of the optimization can either be followed in Tosca Structures logfile TOSCA.OUT or in the optimization_report.csv-file.
The default bead width is determined from the average element edge length
in design area. In the logfile TOSCA.OUT is the average element edge length
found to be 8.3 mm and the BEAD_WIDTH 53.0 mm (see log file
TOSCA.OUT).
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Fig. 56
b)
SIMULIA
Tosca Structure
2.5
Sizing Optimization with Tosca Structure.gui

Fig. 57
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2.5.1
Sizing for chassis components

less fixed.
areas.
SIMULIA
Tosca Structure

eigenfrequencies;
weight, volume;
center of gravity;
moment of inertia.
that the design proposal can be produced. Different constraints like, e.g.,
symmetry constraints can be defined.
2.5.2
Model
The component to be used within the tutorial represents a holder for a gear
shift control and is found in the Tosca Structure installation directory (<tosca>)
according to your FE-solver (<solver>) (available for Abaqus and ANSYS):
<tosca>/<solver>/examples/sizing/holder
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The model is meshed with linear homogenous shell elements with an initial
thickness of 3.5.
There are two loadcases defined. The first one is a bending loadcase with a
load Fx =-2500N at node 5 and the second one is a torsional moment Mx =
80000Nmm at node 5. Further, all drill holes are fixed in all directions (cf. Fig.
58)
SIMULIA
Tosca Structure
Fig. 58
Original design of a holder with loads and design area (yellow

coloured)
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The design area consists of the elements in the interior of the structure, colored yellow in Fig. 58 . The elements of the design area are combined to a
group design_all which can later be used for the optimization. For further
SIMULIA
Tosca Structure
Fig. 59
2.5.3
Clustering groups:Horizontal clustering groups named DES_HOR1

(on the top) until DES_HOR12 on the left, vertical clustering
groups named DES_VER1 (left group) until DES_VER6 in the middle and cicular clustering groups named DES_RING1 (outer ring)
until DES_RING3 on the right.
Optimization Task
The optimization task is to find a structure with maximum stiffness for the
component for both static load cases. Additionally, a weight constraint of
maximum 100 % of the initial weight should be considered.
The value for the first constraint is calculated from the sum of the volumes of
all elements.The first eigenmode is derived from a modal analysis.
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tasks using clustering this design domain is split into several subgroups as
described below:
SIMULIA
Tosca Structure
The shell thicknesses should vary between an absolute value of 0.1 and 3.0.
Four variants of the optimization can be performed:
Free sizing (i.e. the shell thicknesses of all design elements can be modified independently)
Clustering with horizontal areas (the design area is split horizontally into
several areas in which the shell size will vary simultaneously)
Clustering with vertical areas (the design area is split vertically)
Clustering with "circular" areas (the design area is split into several "round"
areas) - this cluster variant is motivated by the result of the free sizing.
2.5.4

Preprocessing
3. Design area: Tosca Structure.pre | DV_SIZING
4. Design variable constraints: Tosca Structure.pre | DVCON_SIZING
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6. Objective function: Tosca Structure.pre | OBJ_FUNC | Minimize

8. Define optimization Task: Tosca Structure.pre | OPTIMIZE
9. Saving Tosca Structure parameter file: Tosca Structure.pre | FILE |
Save As
Start Optimization
Start TOSCA
SIMULIA
Tosca Structure
Postprocessing
Report
Please note that Tosca Structure 8.0 or higher is required in order to complete the optimization task.
2.5.5
Preprocessing
In the following detailed description the setup of a typical sizing optimization
task with Tosca Structure.gui is shown.

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on the right.

dialog appears.

(holder.<ext> where <ext> is
appears in the The finite
element input files field.
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In sizing optimization, the design area denotes the set of elements that may
be changed (whose thicknesses are modified) during the optimization. A
subset can be defined as frozen areas which will remain unchanged.
SIMULIA
Tosca Structure
1. Select the item DV_SIZING

The DV_SIZING menu appears
on the right.
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2. Choose the group

DESIGN_ALL from the dropdown list next to EL_GROUP
item MY_DV_SIZING to the
SIMULIA
Tosca Structure
2.5.5.4 Choice of thickness bounds (design variable constraint)

Design variable constraints introduce restrictions on the shape of the optimized model. Besides the shell thickness constraint discussed below, other
types of design constraints such as symmetry and minimum member size
restrictions are supported by Tosca Structure.
1. Select the item
DVCON_SIZING from the optimization task tree. The
DVCON_SIZING menu appears
on the right.
2. Select DESIGN_ALL from the

dropdown list next to Element
Group. The constraint will now
be applied to all elements of the
selected group.
3. For defining a thickness restriction for the selected element

group activate the radio button
Thickness Bounds and
define a lower and upper bound
of 0.1 and 3.0 respectively in
the corresponding fields. Select
Magnitude = ABS for absolute
magnitude.
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Please note that the ID_NAME is a special mark of any component of the
optimization task. The ID_NAME must be unique for each component.
Using the ID_NAME you can select between different components of the
same type during the optimization setup. If no other component of the same
type appears in the optimization task, the change of the ID_NAME is
optional and the Tosca Structure default ID_NAME can be used.
SIMULIA
Tosca Structure

It is always recommended to perform a first sizing optimization without too
much additional constraints to use the maximum design flexibility for the
optimization. Influenced by a first design proposal clustering may be introduced. With Clustering, certain areas of the model are grouped such that
they get a common shell thickness during the optimization. Clustered areas
may later be manufactured by sheets of constant thickness. An example is
the optimization of an assembled sheet structure like a car body in white,
where each sheet has one thickness.
1. Select the item
DVCON_SIZING from the optimization task tree. The
DVCON_SIZING menu appears
on the right.
3. For horizontal clustering choose the groups DES_HOR1 till DES_HOR12,

for vertical clustering choose the groups DES_VER1 till DES_VER6 and
for circular clustering choose the groupsDES_RING1 till DES_RING3 as
shown in Fig. 59
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DVCON_CLUSTER_GROUPS.
Activate the radio button
CLUSTER_GROUPS and Select
all element groups for which
elements the thicknesses shall
remain the same.
SIMULIA
Tosca Structure

design responses. The design responses are assigned to output parameters from the FE analysis. In this example design responses for the volume
and the strain energy will be needed.
right.
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DRESP_VOLUME, and choose
the type VOLUME in the field
Type of the Base category.
3. Choose DESIGN_ALL from the

Element/Elementgroup
dropdown list and set the
Group Operator to Sum to
build the sum of the volumes of
each element in the model.
Thus the whole volume of the
structure is determined.
Click Create to add the design
4. Repeat step 1 to define another design response.
SIMULIA
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5. Type a ID_NAME for the new

design response, for example
DRESP_STRAIN_ENERGY_1,
in the corresponding field and
choose Stress/Strain from
and in the Type field choose
the type STRAIN_ENERGY.
6. Activate the Element/Elementgroup radio button and

select ALL_ELEMENTS from
the Element/Elemtgroup
dropdown list.
7. Set the Group Operator to
Sum.

dialog, choose Static as
Analysis Type and enter 1
as Loadcase Number. Click
OK: The new entry appears in
the Loadcase Selection
field.
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8. Click Add LC to selct the load

case for the design response.
The Select Loadcase dialog
appears.
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10. Click Create to add the

design response
DRESP_STRAIN_ENERGY_1 to
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11. Repeat steps 4-10 to define a second design response for the strain
energy of load case 2.
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the right.

appears.
4. Select the radio button MinMax

next to Target and click
MY_OBJ_FUNC to the optimization task tree.
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design responses
DRESP_STRAIN_ENERGY_1
and
DRESP_STRAIN_ENERGY_2
and press Ok. The window
closes and the selected design
responses appear in the field.
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The CONSTRAINT menu

choose the design response
DRESP_VOLUME from the
Design Response dropdown
list.
4. Select the less or equal

radio button next to Constraint Type, thus the target
volume for the optimization is
restricted by 100 percent of the
original volume, and click
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slider to 100 or type the value
in the field manually.
SIMULIA
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the right.
2. Select SIZING_SENSITIVITY
automatically.

dialog, activate the design variable constraints
DVCON_SIZING and
DVCON_CLUSTER and press
Ok. The corresponding items
appear in the DV Constraints field.
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6. Activate
press Ok. The corresponding
items appear in the Constraints field.
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2. In the Save As dialog choose

The file automatically receives
the extension .par and
becomes the parameter file for
Tosca Structure.
Start Optimization
upper right corner.
2. Choose all from the Type
dropdown list . This option
includes a preprocessing test
and the optimization run.
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2.5.6
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3. Select the solver (Abaqus or

ANSYS) of your choice from the
Solver dropdown list.

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5. After approx. 15 design cycles

the optimization run is finished
and the status TOSCA job
finished is displayed.
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2.5.7
Postprocessing
Viewing the intermediate results using Tosca Structure.report.
Using Tosca Structure.report, the intermediate results of sizing optimization, namely the thicknesses of element shells, can be visualized.
upper right corner.
3. To see every design cycle click

in the field below Iter
(concerning the result
ELEMENT_THICKNESS) and
select All from the Iter dropdown menu (default). Repeat
this for the result
ELEMENT_DELTA_
THICKNESS (second field
below Iter).
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Results ELEMENT_THICKNESS
and ELEMENT_DELTA_
THICKNESS. A standard report
is available in the directory
Structure.view.
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in the field below.


dialog appears.
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starts.
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8. The animation starts and stops by clicking on the start forward/backward, pause and stop symbol in the task menu.
The described example is generated using the FE solver Abaqus. Please
note that slight differencies in the optimized design are possible for the
different solvers. However the design conception remains the same.
2.5.8
Report Generation

the element thickness distribution of your model on the left
side of the split window. The
right side is still empty.
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file.
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View 1.
mouse).
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window named GLview

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repository.
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10. In Tosca Structure Report Builder window both model siutations are
order.
13. Load the optimization result ELEMENT_DELTA_THICKNESS (right
window in Tosca Structure.view) as image into the Tosca Structure
Report Builder. (Look at step 6 and 7, if necessary, and do not forget to
activate the window).

plot as Table.
Cases).
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doubleclick at
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Tosca Structure

Doubleclick at one entry to
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PowerPointReport.
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type. Click OK.
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2.5.9
Result Discussion
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A free sizing optimization without additional restrictions leads (naturally) to

the best results, in this case a reduction of the maximum displacement by
45%. An optimization with clustering (circular in this case), required by manufacturing, still leads to an improvement of 30%. In the figure below (Fig. 60)
the displacement results are shown:
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Tosca Structure
Displacement magnitude: initial model, optimization result without

clustering and with circular clustering (top to bottom)
Fig. 61 and Fig. 62 show the shell thickness in the design area for different
cases: The differences in the results of the optimization without clustering and
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Fig. 60
SIMULIA
Tosca Structure
Fig. 61
Optimization results: Final shell thickness in the design area without clustering (left) and with horizontal clustering (right)
Fig. 62
Optimization results: Final shell thickness in the design area with

vertical clustering (left) and with circular clustering (right)
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with the several kinds of clustering are obvious. Furthermore, the result of
optimization with vertical clustering indicates the unsymmetric load.
SIMULIA
Tosca Structure
Getting Started with Tosca Extension for
Getting Started with Tosca

Extension for ANSYS/WB
Tosca Extension for ANSYS/Workbench allows the integration of Tosca Structure.topology and Tosca Structure.shape in ANSYS Workbench. Tosca
Extension for ANSYS/Workbench is not supported for bead and sizing optimization yet.
Tosca Structure.topology and Tosca Structure.shape is treated like every
other system in the Project Schematic and sources its Geometry, Model
and Load/Boundary Conditions input data via connection to other systems
within the Project Schematic.
The optimization and all its available options will be set up in the Mechanical Application. Once every wished option is selected the optimization
run can be started.
The resulting model of this iterative optimization run is visualized and can be
used for further postprocessing such as a complete validation run.
3.1
User Interface
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The entire optimization from model creating to the last step of the optimization takes place in three main windows / applications.
The main window, the ANSYS Workbench with its Project Schematic
collects all parts of a project in a graphically clear manner. Every subsystem
or template is listed and connections between the single systems are visible.
SIMULIA
Tosca Structure
Fig. 63
ANSYS Workbench overview. The Project Schematic shows the used systems / templates
Fig. 64
Design Modeler is Workbenchs default CAD

application
Fig. 65
Mechanical is a FEA graphical user interface. It is

included as an application in Workbench, too
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User Interface
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Fig. 66
3.1.1
Tree Outline (left) and Details View (right)
Buttons
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The relevant buttons for the use of the Tosca Extension for ANSYS/Workbench can be found in the upper toolbar of the Mechanical application. All
optimization options, controls and conditions will be inserted with these buttons.
Under this point, buttons can be found to set a

design area or define different manufacturing
restrictions.
Defines the part of the geometry that has to
be optimized.
Defines parts that have to be left out of the
optimization.
SIMULIA
Tosca Structure
User Interface
Inserts direction for pulling out the model of

a casting mold.
Is able to avoid material accumulation in
certain areas or to set a minimum size / circumference for bars.
Adds different kinds of symmetry for the
topology optimization.
Under this point, buttons can be found to set a

design area or define different manufacturing
restrictions. These buttons are only applicable for
TOSCA Structure.shape
Defines the part of the geometry that has to
be optimized. The area for mesh smoothing
is also defined here in order to prevent a
bad quality mesh.
Different design variable constraints to limit
or influence the nodal movement of the
design nodes during the optimization can
be defined.
Constraints and Objective Functions for the optimization can be chosen

Defines the kind of system output.
Inserts values for a design response to converge to.

Generates Tosca Input Files (parameterfile, FE-Input-Deck) and saves them to a
user defined directory for external solve.
Here you can add result options.

Shows the result of the topology optimization (relative densities).
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Minimizes or maximizes a certain design

response.
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Adds a smoothed surface model of the optimization result. Smooth Result is needed
for the Valudation Run.
Imports external solved results.
After an optimization run an optional validation

run can be performed.
Starts the validation run.
Imports Contact Definitions into the Validation System.
3.1.2
Handling Tips
If there are for example optimization options inserted in the Tree Outline and you want them to be ignored during an optimization run, the
Suppress / Unsuppress buttons work with Tosca Extension for
ANSYS/Workbench as well as with any other system in ANSYS Workbench.
Tosca Extension for ANSYS/Workbench creates certain files into different

directories. In general it is possible and sometimes recommandable to look
up TOSCAs parameter-file or several report files to get an overview or to
find mistakes that influence the optimization. To find these files efficiently,
use the right click option on headlines in the Tree Outline and choose
Open Solver Files Directory.
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It is often mandatory to apply the concerned geometry for an optimization

option like Frozen area for example. Make always sure that the correct
selection button is activated as well as the Select Mode (Single / Box).
SIMULIA
Tosca Structure
User Interface
Using Tosca Extension for ANSYS/Workbench it is often required to apply

a part of the geometry to an optimization option. Instead of selecting a certain geometry for different occasions over and over again by hand, it is also
possible to create a Named Selection beforehand. This selection can
be chosen later and applied as Geometry much easier.
A second advantage of Named Selections is that in the .par-file a selection will be named after your selections labeling instead of a list of nodes or
elements. The .par-file (or other files) becomes more comfortable to read.
Therefore define a Named
Selection for example in
Design Modeler by clicking
Tools | Named Selection.
It will be listed in the Tree Outline. Rename it (F2 button) in
order to find and use it later with
ease.
The Named Selection is listed

from now on in the Tree Outline of the Mechanical application.
(A Named Selection can also
be defined directly in Mechanical)
Use it later when for example

defining a force. Instead of choosing the geometry by hand, you
can now simply change the Scoping Method to Named Selection and find yours in the list.
When using multiple shared Analysis Systems for the Optimization, they
can be used again for the Validation Run. Since they are copies of the ini-
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The concerned geometry has to

be defined.
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tial systems, they cant be shared anymore. You have to reassign faces for
the boundary conditions for each system again. Alternatively its possible to
use multiple steps in one analysis instead of multiple systems.
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Tosca Extension for ANSYS/WB needs to know the path of the Tosca
Installation (Tosca Bin Dir). If you use the Extension for the first time, you
have to specify the path in Mechanical in Analysis Settings | Tosca
Bin folder (ends with "...\bin"). When clicking Solve to start the first
Optimization, the entered path will be saved and used again in your future
projects.
If you want to change the path again, declare a new one in the analysis settings. Clicking Solve will save it again as default path.
SIMULIA
Tosca Structure
User Interface
It is possible to edit the parameterfile manually before starting the Optimization.

Go to the Analysis Settings
and set Edit PAR before
calling Tosca to Yes.
Set up your Optimization and click
on Solve.
The parameter-file and FE-InputFile will be generated and then
the solve process will be paused.
The par-file will be selected in a
new Explorer Window and can be
edited.
If you just want to set up the optimization and run it on another machine or
cluster, it is possible to generate the needed input files (parameter-file and
FE input deck) using Tosca Extension for ANSYS/WB. Set up the whole
optimization (FE-Mesh, Boundary Conditions, Design Area, Design
Responses, Objective Function, Constraint, etc.) within the extension,
select Tosca in the Tree Outline and then click on Optimization |
Write out PAR-File. Choose or create the desired export folder in the
pop up window and click OK.
In addition to watch the Optimization Status in the Command Shell, the

more detailed solver output (TOSCA.OUT) can be displayed in Workbench
after or during the optimization. Therefore, select Toscas Solution
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After saving your changes, go

back to Mechanical. There is a
message which informs about the
paused process. Click OK to continue the Optimization with the
edited par-file.
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Tosca Structure
Information in the Tree Outline. The Tosca Loglevel can be

changed in the Analysis Settings before starting the optimization.
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The captions of all Tosca "loads" (Design Area, Design Response etc.) in
the Tree Outline of Mechanical will be reused in the Tosca parameter-file.
Rename these objects (F2-button) to avoid missunderstandings in Workbench and to facilitate the readability of the parameter-file.
Attention:
Do not name your items manually with a blank followed by a number
SIMULIA
Tosca Structure
User Interface
("DRESP 3 Volume"). Workbench will slice the caption internally

("DRESP"). Use underlines or omit the blank ("DRESP_3_Volume" or
"DRESP3Volume") to avoid this behavior.
Its possible to display a Demold and Symmetry Plane. Go to the Demold or
Symmetry Control in the Tree Outline and choose a Coordinate System
and Demold Direction/Symmetry Axis.
The Show Plane option is used
to show (Yes) or hide (No) the
plane.
The diameter of the displayed
disc depends on the size of the
Bounding Box of your assembly.
The second option Center |

Origin of Coordinate System uses the origin of the
selected CS.
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For the center of the displayed

disc there are two possible settings. Center | Projected
Center of Assembly is the
default setting. The center of the
disc depends on the center of the
assembly (unsupressed parts).
SIMULIA
Tosca Structure
To have a better understanding of your optimization setup, the Frozen Area

Elements, which will be excluded from the optimization, can be displayed in
Workbench.
Select the Frozen Area in the
Tree Outline. In Details
View, set Show Frozen Elements to Yes. The display will be
updated automatically if you
change this setting or the geometry selection.
Remark:
This view is not recommended, if
Frozen Area is a Body.
The selected faces are colored
blue, the elements are green.
With the default viewing option,
you cant see the elements, since
they are inside the part.
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Select Wireframe in the upper

ANSYS toolbar, to hide the faces
of the part and show the Frozen
Elements.
SIMULIA
Tosca Structure
User Interface
Additionally to the Wireframe

view, the Show Mesh option in
the upper toolbar might be useful.
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If you run an optimization, change some settings and want to start a second optimization, there might occur an error. Before starting the new optimization, its recommended to delete the existing files (Tree Outline |
Solution | Clear Generated Data) and close and reopen the
Mechanical application.
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Tosca Structure
3.2
Topology Optimization with Tosca Extension

for ANSYS/WB
This little instruction should help to get in touch with the Tosca Extension for
ANSYS/Workbench. Some guided clicks should provide a first overview, setting up an optimization example.
3.2.1
The model
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A cars control arm is used as an example. A control arm is a part of a cars

independent wheel suspension and supports against occuring cross forces.
That means on the one hand that it is a mass-produced component, so any
material and cost reduction pays off. On the other hand every weight reduction in cars is welcome in general because dynamic characteristics increase
and less mass has to be accelerated and slowed.
Fig. 67
3.2.2
This model shows an example of a topology optimization with

Tosca Extension for ANSYS/Workbench
Loading the Extension

In order to load the extension, open the Extension Manager by clicking
Extensions | Manage Extensions.
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Tosca Structure
Topology Optimization with Tosca Extension for ANSYS/WB
Check the box for the current Tosca Extension for ANSYS/Workbench (8.1.0).
The extension is loaded immediately; close the Extensions Manager and
wait for the Busy icon in the down left corner of the screen to disappear.
Fig. 68
Use the Extension Manager to load Tosca Extension for

ANSYS/Workbench
3.2.3
Example files
Dependent on where you want to start the procedure, you can choose one of
the following files. You find all necessary files in the directory
<tosca_install_dir>\ansys\TS_Ext_for_WB\examples\topo\.
1. Start from scratch using the provided control_arm.stp geometry file. Continue at chapter 3.2.4 Preparing the model.
2. Start the project with an imported geometry file. Use the ANSYS Workbench project archive control_arm.wbpz. Continue at chapter 3.2.4 Preparing
the model, step 15.
3. Start the project with an imported geometry file and defined boundary conditions. Use the ANSYS Workbench project archive control_arm_bc.wbpz.
Continue at chapter 3.2.5 Optimization preprocessing.
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If you save a project and the extension is used, it is loaded automatically the
next time the project will be opened.
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3.2.4
Preparing the model

At first, the task has to be set up. Then the model is loaded into ANSYS
Workbench and loads and boundary conditions are added, using the different applications in ANSYS Workbench.
Make sure the extension is loaded (See chapter Loading the Extension).
1. Add a Static Structural
system to the Project Schematic by dragging the corresponding template onto the
Project Schematic surface.
2. Right click on the Geometry
cell in order to import the
provided model
"control_arm.stp".
4. The imported geometry is listed

in the Tree Outline. The
yellow lightning symbolizes that
the import is not finished yet.
Click on Generate to execute
the import of the control arm
model.
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3. Double-click Geometry in
order to open the application
Design Modeler.
Select mm as unit and confirm.
SIMULIA
Tosca Structure
5. In order to create an isolated

part of the geometry that can be
used as Design Area to be optimized later, slice the geometry.
Activate the XYPlane in the
Tree Outline and click New
Sketch.
6. The button Look at Face/

Plane/Sketch will turn the
activated plane if necessary.
7. Click the tab Sketching to
open the sketching toolbar. Add
geometry to mark the areas of
the model that are not to be
changed during the optimization. Be careful with overlapping geometry which causes an
error. Trim (Modify | Trim) if
necessary.
9. Click Extrude.
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8. Make sure that the marked

areas are defined correctly.
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10. If Extrude is clicked immediately after having sketched, the

correct sketch will be highlighted as Geometry. If not,
choose the correct sketch. Click
Apply.
11. Choose Slice Material
as Operation.
12. Click Generate. Different

body colors mark the different
parts; the transparency indicates the parts as Frozen.
Unfrozen geometries in
contact would be combined to a
single body automatically.
14. It is recommended in general

to save the project from time to
time. Therefore use the button
Save or Save as in the upper
toolbar of ANSYS Workbench.
15. Double-click the Model cell in
order to open the Mechanical
application.
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13. Close DesignModeler.
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Tosca Structure
16. Check if units are defined

correctly (Metric - mm, kg, N).
18. Assign the entire geometry

(5 Bodies). Enter 5 (mm) as
Element Size. A click on
Update creates a tetrahedral
(automatic) mesh.
19. It is possible to display the

generated mesh of the model.
Either use the Show Mesh
button in the upper toolbar or
click on the Mesh folder in the
Tree Outline.
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17. Activate Mesh in the Tree

Outline by clicking on it once.
That makes appear the
concerned buttons in the upper
toolbar. Mesh control |
Sizing adds a mesh sizing
operation.
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Tosca Structure
20. Activate Model in the Tree

Outline. Click on the
Symmetry button.
21. Right click the inserted
Symmetry unit in the Tree
Outline, choose Insert |
Symmetry Region.
22. Apply the control arms mid

plane as Geometry by holding
CTRL while selecting the
different faces (make sure
Face Selection is activated,
see chapter "Handling Tips").
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23. Select Z Axis as Symmetry

Normal.
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Tosca Structure
24. Activate the Static Structural in the Tree Outline.

25. Add a load to the Tree
Outline with the button
Loads | Force. Make sure
the selection option Face ist
activated.
27. In the definition, change

Define By from Vector to
Components and enter 7071 N
as X Component and -7071 N
as Y Component magnitude.
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26. As Geometry choose the

inner face of the lower drill-hole;
click Apply.
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28. Add an Elastic Support

by clicking Supports |
Elastic Support on the
outer face of the upper anchor.
29. Select the outer face with the

face selection tool.
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30. Enter 10 N/mm as Foundation Stiffness.
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31. Select the upper bearings

inner face.
32. Add a Remote Displacement.
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33. In the corresponding

Details View, set the X
Coordinate to 25.65 mm, and
the Y and Z Coordinate to
0 mm. Within the DefinitionGroup, change all Components from Free to 0, except
for the Rotation X.
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Tosca Structure
34. Activate Solution in the

Tree Outline. Click on
Stress | Equivalent
(von-Mises) to add a stress
analysis as result output. Make
sure all five bodies are selected
for the analysis.
A stress analysis is set up.
Click Solve to execute the
analysis.
35. Save the project.
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3.2.5
Now that the calculation put out all the requested solutions, an optimization
task can be set up.
It is not mandatory to solve any stresses or strains before the optimization.
Loads and boundary conditions are enough. It is recommended though, since
it can be checked whether the analysis is correctly set up or not.
36. Close the Mechanical application and continue working in the
Project Schematic. Now
use a TOSCA Structure.topology system.
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Tosca Structure
37. Drag a TOSCA Structure.topology template

onto the Model cell of the
existing Static Structural
in the Project Schematic.
This way both systems are
connected on the level of the
Model and the TOSCA Structure.topology draws on the
generated data of the Static
Structural system.
Important: If you connect the
systems otherwise, the TOSCA
Structure.topology is not
able to perform correctly.
Mechanical needs to be closed
when you connect the systems.
39. For the TOSCA Structure.topology |

Analysis settings in the
Tree Outline, choose
Controller as Strategy in
the Details View. Auto
Frozen is not needed, set it to
Off.
If you use Tosca Extension for
ANSYS/WB for the first time,
you have to define the TOSCA
bin folder ("...\Tosca80\bin").
Otherwise the solver does not
start. After you set a path, and
solved the first project, your
future projects will use this path
by default.
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38. Double-click the Setup cell

on the TOSCA Structure.topology in order to
open the Mechanical application.
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40. Add the options for the optimization run. The area to be optimized is defined with a
Topology | Design Area.
41. Insert the Design Area in

the TOSCA Structure.topology in the Tree
Outline.
42. Apply the main area as
Geometry (1 Body).
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43. Add a Demold Control.
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44. Select the Global Coordinate System as Coordinate System and Z as

direction. Therefore make sure
the resulting vector equals
(0, 0, 1).
Remark:
Use the Show all Coordinate Systems button (upper
ANSYS toolbar) to facilitate the
definition of the Demold Direction.
The displayed disc shows the
Demold Direction.
46. Add the first of two Design

Responses via Optimization | Design Response.
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45. Select the main part of the

geometry as Geometry and
CheckGroup.
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Details View select Volume
as Response Type and
choose the same geometry as
in Design Area as Geometry
(1 Body).
48. Rename the Design
Response to "Dresp_Vol"; click
on it once in the Tree
Outline and then use the F2
button.
49. Add the second of the two
Design Responses.
50. Select Stress/Strain as
Category. Again, select the
main area as Geometry and
choose All as Load Case.
Rename the design response
to "Dresp_Stren".
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51. Add an Objective Function by clicking Optimization | Objective

Function.
52. Choose Minimize sum as
Target.
53. Click on Tabular Data in

the Details View window,
create a new table; select
Dresp_Stren as Design
Response. Click Apply.
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Tosca Structure
54. Add a Constraint to the

optimization task by clicking on
Optimization | Constraint.
55. Select Dresp_Vol as Design
Response and 0.7 as Value.
56. Click the toolbar button

Results and add an Optimization Result and a
Smooth Result.
For more information about the

smooth options, see the Tosca
Structure Documentation.
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57. For the Smooth Result,

choose 0,1 as Iso Value.
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58. Click Solve to start the optimization.

Save the project.
3.2.6
Postprocessing
The Tosca Extension for ANSYS/Workbench offers in the Mechanical application some visualization options. The optimization result can be displayed in
different ways, single iterations can be showed, too.

To display a topology optimization result correctly in the Mechanical application, make sure that the correct Geometry option in the upper toolbar is
activated.
leads to
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Geometry view option
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With the option Capped IsoSurfaces it depends on the elements

relative density whether they are displayed or not. This limit density
(elements above or below are displayed) is adjustable.
With IsoSurfaces activated, no

result will be displayed.
The Graph window in the Mechanical application provides an overview of

the optimization steps. Its either possible to have a look at each single iteration or to show even a little animation from the beginning until the end of the
optimization run.
To display a single iteration step, select it with the left mouse button, then
right click | Retrieve this result. For a little animation it is possible to use a Play and Stop button or regulate animation speed. All the
needed buttons can be found in the Graph window.
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3.2.7
Validation Run
As continuation after an optimization and smoothing run, a validation run can
be performed.
The smoothed model describes the surface of the optimization result. Based
on this resulting model, a solid three dimensional model is reconstructed
which can be loaded with the original forces and supported with the original
boundary conditions.
The validation run can only be executed after a smoothing run.
The Project Schematic after the

Validation looks like shown on
the left.
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59. Click Validation | Run to

start the Validation. The procedure might take a few minutes
and is finished as soon as the
new Validation System is
opened automatically.
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61. Begin with the Symmetry

Condition. Reselect the mid
plane faces and apply it as
Geometry of the Symmetry
Region.
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60. Forces, boundary conditions

and other options, too, have to
be reassigned.
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62. As Geometry of the Force,

reassign the inner face of the
lower drill-hole.
63. Select the Elastic

Support in the Tree
Outline and choose the
corresponding face(s) as
Geometry.
Remark:
Its possible, that the initial face
is split into several small
pieces. Select all of them to
recreate this boundary condition.
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64. Reassign the face of the

Remote Displacement.
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Tosca Structure
3.2.8
Troubleshooting
Wrong connection in Project Schematic
Make sure the Tosca Optimizer has all the input it needs: Engineering
Data, Geometry, Model. Loads cannot be specified in a standalone
TOSCA Structure.topology system.
Optimization strategy
The controller based algorithm is developed to solve a volume contraint / stiffness maximization. For problems involving Displacement or Membersize Control for example, a sensivity based algorithm is needed.
At the same time, controller based algorithm solutions work with equality constraints while the sensivity based algorithm handles unequality constraints
like greater or less than a certain value.
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65. When all options are reassigned to the model, click

Solve.
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To receive appropriate solutions, approximately 15 design cycles / iterations

are needed for the controller strategy and 35-45 cycles for sensitivity strategy
(see, e.g., vol.2 chapter 5.2.1, Controller versus sensitivity based topology
optimization). Otherwise the solver will not converge.
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3.3
Shape Optimization with Tosca Extension for

ANSYS/WB
This little instruction should help to get in touch with the shape optimization
module in the Tosca Extension for ANSYS/Workbench. Some guided clicks
should provide a first overview, setting up an optimization example.
3.3.1
The model
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A connecting rod (conrod) is used as an example. A conrod is a part of a car's

reciprocating piston engine and is used to turn the reciprocating motion of the
piston into rotating motion. This means that high stress levels in the component generally lead to a premature failure of the component since it is used in
many different load cycles. If the stress peaks in the conrod can be reduced,
this also means that the life of the component prior to failure can be
extended.
Fig. 69
This model shows an example of a shape optimization with Tosca

Extension for ANSYS/Workbench
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Tosca Structure
Shape Optimization with Tosca Extension for ANSYS/WB
In the FE-Model of the conrod loaded nodes are connected with MPCs to the
inner side of the conrod mounts. Nodes on the inner radius of the big eye
(crankshaft bearing) are fixed in all three coordinate directions.
Loadcase 1:
Screw fixation
Loadcase 2:
Loadcase 3:
Bending about the x-axis, 1000 N applied in negative x-direction
Loadcase 4:
Bending moment about the y-axis (-10000Nmm)
Loadcase 5:
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Torsion about the z-axis (10000Nmm)

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Loads and boundary conditions of the conrod model:

left: (A) centrifugal force, (B) and (C) screw fixation
right: force caused by gas pressure (A), bending and torsion
about x-, y- and z-axis (C), (D) and (E). Fixation in nodes of big
eye (B).
For simplicity reasons only loadcase 2 will be described in depth in this manual as this is the most dominant loadcase causing the highest stresses. An
optional ANSYS Workbench project archive exists in which all five loadcases
are predefined.
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Fig. 70
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Tosca Structure
3.3.2
Loading the extension

In order to load the extension, open the Extension Manager by clicking
Extensions | Manage Extensions.
Check the box for the current Tosca Extension for ANSYS/Workbench (8.1.0).
The extension is loaded immediately; close the Extensions Manager and
wait for the Busy icon in the down left corner of the screen to disappear.
Use the Extension Manager to load Tosca Extension for

ANSYS/Workbench
If you save a project and the extension is used, it is loaded automatically the
next time the project will be opened.
3.3.3
Example files
Dependent on where you want to start the procedure, you can choose one of
the following files. You find all necessary files in the directory
<tosca_install_dir>\ansys\TS_Ext_for_WB\examples\shape\.
1. Start from scratch using the provided control_arm.stp geometry file. Continue at chapter 3.3.4 Preparing the model.
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Fig. 71
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2. Start the project with an imported geometry file. Use the ANSYS Workbench project archive control_arm.wbpz. Continue at chapter 3.3.4 Preparing
the model, step 15.
3. Start the project with an imported geometry file and defined boundary conditions. Use the ANSYS Workbench project archive control_arm_bc.wbpz.
Continue at chapter 3.3.5 Optimization preprocessing.
3.3.4
Preparing the model

At first, the task has to be set up. Then the model is loaded into ANSYS
Workbench and loads and boundary conditions are added, using the different applications in ANSYS Workbench.
Make sure the extension is loaded (See chapter Loading the Extension).
1. Add a Static Structural
system to the Project Schematic by dragging the corresponding template onto the
Project Schematic surface.
3. Double-click Geometry in
order to open the application
Design Modeler.
Select mm as unit and confirm.
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2. Right click on the Geometry

cell in order to import the
provided model "conrod.stp".
SIMULIA
Tosca Structure
4. The imported geometry is listed

in the Tree Outline. The
yellow lightning symbolizes that
the import is not finished yet.
Click on Generate to execute
the import of the conrod model.
5. In order to create an isolated

part of the geometry that can be
used as Design Area to be optimized later, slice the geometry.
Activate the XYPlane in the
Tree Outline and click New
Sketch.
7. Click the tab Sketching to

open the sketching toolbar. Add
geometry to mark the areas of
the model that are not to be
changed during the optimization. Be careful with overlapping geometry which causes an
error. Trim (Modify | Trim) if
necessary.
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6. The button Look at Face/

Plane/Sketch will turn the
activated plane if necessary.
SIMULIA
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8. Make sure that the marked

areas are defined correctly. The
area should encompass the
lower half of the small eye to
the area above the big eye
where the conrod starts to
widen up.
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9. Click Extrude.
10. If Extrude is clicked immediately after having sketched, the
correct sketch will be highlighted as Geometry. If not,
choose the correct sketch. Click
Apply.
11. Choose Slice Material
as Operation.
SIMULIA
Tosca Structure
13. Select all three bodies in the

Tree Outline and click on
Form New Part from the
context menu. This causes the
conrod to be treated as a single
part in Mechanical later, but
the single bodies are still selectable. This is especially desirable since the mesh will be
continuous.
14. Close DesignModeler.
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12. Click Generate. Different

body colors mark the different
parts; the transparency indicates the parts as Frozen.
Unfrozen geometries in
contact would be combined to a
single body automatically.
SIMULIA
Tosca Structure
15. It is recommended in general

to save the project from time to
time. Therefore use the button
Save or Save as in the upper
toolbar of ANSYS Workbench.
16. Double-click the Model cell in
order to open the Mechanical
application.
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17. Check if units are defined

correctly (Metric - mm, kg, N).
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Tosca Structure
18. Activate Mesh in the Tree

Outline by clicking on it once.
That makes appear the
concerned buttons in the upper
toolbar. Mesh control |
Sizing adds a mesh sizing
operation.
20. The upper half of the small

eye will most likely not be
meshed with tetrahedral
elements like the other two
bodies. In order to achieve a
homogenous mesh, the upper
half of the small eye needs to
be meshed with tetrahedrals
manually. Mesh control |
Method adds an Automatic
method. Assign the entire
geometry (3 Bodies). Change
the Method to Tetrahedrons.
21. A click on Update creates an
automatically generated tetrahedral mesh.
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19. Assign the entire geometry

(3 Bodies). Enter 2 (mm) as
Element Size. A click on
Update creates a tetrahedral
(automatic) mesh.
SIMULIA
Tosca Structure
22. It is possible to display the

generated mesh of the model.
Either use the Show Mesh
button in the upper toolbar or
click on the Mesh folder in the
Tree Outline.
23. Activate the Static Structural in the Tree Outline.
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24. Add a load to the Tree

Outline with the button
Loads | Remote Force.
Make sure the selection option
Face ist activated.
SIMULIA
Tosca Structure
25. As Geometry choose the

inner faces of the conrod mount
(the small eye) by holding
CTRL while selecting the
different faces (make sure
Face Selection is activated, see chapter 3.1.2
Handling Tips); click Apply.
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26. In the definition, change

Define By from Vector to
Components and enter
-25000 N as Z Component
magnitude.
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27. Add a Displacement by

clicking Supports |
Displacement on the inner
face of the big eye.
28. Select the inner face of the big

eye with the face selection tool.
Click Apply.
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29. Within the Definition

Group, change all Components from Free to 0.
SIMULIA
Tosca Structure
30. Activate Solution in the

Tree Outline. Click on
Stress | Equivalent
(von-Mises) to add a stress
analysis as result output. Make
sure all five bodies are selected
for the analysis.
A stress analysis is set up.
Click Solve to execute the
analysis.
3.3.5
Now that the calculation put out all the requested solutions, an optimization
task can be set up.
It is not mandatory to solve any stresses before the optimization. Loads and
boundary conditions are enough. It is recommended though, since it can be
checked whether the analysis is correctly set up or not.
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31. Save the project.
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32. Close the Mechanical application and continue working in the

Project Schematic. Now
use a TOSCA Structure.shape system.
34. Double-click the Setup cell

on the TOSCA Structure.shape in order to open
the Mechanical application.
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33. Drag a TOSCA Structure.shape template onto the

Model cell of the existing
Static Structural in the
Project Schematic. This
way both systems are
connected on the level of the
Model and the TOSCA Structure.shape draws on the
generated data of the Static
Structural system.
Important: If you connect the
systems otherwise, the TOSCA
Structure.shape is not able
to perform correctly.
Mechanical needs to be closed
when you connect the systems.
SIMULIA
Tosca Structure
35. In the TOSCA Structure.shape | Analysis

settings in the Tree
Outline the default settings
do not have to be changed.
If you use Tosca Extension for
ANSYS/WB for the first time,
you have to define the TOSCA
bin folder ("...\Tosca81\bin").
Otherwise the solver does not
start. After you set a path, and
solved the first project, your
future projects will use this path
by default.
36. Add the options for the optimization run. The area to be optimized is defined with a Shape
| Shape Design Area.
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37. Select the Design Area in

TOSCA Structure.shape in
the Tree Outline.
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38. Apply the the surfaces of the

main area as Design Variables. The design area (design
variables) always has to be a
subset of the mesh smooth
area. Thus only surfaces on the
main body are allowed to be
selected. Make sure that the
interior of the small eye are not
selected (indicated by the
eclipse). Click Apply.
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39. Click in the Geometry field

of the Mesh Smooth area.
This will define the body which
will be considered during the
optimization.
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40. Select the center body as the

Geometry of the Mesh
Smooth area Make sure that
Body/Element Selection
is activated. Click Apply.
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41. In order to make sure that the

functional area of the small eye
isnt moved during the mesh
smooth it has to be fixed. Add a
Shape | DV Constraints
Shape.
SIMULIA
Tosca Structure

Details View select the
lower half of the small eye and
the adjacent outer surface as
Geometry. Make sure that the
outer surfaces on both sides
are selected.
44. Add the Design Response

via Optimization | Design
Response.
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43. Select CHECK_DOF as Constraint Type and choose the

Global Coordinate as
System Coordinate
System. Change
Check_dof1, Check_dof2
and Check_dof3 to Fix. This
will fix the nodal movement in
all directions during the mesh
smooth.
SIMULIA
Tosca Structure
45. Select Stress/Strain as

Category and SIG_Mises as
Response Type. Choose the
same geometry as in Design
Area as Geometry and select
All as Load Case. Rename
the Design Response to
"Dresp_Stress"; click on it once
in the Tree Outline and then
use the F2 button.
46. Add an Objective Function by clicking Optimization | Objective
Function.
47. Choose Minimize sum as
Target.
49. Click the toolbar button

Results and add a Controller Input.
50. Click Solve to start the optimization.

Save the project.
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48. Click on Tabular Data in

the Details View window,
create a new table; select
Dresp_Stress as Design
Response. Click Apply.
SIMULIA
Tosca Structure
3.3.6
Postprocessing
The Tosca Extension for ANSYS/Workbench offers some visualization
options in the Mechanical application. The optimization result can be displayed in different ways, single iterations can also be shown.
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To display the stress results of a shape optimization in the Mechanical

application, the created Controller Input has to be selected. This will
display the resulting stresses and optimized shape of the component.
Alternatively it is also possible to display the nodal displacement for each iteration in order to determine to what extent each node is moved during the optimization. Right click on Solution in the Tree Outline and then Insert
| Deformation | Total. Please note that this does NOT refer to the
total deformation of the component subject to the different loadcases of the
static structural analysis..
Besides the total nodal displacement, the directional nodal displacement can
be visualized as well. Right click on Solution in the Tree Outline and
then Insert | Deformation | Directional if you wish to visualize the
directional results.

the optimization steps. It is either possible to have a look at each single iteration or to show an animation of the course of the optimization run. This can be
done for Controller Input (stresses) as well for the nodal displacements.
To display a single iteration step, select it with the left mouse button, then
right click | Retrieve this result. For an animation it is possible to
SIMULIA
Tosca Structure
use a Play and Stop button or regulate animation speed. All required buttons can be found in the Graph window. .
3.3.7
Troubleshooting
Wrong connection in Project Schematic
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Make sure the Tosca Optimizer has all the input it needs: Engineering
Data, Geometry, Model. Loads cannot be specified in a standalone
TOSCA Structure.shape system.
Volume II
User Manual
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Preface
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Preface
The User Manual is the standard reference describing the available functionalities of all Tosca Structure modules.
chapter 1 Overview of Tosca Structure gives a brief overview of Tosca Structure. This includes a short description of each module (chapter 1.1 The Tosca
Structure Modules), the chronological sequence of the optimization process
with Tosca Structure (chapter 1.2 Overview of the Optimization Process) and
a diagram (chapter 1.3 Workflow for Optimization) showing the step-by-step
process of the optimization with useful links to the documentation. The chapter 2 Working with Tosca Structure shows how each module can be started
with or without a graphical user interface. The contents of these two sections
together with the manual vol.1 Start Manual give a sufficient description to
understand the process for a standard topology, shape and bead optimization. A more detailed description of the optimization process with the relevant
data flow can be found in chapter 12 Tosca Structure Control.
The chapter 3 The Model explains requirements for the optimization model. It
shows how the link between finite element model and optimization task is
established and how further model specifications like group or coordinate
system definition can be made.
chapter 4 Terms for Optimization explains terms required for the optimization
(objective and constraint) and their definition using the several front ends. It
further lists design responses (e.g. analysis results) allowed for the definition
of optimization targets and constraints.
A more detailed description of the functionalities available for topology optimization (chapter 5 Topology Optimization), shape optimization (chapter 6
Shape Optimization), bead optimization (chapter 7 Bead Optimization) and
sizing optimization (chapter 8 Sizing Optimization) discusses e.g. manufacturing constraints and typical optimizations tasks. Each command is
described only in the context of its functionality with other commands. A more
detailed description of the command syntax can be found in volume 3: Commands Manual.
The next chapter (chapter 9 Result Transfer and Validation Run) describes
how optimization results can be transferred to CAD for further processing of
the optimization results and how a validation run can be set up.
The possibilities available for analyzing the optimization results are shown in
chapter 10 Postprocessing of Optimization Results. The different solver-specific functionalities are described in chapter 11 Solver Specific Features
including shape optimization taking into account the lifetime of a component.
chapter 12 Tosca Structure Control shows the program flow of Tosca Structure in detail as well as configuration of the program and file structure of optimization results.
The chapter 13 Troubleshooting describes troubleshooting in case of
unwanted or premature termination of the program.
User Manual 2 - 3
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The Appendix chapter 14 Appendix summarizes the possibilities that are provided by Tosca Structure modules for specific functionalitites. It further lists
the program limits and predefined macros.
2 - 4 User Manual
SIMULIA
Tosca Structure

Tosca Structure is a modular system for non-parametric structural optimization. Topology, shape, bead and sizing optimization of FE models can be performed with Tosca Structure for design of lightweight, rigid and durable
components and systems. A parameterization of the model is not needed.
Topology optimization determines an optimum design proposal starting with a
given maximum design domain.
In Shape optimization, the components surface is modified to reduce local
stress or damage peaks.
Bead optimization is used to determine the optimum location and orientation
of bead stiffeners for sheet metal components. With Tosca Structure.bead,
the static stiffness and the vibration behavior can be improved.
Sizing optimization derives optimal thicknesses for a shell structure to, e.g.,
increase stiffness or reduce vibrations.
Structural optimization with Tosca Structure is an iterative process. The structural response of the component is calculated in each design cycle with an
external FE solver. The user can work with his favorite solver in his favorite
pre- and postprocessing environment and does not need additional training in
a new CAE environment. Working with Tosca ANSA environment this link is
even closer and allows the complete setup, start and validation of an optimization task with one front end.
A closed development process can be achieved by the interaction of the components of Tosca Structure from the first concept to the optimized geometry in
the CAD system.
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1.1
The Tosca Structure Modules

The optimization system Tosca Structure consists of several modules supporting the user with his optimization process. Different front ends are available to set up the process: the Tosca ANSA environment and Tosca
Structure.gui. Further, topology optimization tasks can be processed entirely
within ANSYS Wokbench. All front ends interact with several Tosca Structure
modules for definition of the optimization task, running the optimization process, result transfer, visualization and postprocessing. However, it is not necessary to work with a graphical user interface for carrying out an optimization.
Working in the command shell is described in more detail in chapter 2.4
Working with Tosca Structure in the Command Shell.
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Tosca Structure
The Tosca Structure Modules
1.1.1
Abaqus CAE
Abaqus CAE allows users to setup and perform topology, shape or sizing
optimization tasks with Tosca Structure fully integrated into Abaqus CAE.
Optimization results can be visualized in the visualization module of CAE. For
details about the Tosca integration in Abaqus/CAE, Tosca for Abaqus, see the
Abaqus manuals provided with your Abaqus installation. All other graphical
user interfaces are treated within this documentation.
1.1.2

Tosca ANSA environment is a powerful front end. The graphical user interface supports the complete workflow for optimization setup, optimization,
result transfer and validation run. A task manager guides the user through the
process. For details about the Tosca ANSA environment see vol.1 chapter 1,
Getting Started with Tosca ANSA environment and vol.2 chapter 2.1, Working
with Tosca ANSA environment.
1.1.3
Tosca Structure.gui
1.1.4
Tosca Extension for ANSYS/WB

Tosca Extension for ANSYS/WB allows ANSYS/Workbench users to setup
and perform topology and shape optimization tasks with Tosca Structure fully
integrated into ANSYS/WB. Optimization results can be visualized in the
Mechanical applications within Workbench. Validation runs are also included.
For details about the Tosca Extension for ANSYS/WB see vol.1 chapter 3,
Getting Started with Tosca Extension for ANSYS/WB, vol.1 chapter 3.2,
Topology Optimization with Tosca Extension for ANSYS/WB and vol.1 chapter 3.3, Shape Optimization with Tosca Extension for ANSYS/WB.
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Tosca Structure.gui is the graphical user interface where other modules of the
optimization system can be started. Tosca Structure.gui includes the module
Tosca Structure.pre for interactive input of optimization parameters. For
details about Tosca Structure.gui see vol.1 chapter 2, Getting Started with
Tosca Structure.gui and vol.2 chapter 2.2, Working with the Graphical User
Interface Tosca Structure.gui. Tosca Structure.gui can be used as alternative
to Tosca ANSA environment.
SIMULIA
Tosca Structure
1.1.5
Tosca Structure optimization modules

The modules Tosca Structure.topology, Tosca Structure.shape, Tosca Structure.bead and Tosca Structure.sizing form the actual optimization kernel of
Tosca Structure. Tosca Structure controls the start of data preprocessing, the
optimization and the FE solver run (see vol.2 chapter 12, Tosca Structure
Control). For specific functionalities, further modules are available (see vol.2
chapter 14.1, Additional Tosca Structure optimization modules).
1.1.6
Tosca Structure.report automatically generates vtfx reports for quick navigation through the results of the optimization. It contains important graphical
information of the model and optimization results as well as tables of the process of significant values to be stored in an archive.
1.1.7
Tosca Structure.view is an efficient viewer for fast visualization of optimization
results and reports generated by Tosca Structure.report. For presentation
purposes a plug-in for Microsoft PowerPoint is available (see vol.2 chapter
10.2, Tosca Structure.view). Further, an integrated report generator transfers
Tosca Structure optimization results to MS Office and html documents.
Tosca Structure.smooth prepares the optimization results for import into a
CAD system or FE-preprocessor or a remeshing for a validation run (see
vol.2 chapter 9.1, Tosca Structure.smooth). This validation run is performed
automatically using Tosca ANSA environment.
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1.1.8
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Overview of the Optimization Process
1.2

Each optimization requires several steps independent of the optimization type
(see Fig. 1).
OPTIMIZATION STEPS
PLANNING
PREPROCESSING
CHECK RUN
OPTIMIZATION LOOP
POSTPROCESSING
VALIDATION RUN
Fig. 1
Planning
The optimization and simulation tasks should be carefully thought out and formulated before beginning the optimization. All requirements like the optimization target, the necessary restrictions and the acceptable volume of the whole
project should be considered.
1.2.2
Preprocessing: Model generation

All requirements from the planning step have to be considered for the generation of the simulation model. In order to avoid unnecessary tasks, it is important that the relevant information for the analysis and optimization is carefully
considered before starting.
Model generation covers the following:
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Steps in the optimization
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Tosca Structure
Creating the analysis model

(if not yet created) in the FE preprocessor. It contains all data that is important for the FE analysis. Normally no special specifications for the optimization are required in the FE model. However, some definitions (e.g.
definition of groups) in the FE model may help to simplify the optimization
process. Using Tosca ANSA environment groups can be defined graphically when the optimization task is set up (see e.g. vol.1 chapter 1.1.13,
Managing Groups). The functionalities available for the applied solver and
the relevant preprocessor are depicted in vol.2 chapter 10, Postprocessing
of Optimization Results. The model properties are described in more detail
in vol.2 chapter 3, The Model.
Combination of the optimization model
The optimization model consists of the analysis data (compiled in one or
more analysis models) and the settings for the optimization task. The definition of the optimization task in Tosca Structure can be performed using
Tosca ANSA environment or Tosca Structure.gui. All specifications for the
optimization task are stored in a parameter file. The specifications and data
necessary for an optimization can be found in chapter 5 Topology Optimization (topology optimization), chapter 6 Shape Optimization (shape optimization), chapter 7 Bead Optimization (bead optimization) and chapter 8
Sizing Optimization (sizing optimization).
www.3ds.com/tosca
Version 8.1.0 Rev. 1 - 05.2014
1.2.3
Check Run
The check run should be performed before starting the optimization to avoid
wrong or missing definitions for the optimization task. Using Tosca ANSA
environment (see vol.2 chapter 2.1.2, Check Run) this step is included in the
task manager. With Tosca Structure.gui the check run is a normal optimization run with special settings (vol.2 chapter 2.2.2, Check Run).
1.2.4
Optimization Loop
The optimization can be started in Tosca ANSA environment (see vol.2 chapter 2.1.3), using Tosca Structure.gui (see vol.2 chapter 2.2.3) or Tosca Extension for ANSYS/Workbench (see vol.2 chapter 2.3.2) or by calling Tosca
Structure in a command shell (see vol.2 chapter 2.4.4). Tosca Structure first
starts a preprocessing step to check the definitions and write the complete
optimization model to the database. Then the optimization loop runs until the
stop criteria defined by the user is reached.
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Tosca Structure
1.2.5
Postprocessing: Evaluation of Optimization results

After the optimization is completed, Tosca Structure.report can be called for
data preparation with respect to postprocessing. During the optimization process the optimization results can be combined to animated sequences which
can be visualized by Tosca Structure.view (see vol.2 chapter 10.2, Tosca
Structure.view). Further, the process of specific optimization values like terms
for the objective or constraints can be visualized in graphs and tables. All this
postprocessing data can be combined in vtfx archives.
1.2.6
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Valid optimization results have to be further processed in the design process.

Tosca Structure.smooth can be used to prepare the optimization results for a
transfer to a CAD system or FE-Preprocessor. Further, smoothed topology
optimization results can be remeshed and a validation run can be performed.
The task manager in Tosca ANSA environment supports this feature in an
automated way (vol.2 chapter 9.2, Validation Run in Tosca ANSA environment). In other environments validation runs require a minimal amount of
manual model adaptation (vol.2 chapter 9.4, Workarounds Using Other Environments).
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1.3
Workflow for Optimization

FE-Model creation
Preprocessing
Tosca Structure.pre
Check Run
Start Optimization
Tips on FE-Model vol.2 chapter

3.1 and vol.2 chapter 3.3
Definition of optimization task:

vol.2 chapter 5, Topology Optimization, vol.2 chapter 6,
Shape Optimization, vol.2 chapter 7, Bead Optimization, vol.2
chapter 8, Sizing Optimization.
vol.2 chapter 6.9, Check run

(TEST_SHAPE),
vol.2 chapter 7.9, Check run
(TEST_BEAD)
vol.2 chapter 2.1.3 Tosca ANSA
environment, vol.2 chapter 2.2.3
Tosca Structure.gui, vol.2 chapter
2.3.2 Tosca Extension for ANSYS/
WB, vol.2 chapter 2.4.4 Command Shell,
vol.2 chapter 12.2, Starting

Tosca Structure
If model doesnt run see vol.2
chapter 13
Postprocessing
www.3ds.com/tosca
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Preparation of data for postprocessing see vol.2 chapter 10.1

Visualization and animation of optimization results see vol.2 chapter
10.2
Result Transfer to CAD

Validation
Preparation of data for CAD

see vol.2 chapter 9.1
Validation run see vol.2 chapter 9.2
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Workflow for Optimization
Optimization process with links to documentation
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In this chapter, the general workflow with Tosca Structure is described. More
details and practical examples can be found in vol.1 Start Manual.
Prior to starting Tosca Structure a FE model must exist of the part that needs
to be optimized. The model has to be analyzed at least once and the results
checked. In chapter 3.1 Models for Optimization tips on model building for the
required type of optimization are listed. How much the definition of the optimization problem can be simplified through entries made in the FE preprocessor is described in chapter 10 Postprocessing of Optimization Results for the
relevant preprocessor.
It is recommended to control the whole optimization workflow using Tosca
ANSA environment that allows visual control of your component and geometric definitions or the classical Tosca Structure.gui. All steps of the optimization
process (but not FE modeling and postprocessing) can be accessed from
Tosca Structure.gui. Access to Tosca Structure from the command shell is
described in chapter 2.4 Working with Tosca Structure in the Command Shell.
2.1
Working with Tosca ANSA environment

Tosca ANSA environment provides the user with a workflow oriented tool to
implement the complete optimization process. The graphical user interface
supports
function based definition of the optimization task (preprocessing)
check run to review completeness and correctness of the definitions
start of the optimization
result transfer for CAD and postprocessors

validation run for optimization results.
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visual postprocessing with Tosca Structure.view
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Fig. 3
Optimization Task in Tosca ANSA environment
One big advantage over the classical workflow with Tosca Structure.gui is the
possibility to perform geometric definitions (like design variable constraints or
group selection) interactively. Further, consistency checks and updates of all
dependencies are performed for each step. At the end of a topology optimization the modified model with all boundary conditions and load cases can be
prepared automatically for the validation run.
Tosca ANSA environment can be started with the command
tosca_ansa_env in a TOSCA command shell. The start script can be
found in <install_dir>\bin\tosca_ansa_env.
2.1.1
Preprocessing
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The preprocessing step in Tosca ANSA environment is used to set up the

complete optimization task which can then be stored in a parameter file.
Thereby a new function based approach is applied such that the user no longer needs to care about dependencies or single commands. The task man-
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ager tree view shows a logical sequence of definitions necessary for the
optimization task.
Fig. 4
Preprocessing in Tosca ANSA environment
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First the link to the model has to be established. After loading the linked
model can be used for interactive definitions of groups or constraints on
design variables. Then optimization type dependent items for the optimization
task can be defined and are grouped into folders according to their context. A
detailed description of the setup of the optimization task can be found in vol.1
chapter 1.2, Topology Optimization with Tosca ANSA environment, vol.1
chapter 1.3, Shape Optimization with Tosca ANSA environment and vol.1
chapter 1.4, Bead Optimization with Tosca ANSA environment.
2.1.2
Check Run
Once the optimization task is completely defined, a check run should be
made. Tosca Structure then performs a complete syntax check of the optimization task to ensure a valid definition. Test runs for shape and bead optimization can be added to the CHECK INPUTS folder which will apply hypothetic
optimization displacements to the model to enable the user to check restrictions etc. visually. The test results can be visualized (VTF_VISUALIZATION)
using Tosca Structure.view.
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Tosca Structure
2.1.3
Start Optimization
The optimization task defined in the task manager tree can now be started by
simply updating the RUN item in the task manager tree. Eventually required
settings can be entered in an editor window. When starting the optimization,
all dependencies are actualized automatically. It is possible to deactivate definitions in the tree which are then skipped for the optimization run.
2.1.4
Postprocessing
After the successful completion of the optimization run, the results have to be
carefully checked. In the postprocessing step of your optimization task you
can prepare your optimization results for a visual check with Tosca Structure.view (see chapter 10.1.3 Tosca Structure.report in Tosca Extension for
ANSYS/Workbench andchapter 10.2 Tosca Structure.view) which can be
directly accessed from the task manager (item VTF_VISUALIZATION). The
user can navigate through the several steps of the iterations to visualize the
changes in the model for one or more optimization relevant values. Further,
graphs of specific optimization terms like, e.g., values of the objective or constraints, can be added to the vtfx visualization archive. Additionally Tosca
Structure.view provides you with a plug-in for MS PowerPoint to create interactive presentations including your optimization results (see chapter 10.2.9
VTFX PlugIn for Office applications and Webbrowser).

For topology optimization, a validation of the optimized model is needed to be
able to evaluate the responses without the void material in the simulation.
Tosca Structure.smooth creates smooth surfaces of the area with remaining
material (SMOOTH_RUN). The results from Tosca Structure.smooth can be
displayed by Tosca Structure.view (VTF_VISUALIZATION).
Fig. 5
Smoothing and Visualization inTosca ANSA environment
Then the smoothed structure can be prepared for a validation run (VALIDATE) by performing a reconstruct step to improve the quality of the surface
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mesh, batch creation of a solid mesh and output of the optimized model in
your solver format. All loads and boundary conditions of the design space
model are transferred automatically to the new mesh. Finally, the finite element analysis (VALIDATION_RUN) can be started to evaluate stresses and
displacements.
Fig. 6
Result Transfer and Validation Run inTosca ANSA environment
Satisfying optimization results can now be prepared by Tosca Structure.smooth for transfer into a CAD-system for further treatment in the design
process (Create a new SMOOTH_INSTANCE with suitable output format).
A more detailed description of this process and possible settings can be
found in vol.2 chapter 9.1, Tosca Structure.smooth.
2.2
Working with the Graphical User Interface

Tosca Structure.gui
www.3ds.com/tosca
Version 8.1.0 Rev. 1 - 05.2014
Tosca Structure.gui simplifies the work process of Tosca Structure for the
user. The graphical user interface enables the following tasks to be completed: defining the optimization task (Tosca Structure.pre), starting the optimization in Tosca Structure, calculating iso surfaces, data smoothing and
User Manual 2 - 17
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Tosca Structure
Working with the Graphical User Interface Tosca Structure.gui
reduction (Tosca Structure.smooth), preparing results for postprocessing

(Tosca Structure.report) and viewing them (Tosca Structure.view).
Fig. 7
Graphical user interface of Tosca Structure in Tosca Structure.gui
Tosca Structure.gui can be started with the command tosca_gui in a

TOSCA command shell. The start script can be found in
<install_dir>\bin\tosca_gui.
Preprocessing
Tosca Structure.pre is used to define the settings for the optimization task
which are then stored in a parameter file. The optimization task can either be
created by a wizard, by defining the individual commands or by modifying an
existing parameter file. A tree view with a logical sequence of the commands
supports the user in the definition.
For details about the use of Tosca Structure.pre and tips for the user refer to
vol.1 chapter 2, Getting Started with Tosca Structure.gui. The parameters for
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the optimization commands and their syntax are described in detail in vol.3
Commands Manual.
Fig. 8
2.2.2
Defining the optimization task at Tosca Structure.pre
Check Run
Once the optimization task is completely defined, a check run should be
made. Tosca Structure then performs a complete syntax check of the optimization task to ensure a valid definition. Eventually some test runs for shape
(see vol.2 chapter 6.9, Check run (TEST_SHAPE)) and bead optimization
(see vol.2 chapter 7.9, Check run (TEST_BEAD)) are made which will apply
hypothetic optimization displacements to the model to enable the user to
check restrictions etc. visually (e.g. using Tosca Structure.view).
www.3ds.com/tosca
Version 8.1.0 Rev. 1 - 05.2014
2.2.3
Start Optimization
Optimization with Tosca Structure.bead, Tosca Structure.shape or Tosca
Structure.topology can be started on the "Start Tosca Structure" screen in
Tosca Structure.gui. The job name of the optimization job (chosen by a
parameter file), the start directory and if necessary the name of the FE solver
are defined here. Further (optional) settings can be made using the menu
"additional Parameters".
A protocol window, convergence plots and a small queuing system are available to support the user in his work. For more details about the optimization
User Manual 2 - 19
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Tosca Structure
Working with the Graphical User Interface Tosca Structure.gui
start refer to vol.1 chapter 2.1.3, Starting the Optimization and vol.2 chapter
12.2, Starting Tosca Structure.
Fig. 9
Postprocessing
The module Tosca Structure.report allows a preparation of the optimization
results for postprocessing by Tosca Structure.view (see more chapter 10.1
Generation of Postprocessing Data). The user can navigate through the several steps of the iterations to visualize the changes in the model for one or
more optimization relevant values. Further, graphs of specific optimization
terms like, e.g., values of the objective or constraints, can be added to the vtfx
visualization archive. Tosca Structure.view provides you with a plug-in for MS
PowerPoint to create interactive presentations including your optimization
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Starting optimization from Tosca Structure.gui
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Tosca Structure
results (see more chapter 10.2.9 VTFX PlugIn for Office applications and
Webbrowser).
Fig. 10

Tosca Structure.smooth prepares the optimization result for transfer into a
CAD-system for further treatment in the design process or into your FE-preprocessor for preparation of a validation run. Further, the results from Tosca
Structure.smooth can be displayed by Tosca Structure.view and added to vtfx
visualization archives. In the Tosca Structure.smooth window just choose
your task to perform (surface or isosurface calculation), select your job (corresponding parameter file) and eventually enter more parameters to control
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Preparation of the optimization results for FE postprocessing at

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Working with Tosca Extension for ANSYS/Workbench
smoothing and data reduction and output formats (additional information see
vol.2 chapter 9.1, Tosca Structure.smooth).
Fig. 11
2.3
Input parameters via Tosca Structure.gui at

Working with Tosca Extension for ANSYS/

Workbench
Tosca Extension for ANSYS/Workbench provides the ANSYS/WB user with a
workflow oriented tool to implement and perform a complete topology and
shape optimization process. The graphical user interface supports
function based definition of the optimization task (preprocessing)
visual postprocessing within ANSYS/WB

result transfer for CAD and postprocessors
validation run for optimization results.
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start of the optimization
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Fig. 12
Optimization Task in Tosca Extension for ANSYS/WB
www.3ds.com/tosca
Version 8.1.0 Rev. 1 - 05.2014
One big advantage over the classical workflow with Tosca Structure.gui is the
possibility to perform geometric definitions (like design variable constraints or
group selection) interactively. At the end of a topology optimization the modified model with all boundary conditions and load cases can be prepared for
the validation run.
Tosca Extension for ANSYS/WB is fully included into ANSYS/WB.
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Working with Tosca Extension for ANSYS/Workbench
2.3.1
Preprocessing
The preprocessing step in Tosca Extension for ANSYS/WB is used to set up
the complete optimization task which can then be stored in a parameter file.
The Tree Outline lists all definitions that are made for the optimization task.
Preprocessing in Tosca Extension for ANSYS/WB
Before starting an optimization setup, an FE-analysis has to be set up first.

Then, after loading the extension, all definitions, design variables constraints,
etc. are added to the same Mechanical application. A detailed description
of the setup of the optimization task can be found in vol.1 chapter 3, Getting
Started with Tosca Extension for ANSYS/WB
2.3.2
Start Optimization
The optimization task defined in the Tree Outline can now be started by clicking Solve. It is possible to deactivate single definitions by suppressing them in
the Tree Outline. These definitions are then skipped for the optimization run.
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2.3.3
Postprocessing
After the successful completion of the optimization run, the results have to be
carefully checked. The Tosca Extension for ANSYS/Workbench offers in the
Mechanical application some visualization options (see chapter 10.3 Postprocessing with Tosca Extension for ANSYS/Workbench).
Futher, a standard vtfx report for visualization with Tosca Structure.view is
available in your jobname directory.
2.3.4
www.3ds.com/tosca
Version 8.1.0 Rev. 1 - 05.2014
For topology optimization, a validation of the optimized model is needed to be

able to evaluate the responses without the void material in the simulation.
Tosca Structure.smooth creates smoothed surfaces of the area with remaining material. The results from Tosca Structure.smooth are displayed directly
in the Mechanical application of ANSYS/WB.
Fig. 14
Visualization of smoothed model in Mechanical
Then the smoothed structure can be prepared for a validation run. During the
two validation steps the smoothed surface model - which serves only for visu-
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Working with Tosca Structure in the Command Shell
alization purposes - is reconstructed to first a shell model and eventually a

solid model. This solid model can be used in an FE-analysis again.
Fig. 15
Result Transfer and Validation Run in Tosca Extension for

ANSYS/WB
2.4
Working with Tosca Structure in the

Command Shell
For remote calculations or work with queuing systems it may become necessary to call Tosca Structure modules in batch mode from a command shell.
Please ensure that the Tosca Structure variable is known (e.g. by using a
Tosca Structure command shell on Windows) when working without a graphical user interface. This chapter gives only a brief overview of the basic process and the individual commands. More detailed information regarding the
optimization process can be found in (vol.2 chapter 12, Tosca Structure Control). A quick and very short help is printed using the command:
tosca810 --help
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Satisfying optimization results can now be prepared by Tosca Structure.smooth for transfer into a CAD-system for further treatment in the design
process (Choose suitable output format).
A more detailed description of this process and possible settings can be
found in vol.2 chapter 9.1, Tosca Structure.smooth.
SIMULIA
Tosca Structure
2.4.1
Logging in command shell

Logging is always done to <jobname>/TOSCA.OUT-file. The following levels
can be used.
- WARNING (not recommended) Only WARNINGs and ERRORs are
printed
- NOTICE Default output to STDOUT. Only the most important logging
- INFO
Default output to logfile TOSCA.OUT
- DEBUG
Very verbose output, mostly for support
- TRACE
(not recommended) Extremely verbose,
major performance los, only for developers
To change log level to logfile TOSCA.OUT use the command line parameter:
tosca810
--loglevel <new_level> ...
To increase the amount of output to the command shell set the parameter:
tosca810 --loglevel_stdout <new_loglevel>
Note that --loglevel must be equal or more verbose than --loglevel_stdout.

Example:
1. Increase log level to INFO on the command shell and DEBUG output into
the logfile TOSCA.OUT
tosca810 --loglevel_stdout INFO --loglevel DEBUG ...
2. More information about logging see chapter 12.2.3 Logging
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2.4.2
Preprocessing
Once the FE model has been completed and checked, the optimization task
must be defined. The parameter files containing these definitions can be created with an editor. This is only recommended when single commands in an
existing parameter file need to be modified. Groups and coordinate systems
can be defined in the FE-model to simplify the creation of the optimization
task.
A more detailed description of the command syntax for parameter files can be
found in vol.3 Commands Manual.
Tosca ANSA environment can be started with the command
tosca_ansa_env, Tosca Structure.gui can be started with the command
tosca_gui in a TOSCA command shell. Tosca Extension for ANSYS/Workbench can be started from within ANSYS/Workbench.
The start script can be found in <install_dir>\bin\tosca_ansa_env
or in <install_dir>\bin\tosca_gui.
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2.4.3
Check Run
Before starting the optimization, the FE model (jobname.ext) and the
parameter file (jobname.par) must already exist in the work directory. As part
of a routine check, the FE model should be analyzed and evaluated. Consequently, a test run has to be completed and checked with respect to the optimization task before beginning the optimization.
tosca810 jobname --solver solvername --type test1
(see vol.2 chapter 12.2.8, Testing the optimization process). It is worthwhile to
make different test runs depending on the optimization task. Once the test run
is completed, a visual check of the definition of the optimization task can follow.
2.4.4
Start optimization
Starting the optimization with the standard settings is done with the command
tosca810 jobname --solver solvername
Further command line options are described in chapter 12.2 Starting Tosca
Structure.
Postprocessing
Tosca Structure.report allows the preparation of optimization results for postprocessing using Tosca Structure.view.
The optimization results are written by Tosca Structure in a neutral format
(ONF). A converting module allows the creation of a report file containing
visualization sequences and graphs for specific results. Automatic generation
of a visual post processing file can be done with the command line option report, e.g.:
tosca810 jobname --report
The above automatically call Tosca Structure.report which generates a vtfxfile in the directory TOSCA_POST after a successful optimization.
More details regarding postprocessing can be found in chapter 10.1 Generation of Postprocessing Data. The vtfx-file can be viewed in Tosca Structure.view which allows visualization of the optimization results by an
animation over the iterations of the optimization. The sequences can be created with Tosca Structure.smooth or Tosca Structure.report. Call Tosca Structure.view with the command line:
tosca810 --view jobname/TOSCA_POST/<vtfx-file>
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Tosca Structure
2.4.6
Result Transfer
Tosca Structure.smooth allows the preparation for the transfer of the optimization results into the design process (for more details see chapter 9.1 Tosca
Structure.smooth).
Tosca Structure.smooth is called up in a command shell with the command
tosca810 jobname --smooth
More details regarding postprocessing can be found in chapter 9 Result
Transfer and Validation Run. The vtfx-file can be viewed in Tosca Structure.view which allows visualization of the optimization results by an animation over the iterations of the optimization.
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tosca810 --view jobname/TOSCA_POST/<vtf-file>
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Tosca Structure
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Tosca Structure
The Model
The Model
Each optimization task is based on one or more finite element analysis models. These models form the basis for the optimization, i.e. contain the nodes
or elements to be changed and the loads and boundary conditions for the calculation of important terms for the optimization (see vol.2 chapter 4, Terms for
Optimization). Further, node and element groups or coordinate systems in the
analysis files are available for further definitions in the optimization task. Additional files may contain objects for the definition of constraints or provide supplementary analysis results to be considered in the optimization.
This chapter deals with requirements for optimizable models and discusses
the loading of models. Further, the definition of groups and coordinate systems in your optimization environment is explained.
3.1
Models for Optimization
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When defining a model for analyzing, the selection and definition of the loads
and boundary conditions should be constructed with special consideration
because an incorrectly defined or forgotten load or support may have a very
pronounced effect on the result of the optimized structure. The basic characteristics of the analysis model that can be optimized are described in detail in
vol.2 chapter 11, Solver Specific Features (optimizable element types, number of load cases and permitted boundary conditions, types of analysis, nonlinearities, etc.) and in vol.2 chapter 14.2, Limits of Tosca Structure.
Remark
One single finite element can consist of several laminates which is especially
common for shell elements to specify e.g. several cross sections, materials
etc. In Tosca Structure, this is called a "ply". Currently Tosca Structure supports only one single ply for each element and stops with an error message if
elements with multiple plies are found.
3.1.1
Models for topology optimization

Topology optimization determines the optimized material distribution in a
given space for achieving an optimized design. Based on the external loads
and boundary conditions, Tosca Structure.topology determines the optimum
material distribution in the design space. The topology optimization creates
holes and perforations that extensively alters the shape of the component.
Alternatively, an existing component can be optimized whereby the topology
optimization rearranges the material distribution of the component.
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Tosca Structure
Models for Optimization
The available design space must exist as a FE model. The resolution of the
designed structures depends strongly on the selected discretization. A fine
mesh produces a structure with a higher resolution than a coarse mesh. On
the other hand, it will also substantially increase the processing time required.
A compromise between structural resolution and processing time needs to be
found.
3.1.2
Models for shape optimization
3.1.3
Models for bead optimization

The design area for a bead optimization must be a shell type of structure i.e.
shell or plate elements.
The mesh should be uniform in element size. The element size should be
chosen such that 6 elements covers the wanted bead width. It is recommended to use linear elements, but not necessary.
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In shape optimization, the boundaries or surfaces of a component are modified. At first the optimizer calculates the new coordinates of the design nodes
on the component surface based on the stress condition and then adjusts the
remaining FE mesh accordingly. The calculation of the new coordinates of the
nodes is not based on geometrical parameters, but rather on each individual
coordinate for the nodes. Generally, every FE model can serve as a basis for
shape optimization.
The mesh must be of such quality that the analysis results from the FE mesh
remain essentially unaffected. To assure this, most FE preprocessors have
checking routines. The user must define an adequate mesh density for a subsequent optimization, i.e., high stress gradients should not be present within
an element.
The mesh density must be set correctly in order to achieve smooth contours.
For example, smooth contours cannot be expected when a 90 degree curve
is meshed by only three elements. The finer the mesh density, the closer the
contour will be to optimum.
Tosca Structure.shape features an integrated efficient smoothing mesh algorithm. It is capable of adjusting the FE mesh to the optimized displacement of
the design nodes without re-meshing. It is possible that the FE model will collapse when there is a large optimized displacement of the design nodes due
to a poor mesh. This can be avoided by setting the mesh to an adequate density.
SIMULIA
Tosca Structure
The Model
3.1.4
Models for sizing

The design area for a sizing optimization must be a shell type of structure i.e.
shell or plate elements. The shell thicknesses of the most typical modeling
shell elements are supported as design variables. The mesh should be uniform in element size. Only single layered shells are supported. Contact in the
design area is also allowed. Geometrical non-linearities ae not supported.
Constitutive non-linear modeling is only allowed outside the design area (e.g.
a non-linear spring).
3.2
Optimizable Element Types

In general, Tosca Structure allows all element types listed in Table 1 in the
optimization area. Details concerning specific element definitions for the several solvers are listed in chapter 11 Solver Specific Features. Some design
responses are not allowed for all element types. This can be found in the
coresponding paragraphs of chapter 4 Terms for Optimization.
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Tosca Structure Element Type
Topological Description
PLANE_QUAD_4
Four-node 2D plate element
PLANE_QUAD_8
Eight-node 2D plate element
PLANE_TRIANG_3
Three-node 2D plate element
PLANE_TRIANG_6
Six-node 2D plate element
SHELL_QUAD_4
Four-node 3D shell element
SHELL_QUAD_8
Eight-node 3D shell element
SHELL_TRIANG_3
Three-node 3D shell element
SHELL_TRIANG_6
Six-node 3D shell element
SOLID_BRICK_8
Eight-node 3D solid element
SOLID_BRICK_20
Twenty-node 3D solid element
SOLID_TETRA_4
Four-node 3D solid element
SOLID_TETRA_10
Ten-node 3D solid element
SOLID_PYRAM_5
Five-node 3D solid element
SOLID_PYRAM_13
Thirteen-node 3D solid element
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Preprocessing FE Models for Optimization
Tosca Structure Element Type

SOLID_PENTA_6
Six-node 3D solid element
SOLID_PENTA_15
Fifteen-node 3D solid element
Fig. 16
Optimizable element types
Optimizable element types

*supported with Tosca Structure 7.3 for controller based optimization for ANSYS

Preprocessing of a finite element analysis may be performed in various preprocessing systems. To be able to use Tosca Structure in a familiar environment, Tosca Structure offers several preprocessing interfaces.
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Table 1
3.3
Topological Description
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Tosca Structure
The Model
The finite element model may be generated in every finite element preprocessor that can generate an input model for the supported finite element solvers.
Simplifications for the formulation of the optimization task (such as groups,
different properties, ...) may also be defined in many FE preprocessing systems that are not mentioned below (e.g. Hypermesh).
The optimization preprocessing of Tosca Structure is mainly based on group
information. Using Tosca ANSA environment, group definition can be made
by graphical selection of nodes and elements or already in the FE-preprocessor.
Using Tosca Structure.gui, all necessary information such as design nodes or
frozen elements should be defined as groups in the FE-preprocessor. These
groups may be read by Tosca Structure.pre and then be referenced in the further definitions of the parameter file.
3.3.1
Abaqus/CAE
The analysis model for the optimization procedure may be generated in the
standard way in Abaqus/CAE. All groups that are necessary for the optimization should be generated in Abaqus/CAE.
Currently, the use of parts and assemblies in the Abaqus input file is not supported by Tosca Structure. It is recommended to configure Abaqus/CAE such
that no parts & assemblies are written. To achieve this, the following parameter must be set in the configuration file abaqus_v6.env:
cae_no_parts_input_file=ON
Alternatively before writing the input deck, right click on the model in the
Model Database, select "Edit Attributes..." and activate "Do not
use parts and assemblies in input files".
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3.3.2
Preprocessing with ANSYS/Prep7

The analysis model for the optimization with Tosca Structure and ANSYS can
be generated in /PREP7 in the standard way.
For the batch processing of ANSYS the ANSYS CDB, inp and dat format can
be used. An ANSYS CDB file contains the complete finite element information without the solution strategy (/SOLU). The solution strategy has to be
added manually by the user.
3.3.2.1 Generation of the finite element input file

The CDB File is generated in ANSYS/PREP/ with the following command:
CDWRITE, OPTION, FNAME, EXT, DIR, FNAMEI, EXTI, FMAT
The option DB has to be used to ensure that the complete finite element information is written into the file. The file name (Fname) and the extension (Ext)
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Tosca Structure
have also to be specified. In the examples of the Tosca Structure installation,

the extension "cdb" is used.
A complete command for the generation of a CDB file looks as follows:
CDWRITE, DB, HOLEPLATE, ANS
This file does not contain the solution strategy.
3.3.2.2 Load cases

If only one load case should be calculated, the load case information is
already included in the CDB file. In this case only the solution strategy has to
be added:
/SOLU
SOLVE
FINISH
If multiple load cases are used, the load cases can be stored in load case
files (file.s01, file.s02, ...). These files are generated using the following command:
LSWRITE, LSNUM
The solution strategy for multiple load cases has to be added to the CDB file:
/SOLU
LSREAD, 1
SOLVE
LSREAD, 2
SOLVE
...
3.3.2.3 Check of the batch input file

To check if the CDB file is running correctly in batch mode, an analysis should
be started on the command line before starting the optimization with Tosca
Structure. Using the ANSYS 14.5 solver, the command line looks as follows:
Windows
ANSYS145 -B -I [INPUT FILE] -O [OUTPUT FILE] -P[PRODUCTVAR]
Unix
ANSYS145 -P -P[PRODUCTVAR] < [INPUT FILE] > [OUTPUT FILE]
Errors are reported to the *.err file. In case of errors, the input file must be
modified.
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FINISH
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Tosca Structure
The Model

The node and element groups (assemblies and components) are generated
using the "component manager" or with the following commands:
CM, CNAME, ENTITY
CMGRP, ANAME, CNAM1, CNAM2, CNAM3, CNAM4, CNAM5, CNAM6,
CNAM7, CNAM8
These components or assemblies are treated as node and element groups in

Tosca Structure. These groups are extracted from the cdb file and are accessible via the group name in the optimization preprocessor. If node and element groups are generated with the same name, the groups get the suffix
"_NODE" and "_ELEM" during the import in order to keep the group names
unique.
3.3.3
Preprocessing with ANSYS Workbench

Topology optimization with Tosca Structure is available fully integrated into
ANSYS/Workbench. ANSYS/Workbench can further be used to set up models for shape and bead optimization or the further processing with Tosca
ANSA environment or Tosca Structure.gui.
3.3.3.1 Export of finite element input model
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Topology optimization with Tosca Structure is available fully integrated into

ANSYS/Workbench. Nevertheless, for shape and bead optimization respectively, the ANSYS Workbench *.wbpj simulation database cannot be directly
used in combination with Tosca Structure. Before starting the Tosca Structure
optimization, a CDB, dat or inp file has to be exported from the Workbench.
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Tosca Structure
For the export of a CDB File, the corresponding solution has to be activated
first. If the solution is active, Write ANSYS Input command can be selected
from the Tools menu.
Activate "Solution"
"Tools" | "Write ANSYS Input File"

Fig. 17
Generation of ANSYS CDB Files
Enter <filename>.cdb
Fig. 18
Switch to "All Files(*.*)"
File name specification with *.cdb extension

In ANSYS Workbench, groups/components are generated dependent on the
selected geometric entities. If a volume is selected, all finite elements of the
volume are selected to an element group. If area, line or point entities are
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For the selection of the filename in the ANSYS Workbench File Export, the
file extension can be specified: to prevent the standard Extension *.inp from
being used during export, one should switch to ALL FILES in the output file
dialog and specify the *.cdb extension manually.
SIMULIA
Tosca Structure
The Model
selected in the workbench, the connected nodes are selected to a node

group.
Fig. 19
Selection of element and node groups in ANSYS Workbench
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With ANSYS version 14.0 and later, node groups can also be defined independent of hte geometry using Select Geometry | Select Mesh (Activate "show Mesh" before).
The name specified for the component in ANSYS Workbench is output to the
CDB file and may be used to reference the groups in the definition of the
Tosca Structure optimization task.
Fig. 20
Definition of group names in ANSYS Workbench
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Tosca Structure
3.3.3.3 Suitable meshes for topology optimization

In general, ANSYS Workbench provides suitable meshes for topology optimization. For topology optimization, the mesh should be homogeneous in order
to be able to represent the inner surfaces during the redistribution of the
material. Nevertheless, if the homogenity of the mesh needs to be improved,
in ANSYS Workbench this can be achieved using the Patch Independent
meshing algorithm.
Choose
"Method": Tetrahedron
"Algorithm": Patch Independent
Choose linear element

formulation
Define min. and max. element

size in a small range
Patch Independent meshing algorithm in ANSYS Workbench
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The Model
If the minimum and maximum element sizes are chosen in a small range, a
homogeneous mesh is generated inside the volumetric parts, which is more
suitable for a topology optimization task.
Fig. 22
3.4
Mesh for topology optimization
Loading FE Data
All FE models used for the optimization can be loaded using the
MODEL_LINK folder in the task tree of Tosca ANSA environment or the
FEM_INPUT command in Tosca Structure.gui. Here, several models can be
linked to your optimization task:
The ADD_FILE item refers to analysis files which may contain additional
geometry for definition of geometric constraints.
The COPY_FILE item allows to copy files to the working directory.
The LIFE_FILE item refers to an analysis model for a durability solver.
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The FILE item refers to analysis files with always the same geometry
(node and element structure) which describe the design space.
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Loading FE Data
The TEMPERATURE_FILE item refers to an analysis model for a temperature solver run.
Fig. 23
Analysis Files for Optimization (FEM_INPUT)

Optimization with Tosca Structure always refers to one or more analysis files
which provide the design space and necessary values for the optimization as
results of a finite element analysis run.
A single finite element file or several finite element files are referenced in the
item FILE in the command FEM_INPUT or the folder MODEL_LINK in Tosca
ANSA environment. However, all finite element files should have the same
number of elements, nodes, material properties, element groups, nodes
groups etc. The only difference allowed between the different input finite element files is that the analysis types can vary. The analysis type can either be
linear static, non-linear static, modal eigenfrequency or frequency response
analysis.
The FEM_INPUT command is applied for reading the finite element files in
the following way:
FEM_INPUT
ID_NAME
FILE
FILE
FILE
...
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=
=
=
=
id_read_files
fe_file_name_1
fe_file_name_2
fe_file_name_3
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3.4.1
Loading data by MODEL_LINK in Tosca ANSA environment (left)

and FEM_INPUT command in Tosca Structure.gui (right)
SIMULIA
Tosca Structure
The Model
END_
Working with Tosca ANSA environment, all three files can be entered into the
MODEL_LINK folder in a similar way.
The possibilities available to the user for loading the analysis model when
creating the optimization model depend on the chosen solver (see vol.2 chapter 10 and vol.2 chapter 11) and the option set (volume 3: OPTIONS). The
model data is loaded using an internal interface. After reading the model, the
following FE objects are available for further reference in the optimization
task:
Node groups
Element groups
Nodes
Elements
Coordinate systems
Materials
Properties
Element types
Boundary conditions (depending on the OPTIONS)
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Load cases
Analysis results used as terms for objective or constraint, so called design
responses (DRESP), are built by referring the load case numbers for the
desired responses.
The load cases in the first file (fe_file_name_1) are numbered using the original load case numbers used in the finite element file.
The load cases in the second file (fe_file_name_2) are numbered using the
original load case numbers used in the finite element file plus 10.000.
The load cases in the third file (fe_file_name_3) are numbered using the
original load case numbers used in the finite element file plus 20.000 and etc.
E.g. the load cases 1, 3 and 4 in the first finite element file have the numbers
1, 3 and 4 in the parameter file, the load cases 1, 3 and 4 in the second finite
element file have the numbers 10001, 10003 and 10004 in the parameter file,
the load cases 1, 3 and 4 in the third finite element file have the numbers
20001, 20003 and 20004 in the parameter file and etc.
In vol.2 chapter 11 the different allowed analysis types for the specific solvers
are described. Furthermore, vol.2 chapter 4.5.2.1 describes how the load
case numbers for the different finite element solvers are applied in the design
response definitions (DRESP). This is especially important for the finite element input decks using no numbers when defining load cases. For the finite
element solvers using no numbers the general rule is that the load cases
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Tosca Structure
Loading FE Data
have the numbers according to the order within they are defined. Meaning
that the load case number one will always have the load number of one for
Tosca Structure etc.
Remarks
1. A model link can only be made once for an optimization task, i.e. the
command FEM_INPUT can only be used once in a parameter file.
2. Several analysis files can be added, i.e. the item FILE can be repeated
several times. The first file in the list of files will be handled as master file,
which means that the configuration of the finite element model will be read
from this file. The second and all later referenced files will be used to
perform a finite element calculation. The model in these files has to be
identical to the original FE model. The files will be modified during the optimization.
3.4.2
LIFE_FILE
Is used to define input files for the durability solver (life_solver). Please see
vol.2 chapter 11.6, Shape Optimization Based on a Durability Analysis.
TEMPERATURE_FILE
This parameter allows Abaqus users to specify an Abaqus input file for a
sequential temperature analysis. First, a temperature calculation is carried
out, of which the results are used as boundary conditions for the following
finite element calculation.
The input file, which is used for the temperature calculation, can be specified
using the TEMPERATURE_FILE command. All model changes due to the optimization are also changed to the temperature model.
3.4.4
ADD_FILE
In certain circumstances it is useful to define additional nodes and elements
in the optimization model that are not required in the FE analysis. In this case,
it is practical to write the additional nodes and elements in a separate file.
This file can be read using the item ADD_FILE in the MODEL_LINK folder in
Tosca ANSA environment or the FEM_INPUT definition in Tosca Structure.gui.
For example, these additionally loaded elements can be used to define
restriction areas of any form. To simplify the selection of the elements in the
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The Model
parameter file, it is recommended to assign these elements with specific element properties, which can be used as selection criteria.
Remarks
1. The item ADD_FILE can be repeated several times. All nodes and
elements stored in the file referenced with this item are not available for the
optimization. This item can be used for the specification of neighbouring
elements for the definition of manufacturing constraints.
2. Tosca Structure can not manage double numbers. The user should be
aware of this and be sure that there is no conflict of numbers during file
loading (e.g. elements with identical numbers in the different files in the
MODEL_LINK or FEM_INPUT command).
3.4.5
COPY_FILE
The COPY_FILE command is the easiest way to copy a file into the working
directory of Tosca Structure. This could be an extra configuration file for your
FE-solver or another file that has no direct influence on Tosca Structure.
The item may be repeated several times.
Example:
If the file my_copy_file should be present in the working directory, e.g.
because it is required by the users solver or for use in a script call, it could be
copied as follows:
FEM_INPUT
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ID_NAME
FILE
COPY_FILE
END_
3.4.6
= OPTIMIZATION_MODEL
= holeplate.bdf
= my_copy_file
Special FEM_INPUT-commands
The special extra commands: FILE_SOLVER_EXE,
FILE_CMDLINE,
FILE_ADD_CALL, LIFE_FILE_SOLVER_EXE, LIFE_FILE_CMDLINE,
LIFE_FILE_ADD_CALL, DEPENDENT_FILE are all related to the last FILE
or LIFE_FILE command. These are only be used in very advanced setups
and should normaly be avoided.
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Tosca Structure
Loading FE Data
3.4.7
Options for loading FE Data (OPTIONS)

The default settings for loading the FE data can be changed with the
OPTIONS command: the settings influence, for example, the loading of the
boundary conditions, the identification of the model surface and the loading of
the FE results. The loading options refer to the command FEM_INPUT (see
vol.2 chapter 3.4) and must be specified before loading the FE data. Using
Tosca Structure.gui the OPTIONS command is available in the command drop
down menu. In Tosca ANSA environment the command can be entered using
the modules menu. A list of all possible parameters can be found in volume 3:
Commands Manual.
3.4.7.1 Loading displacement restrictions

When the model is loaded with the FEM_INPUT command all existing nodes,
elements, material properties, coordinate systems and essential element
properties are read from the FE input file. Forces, pressures and other loads
are not required by the optimization model and therefore not loaded. By
default fixed nodes are not loaded. Using the READ_BC = ALL option in the
command OPTIONS, all fixed nodes are loaded directly as node displacement restrictions for the optimization model. This option is activated with the
command:
OPTIONS
READ_BC
= ALL
END_
1. For some solver interfaces it is also possible to directly enter a number to

specify which fixed nodes are loaded as optimization boundary conditions.
This proves especially useful when the optimization boundary conditions
are defined as an additional load case in the FE model. The exact function
of this load option depends on the different interfaces (see vol.2 chapter
10).
2. Fixed nodes can also be defined in the parameter file with the command
DVCON_SHAPE. However, defining fixed nodes in the FE model is more efficient.
3. Only fixed nodes with a translation equal to zero in the one, two or three
direction according to the coordinate systems of the nodes can be loaded
from the FE input in the optimization model. Constraint displacements not
equal to zero are not loaded.
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Remarks
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Tosca Structure
The Model
3.4.7.2 Identifying surface nodes for shape optimization

The identification of surface nodes is necessary for shape optimization. During the optimization preprocessing the surface nodes are automatically identified when the design variables are defined (DV_SHAPE).
The surface nodes can already be identified when reading the analysis
model, such that a selection of the surface nodes is possible for the definition
of groups. When using the parameter READ_SF_IDENT = ON in the
OPTIONS command all surface nodes are identified and can be used for
further definitions.
In certain cases problems can occur in the surface node recognition for the
whole model. In these cases, only the elements should be selected which are
meant to be assigned with the surface nodes. For example, if shells lie on the
surface of solid elements, only the free boundary of the shell is identified as
being a surface. In this case the solid elements have to be selected (command SELECT) and their surface nodes have to be identified with the command SF_IDENT. The command SF_IDENT can only be used once.
This command is not available using Tosca ANSA environment and must be
entered manually in Tosca Structure.gui.
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3.5
Include Files
The parameter files can consist of several parts which can be encapsulated in
separate files. These files are referenced in the actual parameter file
(jobname.par) with the command INCLUDE. This is useful in cases where
the file is too large due to long selection lists used to define groups. The user
can save these group definitions in a separate file and link this with INCLUDE
at the relevant position. A second command INCLUDE can be used also in
the included file.
The INCLUDE files are searched for in the given directory. Should no directory be entered, a search is made in the current working directory or the subdirectory macros of the Tosca Structure installation directory.
Please Note:
The command INCLUDE is not required for your work with Tosca ANSA environment and thus is not available there.
3.6
Group Definition (GROUP_DEF, GROUP_AUTO_DEF)

The definition of groups is a very important function in Tosca Structure. For
example, if one or more nodes should be assigned a specific attribute (e.g. a
restriction), the nodes are first assembled in an object node group. Then the
attribute is assigned to the object node group.
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Tosca Structure
In Tosca Structure two different types of groups exist: node groups and element groups. Groups can be defined manually using selection of objects or
using lists in Tosca Structure.gui or can be defined using graphical selection
in Tosca ANSA environment. Further, automatic node group definition is
available to define groups following specific geometric patterns like, e.g., on
surfaces of revolution. All groups from the FE input file(s) linked to the optimization task are also available for definitions in Tosca Structure.
Groups are uniquely defined and addressed with their user-defined names
(character string). The use of an identical name for a node group and an element group is not permitted.
Default predefined groups

The system automatically creates a node group named ALL_NODES and an
element group named ALL_ELEMENTS. All nodes and elements respectively
that have been loaded with the first file in the FEM_INPUT command are contained in these groups. However, nodes (or elements) loaded from all other
files are not contained in the ALL_NODES (ALL_ELEMENTS) group.
If a topology optimization is performed, the element group NON_DESIGN is
also generated. This group contains all elements that have not been defined
as design elements. The NON_DESIGN group must be visualized together
with the HARD element group to be able to view the entire structure of the
optimized design in the postprocessing system. The groups defined in the FE
input model are also loaded by Tosca Structure and therefore can be referenced in the same way as the groups defined in the parameter file. The
names of the groups imported from the input model remain unchanged, with
the following exceptions:
- if a node group (NSET) and an element group (ELSET) have the same
names in an Abaqus input model, they get the suffices _NODE and
_ELEM respectively. See vol.2 chapter 11.1.3 for details.
- if the Abaqus input file contains more than one instance of the same part,
the group names are modified as described in vol.2 chapter 11.1.1.
3.6.2
Group definition in Tosca ANSA environment

Groups are usually defined in Tosca ANSA environment right when they are
needed in some item of Task Manager (e.g., DV_TOPO). All groups from the
FE input model are also available in the group selection windows. To create a
new group, click the Action button and select New. In a dialog that lists all
groups, select the nodes or elements you choose for the group and confirm
the selection with a middle mouse button click.For details of group selection
refer to vol.1 chapter 1.1.13, Managing Groups.
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3.6.1
SIMULIA
Tosca Structure
The Model
3.6.3
Group definition in Tosca Extension for ANSYS/WB

Groups are usually defined in Tosca Extension for ANSYS/WB right when it is
needed for some item of the optimization task (e.g., DV_TOPO). It is recommended to define named selections in advance for later use in the definition
of, e.g., design area or responses for objective and constraint. For examples
see vol.1 chapter 3.2.5, Optimization preprocessing.
3.6.4
Manual group definition in Tosca Structure.gui

In Tosca Structure.gui node and element groups can be defined manually
using lists of node IDs or element IDs in the GROUP_DEF command:
GROUP_DEF
ID_NAME
= ndgr_name
TYPE
= NODE
FORMAT
= LIST
LIST_BEGIN
1,2,5,3000,...
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END_
Changing the TYPE to ELEM assembles the elements with the numbers listed
into the group. Further, a list of materials or properties can be specified using
the LIST_MAT or LIST_PROP entry for FORMAT to combine all nodes or elements related to the listed materials or properties.
In Combination with the command SELECT,... (see volume 3: SELECT or
vol.2 chapter 3.7, Selection of Objects in Tosca Structure.gui) more complex
group definitions are possible. To this end, the nodes (or elements) to be
included in the group must first be selected according to their numbers, geometric position, belonging to a certain area etc., sometimes using several
SELECT commands sequentially in order to collect specific nodes or elements
in the selection list.
Subsequently, the group is defined with GROUP_DEF. A typical command
sequence appears as follows:
SELECT,NODE,S,...
GROUP_DEF
ID_NAME
TYPE
FORMAT
= ndgr_name
= NODE
= SELECTED
END_
The group is given an unique user defined name.
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Tosca Structure
3.6.5
Automatic node group definition (GROUP_AUTO_DEF)

Apart from the definition of individual node groups, several node groups can
be defined automatically using the GROUP_AUTO_DEF command. The
GROUP_AUTO_DEF command is available from the modules button menu in
Tosca ANSA environment or the command menu in Tosca Structure.gui.
This feature is especially important in relation to function based node coupling. For example, if the rotation symmetry of a shaft shoulder loaded with a
bending moment should be maintained during optimization, it is necessary to
couple all nodes of the circumference. This involves a large number of node
groups and node couplings. (For examples see vol.4 chapter 3.4, Shaft or
vol.4 chapter 3.5, Carrier).
Starting with a parent group that has been previously defined by the user, the
GROUP_AUTO_DEF command can be used to automatically define child
groups (children). Employing various methods, search areas are established
originating at every node of the parent group. All nodes located within a
search area are captured and collected in a child group. Thereby, only those
nodes that are currently in the selection list NODES are considered. Per
default, all nodes are selected at the beginning. (Thus, if no SELECT command is activated, all existing nodes are considered. You can "preselect" a
certain area using SELECT to restrict automatic group definition to this area,
see chapter 3.7 Selection of Objects in Tosca Structure.gui).
Child groups are labeled with the name of the parent group and a numerical
index. For example, if child groups are formed from a node group titled parent which contains 4 nodes, the four children groups are named parent_1,
parent_2, parent_3 and parent_4. Various procedures can be used to
define a search area.
GROUP_AUTO_DEF
ND_GROUP
...
SEARCH_TYPE
....
END_
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= parent_group
= CONTINUOUS
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1. Specification of a continuous search area (SEARCH_TYPE = CONTINUOUS):

All nodes located within the search area that are currently selected by the
node selection list are assembled and assigned to a child group:
SIMULIA
Tosca Structure
The Model
dir Direction
-Snap Tolerance
2*Snap Tolerance
Search Area
Not Grouped
Member of Parent Group
Fig. 24
+Snap Tolerance
Length
Continuous search area
2. Specification of a search area divided into discrete sections

(SEARCH_TYPE = DISCRETE):
All nodes located within the discrete sections that are currently selected by
the node selection list are assembled in child groups:
GROUP_AUTO_DEF
ND_GROUP
...
SEARCH_TYPE
....
= parent_group
= DISCRETE
END_
dir Direction
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2*Tolereance 2
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Search-Length
Discrete Length
Discrete Length
2*Tolerance 1
Member of Parent Group
Fig. 25
Not Grouped
Search Area
Discrete area search
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3. Search in various local coordinate systems (SEARCH_TYPE =

CS_MULTI):
The coordinates of the individual nodes in the parent group are determined
in relation to a specified coordinate system. All selected nodes with
matching coordinates in relation to specified search coordinate system are
assembled in child groups together with the corresponding parent node:
GROUP_AUTO_DEF
ND_GROUP
...
SEARCH_TYPE
....
= parent_group
= CS_MULTI
END_
Y1
CS
1
Yparent
X1
CSparent
Xparent
Y2
X2
X 1 in CS 1 = X 2 in CS 2 = X parent in CS parent
Y 1 in CS 1 = Y 2 in CS 2 = Y parent in CS parent
Fig. 26
Multiple coordinate systems in the AUTO_GROUP command
Remarks
1. Only currently active (selected) nodes are considered for the definition of
children groups when using GROUP_AUTO_DEF. Per default, all nodes
are selected at the beginning of the optimization. If - for specific reasons only a subset of nodes was active (selected) and if nowall nodes should be
considered for the children group definition, then all nodes must be activated (again) using SELECT, NODE, ALL before the GROUP_AUTO_DEF
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Tosca Structure
The Model
command is executed (see also chapter 3.7 Selection of Objects in Tosca

Structure.gui).
3.7
Selection of Objects in Tosca Structure.gui

The command SELECT provides the user with powerful possibilities to select
objects, in particular nodes and elements, without using graphical interaction.
The SELECT command can be entered into the parameter file using a text
editor or the text view in Tosca Structure.gui. Due to the advanced graphical
selection possibilities in Tosca ANSA environment, the SELECT command is
not required and thus not supported in this front end.
Most of the FE objects and Tosca Structure objects can be selected with the
SELECT command in the parameter file. Nodes and elements are selected by
addressing certain attributes. Selection of nodes and elements can be used
to define node and element groups. These can be used as optimization
groups.
Object lists
In Tosca Structure a list is created for most object types. At the beginning
each object list is loaded with all the data that is read in by the FE interface,
e.g., the list of elements contains all elements from the first input file linked to
the optimization task. When an object is selected, the selected object is
added to the corresponding list. Selection lists can be used as selection criteria (Fig. 27).
The following types of objects have their own lists and can be selected using
the command SELECT:
Coordinate Systems (CS)
Elements (ELEM)
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Element groups (ELGR)

Nodes (NODE)
Node groups (NDGR)
Element types (ETYPE, see Table 1)
Element properties (EPROP)
Materials (MAT)
Solids (SOLID)
Selection types
Every SELECT command refers to one object type.The user must define
whether the selected objects should be added to the existing object list (ADD)
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Tosca Structure
or removed (UNSELECT) or whether the selection list should be reset

(SELECT). Additionally, it is possible to keep only the actually selected
objects of an existing selection list (RESELECT). All objects of the corresponding type can be registered in the selection list (ALL) or the selection list
can be emptied (NONE). It is also possible to invert (INVERT) the content of
the selection list. Depending on the selection type, existing selection lists can
be extended or varied (Table 2):
Shortcut
Type
Description
Select
Initialization and New Selection.
Reselect
Selection of a subset from a selection list.
Add
Add objects to current selection list.
Unselect
Remove objects from current selection list.
ALL
Select all
Select all objects of the object type.
Select none
Empty selection list.
Invert
Invert: Reverse selected and non-selected

objects of the object type.
NONE
INV
Selection types in Tosca Structure
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Table 2
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Tosca Structure
The Model
MAT
ETYP
EPROP
ELGR
ELEM
NODES:
ND_ALL
ND_ANY
LAYER
SOLID
ELEM
Restrict
NODE
Location
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Design
List
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NDGR
Selection for list A with selection

criterion active list B.
Selection for list A from all entities A.
Property
C
Fig. 27
Selection for list A from entities A

with property C.
Selection lists and selection criteria
Selection criteria
Almost all objects can be added to a selection list using numbers or names.
For nodes and elements a variety of selection criteria exists (Table 3). For
example, it is possible to select elements by their element property or mate-
User Manual 2 - 55
SIMULIA
Tosca Structure
rial number defined in the analysis file. Thus element and node numbers do
not have to be explicitly known by the user.
Selection lists are useful tools that help the user to quickly define element and
node lists. Selection lists are required for group definitions.
.
ELGR
NDGR
ETYP
X
X
MAT
SOLID
EPROP
ETYP
NDGR
ELGR
NODE
ELEM
Table 3
CS
NR.
EPRO
P
SOLID
CS
MAT
Selection lists
NAME
Selection criteria
X
X
Selection lists and selection criteria
The following example serves to illustrate the effect of the selection commands. Each step is accompanied by a description of how the selection lists
change.
The aim of this detailed example is to select a node group by list entries for
which various assignments are applied (e.g. nodes to elements, element to
element properties).
The following steps are taken:
Direct selection of elements by specifying the element numbers (in the
example: elements 1, 3, 5).
Selection of elements using element properties (in the example: element
properties 3 and 5).
Selection of the nodes associated with the actually selected elements.
Step 1: Select element numbers directly:
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Examples
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Tosca Structure
The Model
Elements can be selected directly by entering the element number:

SELECT, ELEM, S, ELEM, 1, 5, 2
- By specifying the list name ELEM, the element list is addressed. The
selection operator S initializes the element list (SELECT). The element
numbers are directly specified as selection criterion (elements 1 to 5 with
increments of 2). The elements 1, 3 and 5 are selected directly with their
numbers and written into the element list. All other lists remain
unchanged.
List
ELEM
Table 4
List entries
1, 3, 5
Selection example (step1)
Step 2: Element Selection using Element Properties

The element list should be extended to include elements with the properties 3
or 5.
First, the element properties 3 and 5 are added to the element property list.
It is also possible to use increments.
SELECT, EPROP, S, EPROP, 3,5,2
- The EPROP list is addressed. The selection operator S initializes the

element property list. The ELEM list remains unchanged:
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List
List entries
ELEM
1, 3, 5
EPROP
3, 5
Table 5
Selection example (step2)
Now all elements with element properties that are currently in the element
property list should be added to the already existing element list.
SELECT, ELEM, A, EPROP
- The element list is addressed. The operator A (ADD) adds elements to

the existing element list where the added elements have properties that
are specified in the element property list:
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SIMULIA
Tosca Structure
List
List entries
ELEM
1, 3, 5;and all elements with the

element properties 3 and 5
EPROP
3, 5
Table 6
Selection example (step 3)
Step 3: Select Nodes

In this step all nodes that belong to the selected elements are added to the
node list. The element list is used as a selection criterion for nodes:
SELECT, NODE, S, ELEM
- The node list is addressed and initialized. All nodes of the elements currently in the element list are included in the node list:
List
List entries
ELEM
1, 3, 5; and all elements with the

element properties 3 and 5
EPROP
3, 5
NODES
all nodes of the elements in the

element list
Table 7
Selection example (step 4)
Remarks
1. To use the selection possibilities for element types, materials and coordinates in Tosca Structure, all quantities must previously be defined and
assigned in the FE analysis file.
2. Upon loading the analysis model, all loaded objects (nodes, elements,
coordinate systems, materials, element types, element properties) are
written into the corresponding lists. Initially, the lists SOLID, ELGR and
NDGR are empty.
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Selection of elements by their material numbers or element types can be also

be carried out this way (vol.2 chapter 10).
SIMULIA
Tosca Structure
The Model
3.8
Coordinate Systems (CS_DEF)

In certain situations, the definition of solids and displacement directions
requires the coordinate systems that differ from those defined in the FE
model.
Cartesian and cylindrical coordinate systems defined in the FE model are
accessible in Tosca Structure and can be referenced in the parameter file by
their names. For details and exceptions refer to chapter 11.1.4 Coordinate
Systems (Abaqus), chapter 11.2.4 Coordinate Systems (ANSYS), chapter
11.3.3 Coordinate Systems (Marc), chapter 11.4.3 Coordinate Systems (MSC
Nastran) and chapter 11.5.4 Coordinate Systems (PERMAS). Additionally,
the command CS_DEF of Tosca Structure parameter file defines the coordinate systems using either the IDs of existing nodes, or coordinates and rotation angles (if needed). Each coordinate system has an ID_NAME value
(editable by the user) that is then used in order to reference the coordinate
system.
In Tosca ANSA environment, the list of defined coordinate systems opens
when the item COORD of the database is clicked twice:
Viewing the coordinate systems in Tosca ANSA environment
The selection window (the right window in Fig. 28) allows the user to create,
edit or delete coordinate systems. An alternative way is to use the buttons in
CS_DEF group of Modules Buttons window. The button INFO opens the list of
defined coordinate systems that is basically equivalent to the selection window. The names of the buttons that create new coordinate systems depend
on the selected solver; they are described below in details.
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Fig. 28
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Tosca Structure
In Tosca Structure.gui, a new coordinate system is created by Command |

CS_DEF main menu command of Tosca Structure.pre screen:
Fig. 29
Definition of coordinate systems in Tosca Structure.gui
Note that the definition of a coordinate system in Tosca ANSA environment,

in case that the coordinates are used, follows the guidelines of some solver
(mostly Nastran) and is different from one used in Tosca Structure.gui. During
the output of the parameter file, Tosca ANSA environment converts the coordinate systems to the format supported by Tosca Structure. In case of coordinate systems defined using nodes, the definitions are basically the same.
Definition by three nodes

In Tosca ANSA environment, the button corresponding to the creation of a
new coordinate system using three nodes is called CORD1 (Nastran), NODE
(Abaqus) or CS (ANSYS); in the latter case, only Cartesian coordinate systems are supported; in the other two cases, the type of the coordinate system
is chosen in the drop down list.
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3.8.1
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Tosca Structure
The Model
Coordinate
system
type
Cartesian
Cylindrical
Spherical
solver
Abaqus
CS_DEF button
label
COORD database
Z RECTANGULAR
ORIENTATION_NODES_R
RECTANGULAR
ORIENTATION_NODES_DYN
Nastran
CORD1R
CORD_NODES_R
ANSYS
CS
LOCAL_NODES_DYN
Abaqus
CYLINDRICAL
ORIENTATION_NODES_C
Nastran
CORD1C
CORD_NODES_C
ANSYS
not supported
not supported
Abaqus
SPHERICAL
ORIENTATION_NODES_S
Nastran
CORD1S
CORD_NODES_S
ANSYS
not supported
not supported
In each case, after the command is chosen, the user selects three nodes
from the model that are used as follows:
the first node is the origin;
the axis that follows after the first one (i.e., Y- or X-axis) lies in the plane
defined by the three nodes, perpendicular to the first axis and closer to the
direction from the origin to the third node;
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the direction from the origin to the second node is the direction of the first
axis that is X-axis (in case of NODES | RECTANGULAR (Abaqus), CS
(ANSYS) or ..._NODES_DYN (in selection window)) or Z-axis (otherwise);
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Tosca Structure
the last axis is perpendicular to the first and the second one, forming a positively oriented basis.
Fig. 30
Definition of coordinate systems using three nodes in Tosca

ANSA environment and in Tosca Structure.gui
In Tosca Structure.gui, the IDs of nodes should be entered in the corresponding fields, and also the fields Axis (x-axis or z-axis) and Plane (xy-plane or
xz-plane) should be specified. Then, the first chosen node (Node ID of
Origin field) is the origin, the second node (Node on Axis field)
defines the axis (specified in Axis field) as described above, and the third
node (Node in Plane field) is needed to define the plane according to
Plane field.
Example
A Cartesian coordinate system with the label, CS_12, should be defined by
the three nodes 101, 102 and 103. Node 101 is located at the origin of
CS_12, node 102 is on Z axis and node 103 is in XZ plane:
ID_NAME
CS_TYPE
DEF_TYPE
CS_AXIS
NODE_ORIGIN
NODE_AXIS
NODE_PLANE
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=
=
=
=
=
=
=
CS_12
RECTANGULAR
NODE
Z_XZ
101
102
103
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CS_DEF
SIMULIA
Tosca Structure
The Model
END_
z
102
103
CS_12
101
x
Fig. 31
3.8.2
Definition of a coordinate system by three nodes
Definition by coordinates of three points
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Instead of choosing three existing points, the coordinates of three arbitrary

points, plus, optionally, one rotation angle can be used in order to define a
coordinate system in Tosca ANSA environment. In Tosca Structure.gui, this
mode of coordinate system definition is not supported; see the next subsection.
Fig. 32
Definition of coordinate systems using coordinates in Tosca

ANSA environment
The commands creating the coordinate systems are found under the buttons
CORD2 (Nastran), CORD (Abaqus) or LOCAL (ANSYS), as well as in the
context menu command New of the selection window for the coordinate systems:
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Tosca Structure
Coordinate
system
type
solver
Cartesian
Abaqus
Cylindrical
Spherical
CS_DEF button
label
COORD database
RECTANGULAR
ORIENTATION_R
OFFSET TO
NODES
ORIENTATION_OFFSET_TO_
NODES
Nastran
CORD2R
CORD_R
ANSYS
RECTANGULAR
LOCAL_R
Abaqus
CYLINDRICAL
ORIENTATION_C
Nastran
CORD2C
CORD_C
ANSYS
CYLINDRICAL
LOCAL_C
Abaqus
SPHERICAL
ORIENTATION_S
Nastran
CORD2S
CORD_S
ANSYS
SPHERICAL
LOCAL_S
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After a command is chosen, the user should select three points from the
model. If a point close to an edge is clicked, the middle point of the edge is
chosen; otherwise, if the point is close to a node, this node is chosen. Please
take care not to select the edges in case you need the nodes. To do this,
choose a point between the edges going from the node you wish to choose,
sufficiently close to the node but not to any edge.
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The Model
When all three nodes are chosen, the following dialog appears:
Fig. 33
Definition of coordinate systems using coordinates in Tosca

ANSA environment
This window contains the coordinates of the nodes that have just been chosen (A1..A3, B1..B3, C1..C3 fields). This coordinates may be modified; moreover, if it is needed to define the coordinate system using some points that
not necessarily coincide with nodes or middle points of edges, the easiest
way is to create a coordinate system using any three points and then to set
the correct values in the fields of this dialog window.
The three points are used as follows:
the first point (A1, A2, A3) is the origin;
the direction from the origin to the second point (B1, B2, B3) is the direction
of Z-axis;
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X-axis lies in the plane defined by the three nodes, perpendicular to Z-axis
and closer to the direction from the origin to the third point (C1, C2, C3);
Y-axis is perpendicular to the other two, forming a positively oriented basis.
The field RID defines the reference coordinate system (by default, it is set to
0 indicating the global coordinate system). Pressing "?" key in this field opens
the list of all defined coordinate systems. The values in A1..C3 fields are
interpreted as the points with the corresponding coordinates with respect to
the coordinate system that has ID equal to RID field, with RID = 0 corresponding to the global coordinate system.
Choosing Abaqus or ANSYS as the solver allows (but not requires) the specification of one rotation angle using "rotation axis" field: choosing an axis (1 to
3, i.e., X to Z) in this field and then an angle in degrees in "rotation angle" field
leads to the rotation of the new coordinate system around the specified axis
(the "new" one, i.e., calculated basing on the chosen points).
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3.8.3
Definition by origin and rotation angles

In Tosca Structure.gui, instead of using three points with given coordinates,
the origin and the rotation angles around the three axes are used in order to
define a coordinate system. This is done using Local radio button (this is
equivalent to setting DEF_TYPE = LOCAL in CS_DEF command):
Fig. 34
Definition of coordinate systems using an origin point and three

rotation angles in Tosca Structure.gui
Then, the coordinates of the origin (with respect to the coordinate system
specified in Reference CS field) and the three rotation angles are to be chosen. The directions of the axes of the coordinate system are constructed in
the following manner:
first, the axes X, Y, Z of the reference coordinate system are taken;
then, the axes are rotated around Z-axis by the first angle in Rotation
fields (labeled with 3): axes X, Y, Z = Z are produced;
finally, these axes are rotated around X by the third angle (field labeled
with 1): axes X = X, Y, Z are produced that give the directions for the
coordinate system axes.
All rotations are performed in positive (counter-clockwise) directions; the values of the angles are in degrees.
Examples
A Cartesian coordinate system with the name CS_14 should be defined relative to the global Cartesian coordinate system CS_0. The point of origin of the
new coordinate system should have the coordinates (30, 20, 0). Then, a
cylindrical coordinate system CS_15 should be defined relative to CS_14 with
the origin at the point (60, 5, 0). CS_15 should be rotated 15 around Z axis:
The result coordinate system CS_15 defines a cylindrical coordinate system
with origin (90,25,0) with respect to the global Cartesian coordinate system
CS_0. The polar axis through the new origin is rotated by 15 around the z-
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the resulting axes are rotated around Y by the second angle (field labeled
with 2): axes X, Y = Y, Z are produced;
SIMULIA
Tosca Structure
The Model
axis. The longitudinal axis is parallel to the original z-axis through the new origin:
CS_DEF
ID_NAME
CS_TYPE
DEF_TYPE
CS_REF
ORIGIN_123
ROTATION_321
=
=
=
=
=
=
CS_14
RECTANGULAR
LOCAL
CS_0
30,20,0
0,0,0
END_
CS_DEF
ID_NAME
CS_TYPE
DEF_TYPE
CS_REF
ORIGIN_123
ROTATION_321
=
=
=
=
=
=
CS_15
CYLINDRICAL
LOCAL
CS_14
60,5,0
15,0,0
END_
y
y
CS_15 z
15
CS_14
20
60
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z
CS_0
Fig. 35
3.8.4
30
Definition of coordinate systems using the origin and the rotation

angles
General remarks about coordinate systems

1. When coordinate systems are loaded via the FE interface, their numbers
are treated as names (character strings) in Tosca Structure. For example,
the coordinate system 15 (number) in the FE system is defined in Tosca
Structure as a coordinate system with the name 15.
User Manual 2 - 67
SIMULIA
Tosca Structure
Solids (Geometric Primitives)
2. In Tosca Structure the following coordinate system is defined globally and

can be addressed at any time:
CS_0: Global Cartesian coordinate system
3. A coordinate system defined in Tosca ANSA environment will only be
written to the parameter file if it is used for some reason, e.g., as the value
of PULL_CS field of DEMOLD_CONTROL dialog.
4. Default name of a coordinate system that is defined in Tosca ANSA environment when using ANSYS solver is "Anonymous CS" (without any
index). When defining more than one such coordinate system, their names
should be modified so that they are unique.
3.9
Fig. 36
3.9.1
Geometric primitives (SOLIDs) in Tosca ANSA environment
Definition in Tosca ANSA environment

In Tosca ANSA environment, in order to define a CHECK_SOLID design constraint, call New | CHECK_SOLID command on the item DV_CONSTRAINTS
in Task Manager. In the dialog that appears, only the node group for which
the relations are checked is specified. Then, one needs to define one or more
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In some applications, it is required that the nodes stay in a certain region, or,
conversely, are not allowed to enter a certain region during the shape or bead
optimization. In Tosca Structure, such regions can be defined by geometric
primitives: in two dimensions, rectangles, circles or circular segments; in
three dimensions, bricks, cylinders and cylinder segments are supported. The
type of the geometric primitive depends on the coordinate system it is defined
with.
In the figure, the cylindrical segment 0 r 10 , 0 90 , 5 z 10 in the
cylindrical coordinate system C2 and the cube 5 x 10 , 5 y 10 ,
5 z 10 in the Cartesian coordinate system R1 are shown, as represented
in Tosca ANSA environment:
SIMULIA
Tosca Structure
The Model
SOLIDs using New | SOLID command on the created CHECK_SOLID item

that opens the following dialog:
Fig. 37
Geometric primitives (SOLIDs) in Tosca ANSA environment
The field SOLID_PROP defines how the geometric primitive is to be used:

NEUTRAL: has no effect;
VARIATION: defines the allowed region for the nodes in the node group;
RESTRICTED: defines the prohibited region for the nodes in the node
group.
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Choosing CS_DEF in CS field and pressing "?" key in CS_DEF field opens
the list of all defined coordinate systems. The fields VAL_1_MIN,
VAL_1_MAX,.., VAL_3_MAX define the extents of the geometric primitive in
each coordinate. For Cartesian coordinate systems, the coordinates are x, y
and z; for cylindrical coordinate systems, they are r, phi and z.
The list of all defined SOLIDs is opened by the button SOLID in RESTRICTION panel of Modules Buttons in Tosca ANSA environment.
3.9.2
Definition in Tosca Structure.gui

The main menu command Command | SOLID in Tosca Structure.pre screen
of Tosca Structure.gui creates a new geometric primitive. This command
opens the window where the type of the geometric primitive (Neutral, Varia-
User Manual 2 - 69
SIMULIA
Tosca Structure
tion or Restricted), the coordinate system and the extents of the geometric
primitive in each coordinate are edited. See the previous subsection for more
information about these fields.
The field ID_NAME defines the name of the geometric primitive, so that it can
be referenced in the DVCON_SHAPEcommand (see vol.2 chapter 6.3.3).
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Remarks
Another usage of geometric primitives in Tosca Structure is in SELECT command. In this case, the nodes that lie inside a geometric primitive defined
using a SOLID command are selected. Node selection in solids is independent of the mesh density of the FE model, only depending of geometric
dimensions. This selection method is more complicated than other methods
but is highly recommended for models with varying mesh density.
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Tosca Structure

In this chapter typical optimization definitions are explained. What are your
targets? What are your restrictions? Which values define your targets and
restrictions?
Overview
To optimize anything you need to know what to optimize. Do you want to minimize stresses? Or maximize all eigenvalues?
The two above statements are too unclear for defining an optimization.
Therefore, we usually reduce the what to well defined terms, say: Minimize
the maximal nodal stresses of load case 1 and 2, or maximize the sum of the
first 5 eigenvalues.
The goal or objective of an optimization is usually called the objective function
(OBJ_FUNC), e.g. when you want to minimize or maximize some well
defined terms. You may also want to enforce certain values, for example a
displacement of a given node must not exceed a certain value. This would be
defined through a CONSTRAINT.
In Tosca Structure the objective function depends upon at least one term or
more, whereas a constraint always depends on exactly one term.
These terms or responses are in Tosca Structure called design responses or
DRESP. DRESPs are the fundamental definitions of the optimization problem. In Tosca ANSA environment the DRESPs are available under the
OBJ_FUNC_ITEM_1 item and the CONSTRAINTS item.
Most DRESP definitions depend on a node or element group, but not all e.g.
eigenfrequencies (DRESP, TYPE=DYN_FREQ). This node or element group
may also consist of one single item, say one node, e.g. displacement in Xdirection of a node (DRESP, TYPE=DISP_X). The optimization problem is
summarized in the OPTIMIZE command and the dependencies can be visualized in following way:
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Tosca Structure
Objective Function
4.1.1
Mathematical formulation
An optimization problem can be stated as:
min ( ( U ( x ), x ) )
s.t. i ( U ( x ), x ) 0
s.t.
gi ( x ) 0
where is the objective function (OBJ_FUNC) which depends on the state

variables, U, as well as on the design variables x (DV_BEAD, DV_SHAPE or
DV_TOPO). The problem may be constrained by the constraints i (volume
3: CONSTRAINT), and may have the design variable constraints g i
(DVCON_BEAD, DVCON_SHAPE or DVCON_TOPO). Note, that maximizing the objective is the same as minimizing .
For minimization (MIN) or maximization (MAX) the objective function consists
of a sum of design responses ( i ). Each design response can be given a
ref
weight ( w i ) and a reference value ( i ). By minimizing or maximizing the
objective one gets the formulations:
N
ref
= min
w ( ( ( U ( x ), x ) ) ) i )
i=1 i i
ref
= max
w ( ( ( U ( x ), x ) ) ) i )
i=1 i i
Another important optimization formulation is to minimize the maximum

design response, the so-called MIN-MAX-formulation:
ref
s.t.
i ( U ( x ), x ) 0
s.t.
gi ( x ) 0
The MINMAX formulation should always be used for controller based optimization. For sensitivity based optimization MIN or MAX are prefered because
they tend to converge better and faster. Note remark in next section regarding
default reference value and shape optimization.
4.2
Objective Function
The objective function defines the values to be maximized or minimized during optimization. This function may depend analysis results, geometric values
or combinations of those.
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= minmax { w i ( i ( U ( x ), x ) i ) }
SIMULIA
Tosca Structure
4.2.1
Overview
The objective function depends upon results of the finite element analysis
such as compliance, displacements, stresses, reaction forces, internal forces,
eigenfrequencies or properties of the finite element model such asmaterial
volume or nodal positions. These results are combined to scalar values using
the so called design responses. Initially, one or several responses for the
objective function have to be defined using the command DRESP. These
responses are then added to the objective:
DRESP (scalar value)
......................
Fig. 38
OBJ_FUNC
MIN (scalar values)

MAX (scalar values)
MINMAX (scalar values)
Defining an objective function
Weight and reference values can be applied in the combination using the
command OBJ_FUNC.
OBJ_FUNC
ID_NAME
DRESP
DRESP
DRESP
DRESP
...
TARGET
=
=
=
=
=
...
id_name_1,
id_name_2,
id_name_3,
id_name_4,
WEIGHT,
WEIGHT,
WEIGHT,
WEIGHT,
REFERENCE
REFERENCE
REFERENCE
REFERENCE
= MIN | MAX | MINMAX
The ID_NAME of the OBJ_FUNC must be referenced in the OPTIMIZE command to activate the objective function.
The WEIGHT and REFERENCE values are optional. The default weighting
ref
factor is w i = 1 and the default reference value is i
= 0 , except for controller based shape optimization, see Remark. See also equations in chapter
4.1.1 Mathematical formulation. Because of the default values the user has
not to define WEIGHT and REFERENCE for the most common optimization
formulations.
The command TARGET can be set to MIN, MAX or MINMAX indicating if the
objective function is minimized or maximized or a min-max formulation is
used.
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User Manual 2 - 73
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Objective Function
In logfile TOSCA.OUT the object function value can be monitored:

--------------------------------------------------------------------of OBJ_FUNC_TERM
Value
Weight
Reference
|
--------------------------------------------------------------------DRESP_MAX_MISES1
161.820
1.00000
92.8566
DRESP_MAX_MISES2
80.9101
1.00000
92.8566
--------------------------------------------------------------------of OBJ_FUNC (based on objective function terms):
68.9636
In above example the total objective function =68.9636. Each DRESP 1

= DRESP_MAX_MISES1 = 161.820 and 2 = DRESP_MAX_MISES2 =
80.9101. Also the above shows the weight and reference value of each term.
These values can also be found in two extra log-files, optimization_report.csv
and optimization_status_all.csv. The first file only lists DRESPs that are
included in the optimization task as objective function or constraint. The latter
lists all DRESPs defined in the parameter file.
Example:
Example optimization_report.csv imported into a spread sheet:
ref
ti = wi ( i i )
If constraints are defined in optimization task these are also included in
optimization_report.csv and optimization_status_all.csv.
Remark
1. For controller based shape optimization (chapter 6 Shape Optimization)
ref
the reference value ( i ) has a special meaning. The reference value is
the value around which Tosca Structure homogenizes the stress around.
ref
Thus, a value i
= 0 usually does not make sense and Tosca Struc-
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In above example first the total objective function is listed for each iteration
as MINIMIZE_MAX_MISES. The objective function is always the first colomn.
Then each DRESP in the
1 = DRESP_MAX_MISES1 and 2 =
DRESP_MAX_MISES2
is
listed
as
OBJ_FUNC_DRESP:DRESP_MAX_MISES1 and OBJ_FUNC_DRESP:
DRESP_MAX_MISES2. After each DRESP the terms are listed:
OBJ_FUNC_TERM:DRESP_MAX_MISES1
and
OBJ_FUNC_TERM:
DRESP_MAX_MISES2. The terms include weight and reference value and
are given as:
SIMULIA
Tosca Structure
ref
ture calculates a default reference value if REFERENCE ( i ) is unset.

The reference calculated can be seen in TOSCA.OUT
--------------------------------------------------------------------of OBJ_FUNC_TERM
Value
Weight
Reference
|
--------------------------------------------------------------------DRESP_MAX_MISES
92.5353
1.00000
87.4261
---------------------------------------------------------------------
2. Also, for controller based shape optimization the user must either set all
REFERENCE-values or none at all (automatic reference value calculation).
3. Please note that the reference value for the MINMAX function differs from
the above definition by eigenfrequency optimization for the sensitivity
based algorithm, see for example chapter 7.6.2.5 Maximize band gaps.
4. Please note that the reference value for von Mises stresses in topology
optimization differs from the above definition (see also vol.2 chapter 4:
Reference stress for objective function).
The design responses (DRESP) listed in OPTIMZE will be summed up taking
into account the individual weighting and reference values (see also chapter
4.1.1 Mathematical formulation) if TARGET is set to MIN or MAX.
A min-max formulation is applied if TARGET is set to MINMAX. Then the
design responses (DRESP) are dealt with individually in a multidisciplinary
optimization taking into account the individual weighting and reference values.
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4.2.2
Minimization or maximization of an objective function

This section deals with the minimization or maximization of the objective function. Then the optimization formulation consists of an objective function and a
set of constraints as shown in the first equation of chapter 4.1.1 Mathematical
formulation.
In vol.2 chapter 5.4, vol.2 chapter 6.4 and vol.2 chapter 7.4 is described
which response types are allowed in the objective functions for topology,
shape and bead optimization and how they can be combined. In vol.2 chapter
5.5, vol.2 chapter 6.5 and vol.2 chapter 7.7 is described which response
types are allowed as constraints and how these are added to the constraints.
The objective can be minimized or maximized using the MIN and MAX in the
TARGET parameter of the OBJECTIVE command, respectively. In these
cases the values for the objective function defined by the DRESPs are
summed up.
E.g., if the objective should be minimized (or maximimized):
OBJ_FUNC
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Tosca Structure
Objective Function
ID_NAME
DRESP
DRESP
...
TARGET
= ...
= ...
= ...
= MIN (or MAX)
END_
where the DRESP definitions are referring to the desired responses for the
objective function using the ID name of the defined responses. The defined
responses which should be minimized (or maximized) have to be valid design
responses (see chapter 4.4 Design Responses).
4.2.3
Multidisciplinary objectives (minmax formulation)

This section deals with the minimization of the maximum term referenced in
the objective function. In this case the value of the objective function is generated with a maximum function over a set of terms defined by Design
Responses.
In chapter 4.4 Design Responses is described which response types are
allowed in the objective and how they can be combined (see also chapter
4.1.1 Mathematical formulation).
If the maximum objective term should be minimized, the definition is as follows:
OBJ_FUNC
= ...
= ...
= ...
= MINMAX
END_
where the DRESP definitions are referring to the desired design responses
for the objective function using the ID name of the defined responses. The
defined responses that should be minimized have to be valid design
responses (see also chapter 4.4 Design Responses).
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ID_NAME
DRESP
DRESP
...
TARGET
SIMULIA
Tosca Structure

Tosca ANSA environment only allows design responses to be defined within
either an objective function (OBJ_FUNC) or within the CONSTRAINT object.
Fig. 39
Definition of the minimization of the objective function.
Fig. 40
Definition of the design responses for the objective function.
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In addition to the target definition for the objective function definition, the user
also has to define the design responses for the objective function combined
by the target. These terms then will be minimized or maximized.
User Manual 2 - 77
SIMULIA
Tosca Structure
Objective Function

For the definition of the objective function within Tosca Structure.gui, the
design responses that should be minimized or maximized have to be defined
previously. Please refer to the chapter vol.2 chapter 4.4 and vol.2 chapter 4.5.
Fig. 41
Defining the objective function using a previously defined design

response.
Definition in Tosca Extension for ANSYS/Workbench
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In Tosca Extension for ANSYS/WB an objective function has to be added to

the project using the corresponding button. A design response has to be
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Tosca Structure
defined beforehand and can be referenced within the objective function.

Choose whether you want the design response to be minized or maximized.
Fig. 42
Constraints
Normally, optimization tasks have some restrictions. These restrictions limit
the values of the design responses or linear combinations of the design
responses. If the constraint is not fulfilled the optimization result is not feasible.
Tosca Structure allows inequality constraints in all sensitivity based algorithms. Equality constraints are only allowed in the controller based
approaches.
This means that the item EQ_VALUE defining the equality value may only be
used for controller based optimization. LE_VALUE and GE_VALUE are to be
used for the upper and lower values of constraints in sensitivity based optimization algorithms.
An equality constraint is given as (see also vol.2 chapter 4.1.1, Mathematical
formulation):
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Add and define an objective function and select a previously

defined design response
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Tosca Structure
Constraints
where is the value of the design response. Inequality constraints are given
as (see also chapter 4.1.1 Mathematical formulation):
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The <magnitude> can be defined as ABS or REL, short for absolute or relative value of the design response in the constraint. When using the relative
value the design response is normalized with respect to the initial value of the
design response (design response value of optimization iteration 0).
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Tosca Structure
Fig. 43
Definition of the constraint using the related design response.
For the definition of a constraint within the Tosca Structure.gui the design
response which should be constraint has to be defined previously. Please
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Tosca Structure
Constraints
refer to vol.2 chapter 4.4 and vol.2 chapter 4.5.
Fig. 44
Defining a constraint with a previously defined design response.

In Tosca Extension for ANSYS/WB add a constraint to the project by clicking
on Optimization | Constraint. Within this constraint, choose a previously defined design response and set the other desired settings.
Add and set up a constraint using a previously defined design

response
Tosca Structure Parameter file:

A constraint definition is given as:
CONSTRAINT
ID_NAME
DRESP
MAGNITUDE
EQ_VALUE
LE_VALUE
GE_VALUE
END_
2 - 82 User Manual
=
=
=
=
=
=
<ID_NAME>
<DRESP>
<MAGNITUDE>
<EQ-TARGET>
<LE-TARGET>
<GE-TARGET>
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SIMULIA
Tosca Structure
The <ID_NAME> must be referenced in the OPTIMIZE command for the constraint to be activated. Only one of the constraint items EQ_VALUE,
LE_VALUE and GE_VALUE may be defined. They define the constraint value
.
Fig. 46
Normalized output of constraint in Tosca Structure.view
Remark
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1. In the above plot CONSTRAINT_NORM are all constraints plottet, normalized. CONSTRAINT_NORM is a special normalization so all fullfiled
constraints are < 1.0. This also applies to GE_EQUAL constraints.
4.4
Design Responses
Most design responses are only available for certain analysis types. Others
are independent of the analysis type because they are directly linked to the
geometry of the FE-model. Each design response represents one scalar
value which can be extracted from the model information (like the volume) or
from the FE-results.
All design responses always consist of one single scalar value. So although
you reference a node or element group in the DRESP definition, Tosca Structure will use a group operator (GROUP_OPER) to either use the maximal
User Manual 2 - 83
SIMULIA
Tosca Structure
Design Responses
(MAX), minimal (MIN) or sum of the values (SUM) to combine the responses
to a single value. (see also chapter 4.5.1 Group operations for design
responses)
Although Tosca Structure can handle more load cases within one design
response, it is best practice to use one design response for each load case.
This is done with the item LC_SET:
LC_SET = <ANALYSIS_TYPE>, <LOADCASE_NR>,<SUBSTEP>
If more load cases or sub-steps are referenced in the LC_SET item the maximum (MAX) or minimum (MIN) value will be used within the design response,
depending on the setting of load case selection (LC_SEL). If LC_SEL is not
set explicitly, a default value is used according to the type of the design
response. Using Tosca Structure.gui LC_SEL no longer needs to be defined
manually. Again, this is done to obtain exactly one single value. See also
chapter 4.5.2.1 Load case specification (LC_SET). Command in parameter
file:
DRESP
ID_NAME
DEF_TYPE
TYPE
VAR_OPER
UPDATE
GROUP_OPER
EL_GROUP
ND_GROUP
ELEM
NODE
LC_SET
LC_SEL
=
=
=
=
=
=
=
=
=
=
=
=
.....
.....
.....
.....
.....
.....
.....
.....
.....
.....
.....
.....
Most entries have default values. See definition of a design response

(DRESP) in the commands manual for more information.
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SIMULIA
Tosca Structure

Tosca ANSA environment admits design responses to be defined within an
objective function (OBJ_FUNC) and within a CONSTRAINT.
Fig. 47
Possible categories of design responses for sensitivity based

topology optimization. The number of possibilities varies with
respect to optimization type.
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Allowed objective functions and constraints are shown in the Tosca ANSA
environment, see Fig. 47.
User Manual 2 - 85
SIMULIA
Tosca Structure
Design Responses
Definition in Tosca Structure.gui:
a)
b)
Fig. 48
Defining design responses in Tosca Structure.gui. a) Apply

Template to access the simplest and most used optimization
responses. b) The category selector is used to switch between
the main categories of the design responses.
Add a design response to the project by clicking Optimization | Design

Response. Then choose Category and Response Type and the other
settings.
Fig. 49
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Add a design response to the project and define the desired settings
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4.4.1
Compliance (Stiffness Optimization)

c =
STRAIN_ENERGY
uT Ku
Analysis types: Static linear or non-linear analysis
Ku = F where K may be linear or non-linear
TOPO
OBJ_FUNC
CONSTRAINT
Table 8
SHAPE
BEAD
SIZING
C*,S*
C,S
S*
Compliance (C = controller, S = sensitivity)

* Topology optimization allows nonlinearities as well as temperature loading
Compliance has a large popularity within scientific publications, and compliance is of large importance in engineering applications even though the
expression may not be widely known outside the optimization community.
Compliance may be expressed as the overall flexibility or softness of a
structure given by the sum of elastic or strain energy in a structure. Thus,
compliance can be seen as a stiffness measure or more correctly the reciprocal of stiffness.
To maximize the global stiffness we therefore minimize compliance. Compliance is defined in Tosca Structure by the sum of strain energy of all elements.
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Remarks:
1. In certain cases including prescribed displacements or thermal fields "minimizing compliance" will result in a stiff structure. If a load case is driven by
prescribed displacements or a thermal field the elastic energy / compliance
will only decrease if the structure is made softer. If only prescribed
displacements are present without external loading, the strain energy
should be maximized to obtain optimal results:
R u
max --------------
2
with R=reaction force and u* = nodal prescribed displacements.
If both external loading and prescribed displacements are present, a new
energy stiffness measure is introduced (see chapter 4.4.2 Energy stiffness
User Manual 2 - 87
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Tosca Structure
Design Responses
measure). The "standard" strain energy does not lead to optimal results:
P
u R
u
---------+ -------------2
2
with P=external loading and u = corresponding nodal deflections of the
loaded nodes.
2. Compliance is equal to the overall strain energy. Therefore the strain
energy for all elements is required. Any other element group is not allowed,
because in such cases the optimization problems are not self-adjoint.
3. If no LC_SET is specified (no load case is selected from the existing load
cases) Tosca Structure will always read the last sub-step for each load
case in case of non-linear loading.
4.4.1.1 Compliance example

We want to minimize compliance (maximize stiffness) of a structure with
respect to the 2nd load case in our finite element input deck.
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Tosca ANSA environment only admits design responses to be defined below
either OBJ_FUNC_ITEM_1 item or CONSTRAINTS item.
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1. In the context menu of OBJ_FUNC_ITEM_1, choose Edit. In

OBJ_FUNC_ITEM dialog choose TARGET = MIN, because the compliance
is to be minimized in order to maximize the stiffness.
Fig. 50
Choosing compliance as objective function in Tosca ANSA environment
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2. Apply New | COMPLIANCE command on OBJ_FUNC_ITEM_1. In the

OBJ_FUNC_TERM dialog, press "?" key in LC_SET field. In the LC_SET
dialog click MORE and enter the load case number (2 for the second load
case) in the second text field of the appeared line.
User Manual 2 - 89
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Tosca Structure
Design Responses

1. Choose Command | DRESP. Click Apply Template and choose Sum of
Strain Energy.
Fig. 51
Defining compliance design response using Tosca Structure.gui
2. To choose load case click Add LC. In the field Load case number enter 2.
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3. Choose Command | OBJ_FUNC.
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4. Click Add Dresp and choose the previously defined design response for
compliance.
Fig. 52
Choosing DRESP for compliance as objective function in Tosca

Structure.gui
Fig. 53
Add and define a design response
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In order to minimize the compliance using Tosca Extension for ANSYS/WB,

add a design response at first and choose Stress/Strain as Category and
Strain Energy as Response Type. In addition, select the desired Load Cases.
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Tosca Structure
Design Responses
When done, add an objective function to the project. Select Minimize sum as
Target and select the previously defined design response in a new tab.
Fig. 54
Add an objective function to the project and select the design

response for a minimization
OBJ_FUNC
ID_NAME
DRESP
TARGET
END_
4.4.2
=
=
=
=
=
=
compliance
STRAIN_ENERGY
SYSTEM
STATIC,2,
ALL_ELEMENTS
SUM
= MY_OBJ_FUNC
= compliance
= MIN
Energy stiffness measure

ENERGY_STIFF_MEASURE
2 - 92 User Manual
c = P u R u
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DRESP
ID_NAME
TYPE
DEF_TYPE
LC_SET
EL_GROUP
GROUP_OPER
END_
SIMULIA
Tosca Structure

TOPO
SHAPE
BEAD
SIZING
OBJ_FUNC
CONSTRAINT
Table 9
Energy stiffness measure (C = controller, S = sensitivity)
ENERGY_STIFF_MEASURE describes a new stiffness measure (without

physical meaning) for simultaneous handling of external loading and prescribed displacement in stiffness optimization.
For stiffness optimization of structures with only external loading the strain
energy should be minimized (see chapter 4.4.1 Compliance (Stiffness Optimization)):
Pu
min ----------
2
where P is the external loading and u is the corresponding nodal deflections
of the loaded nodes.
If a load case is driven by prescribed displacements the elastic energy / compliance will only decrease if the structure is made softer. If only prescribed
displacements are present without external loading, the strain energy should
be maximized to obtain optimal results:
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R u
max --------------
2
where u* are the nodal prescribed displacements being different from zero
and R are the corresponding nodal reaction forces.
The physical strain energy with both external load and prescribed displacements is described as follows but may not lead to optimal stiffness results:
P u R u
= ---------- + -------------2
2
The new stiffness measure (ENERGY_STIFF_MEASURE) combines the first
two approaches in the following optimization formulation :
P u R u
min ---------- --------------
2
2
User Manual 2 - 93
SIMULIA
Tosca Structure
Design Responses
Remarks:
1. Energy stiffness measure should always be minimized (TARGET = MIN) in
the objective function independent upon external loading, prescribed
displacement and thermal loading. This requires less user effort compared
to total strain energy !
2. Energy stiffness measure should always be applied to ALL_ELEMENTS.
3. Thermal loading is allowed as long the thermal loading is independent
upon material distribution
4. Energy stiffness measure can also be applied in a min-max optimization
formulation (TARGET = MINMAX).
5. The energy stiffness measure is also allowed in constraints.
6. If only external loading is present in a given loadcase then the energy stiffness measure (TYPE = ENERGY_STIFF_MEASURE) is equal to the total
strain energy (TYPE = STRAIN_ENERGY) also called the compliance.
7. If only prescribed displacements are present in a given loadcase then the
energy stiffness measure (TYPE = ENERGY_STIFF_MEASURE) is equal
to the minus total strain energy (TYPE = STRAIN_ENERGY) also called
the compliance.
8. If both external loading and prescribed displacements are present in a
given loadcase then the energy stiffness measure (TYPE =
ENERGY_STIFF_MEASURE) is not equal to the total strain energy (TYPE
= STRAIN_ENERGY).
9. The energy stiffness measure is not a physical energy measure!
11.Thermal loading is not supported.

12.Mass dependent loading (e.g. gravity) is not supported.
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10.The energy stiffness measure is not available for the controller based optimization strategy.
SIMULIA
Tosca Structure
4.4.2.1
Example for energy stiffness measure

Maximize the stiffness by minimizing the energy stiffness measure subject to
a mass constraint of 35 %. Varying prescribed displacements are assigned.
Fig. 55
Minimize energy stiffness measure for varying prescribed displacements.
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Not yet supported by Tosca ANSA environment.
User Manual 2 - 95
SIMULIA
Tosca Structure
Design Responses

1. Choose Command | DRESP. Choose Type | ENERGY_STIFF_MEASURE.
Select ALL_ELEMENTS in dropdown menu Elementgroup.
Fig. 56
Defining compliance design response using Tosca Structure.gui
2. To choose load case click Add LC. In the field Load case number enter 2.
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3. Choose Command | OBJ_FUNC.
2 - 96 User Manual
SIMULIA
Tosca Structure
4. Click Add Dresp and choose the previously defined design response for
energy stiffness measure.
Fig. 57
Choosing DRESP for compliance as objective function in Tosca

Structure.gui

DRESP
ID_NAME
DEF_TYPE
TYPE
EL_GROUP
GROUP_OPER
=
=
=
=
=
...
SYSTEM
ALL_ELEMENTS
SUM
END_
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4.4.3
Displacement and rotation

DISP_X, DISP_Y, DISP_Z
ui
ROT_X, ROT_Y,ROT_Z
DISP_X_ABS, DISP_Y_ABS,
DISP_Z_ABS
u i2
DISP_ABS
u x2 + u y2 + u z2
Analysis types: Static linear or non-linear analysis*
Ku = F where K may be linear or non-linear.
User Manual 2 - 97
SIMULIA
Tosca Structure
Design Responses
TOPO
SHAPE
BEAD
SIZING
OBJ_FUNC
S*
CONSTRAINT
S*
Table 10
Displacements and rotations (C = controller, S = sensitivity)

* Nonlinear analysis allowed
Displacements and rotations are the primary variables in the FEM solution.
They are also very often the main interest of the FEM-analyst, e.g. the maximal displacement. Displacements and rotations should be defined using a
nodal id, although node groups may also be referenced. Large node groups
can lead to major performance issues, see chapter 4.5.1 Group operations
for design responses.
Displacements and rotations can also be referenced in a local coordinate system.
See also chapter 4.5 Combined Terms.
Remark
1. It is always strongly recommended that the user defines design elements
attached to nodes used in displacement definitions or reaction definitions
(DRESP) as frozen elements. This stabilizes the optimization iterations and
often leads to a significant lower number of optimization iterations.
4.4.3.1 Example of a displacement design response
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The absolute displacement of node 10 in local coordinate system CS_1 is to

be minimized.
2 - 98 User Manual
SIMULIA
Tosca Structure

Apply New | Displacement command on OBJ_FUNC_ITEM_1.
Choosing displacement as objective function.
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Fig. 58
User Manual 2 - 99
SIMULIA
Tosca Structure
Design Responses
Fig. 59
Choosing displacement as design response
Fig. 60
2 - 100 User Manual
Add and define a design response for displacement
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In Tosca Extension for ANSYS/WB an objective function containing a displacement has to be set up in two steps. At first, add and define a design
response containing the displacement. Therefore add a design respone to
the project, choose Displacement as Category and Absolute as Response
Type.
SIMULIA
Tosca Structure
In order to select the node: activate a nodal selection first by clicking Show
mesh and Select mesh. Then select the desired node graphically.
Fig. 61
Activate nodal selection
Then call this design response in an objective function. In order to set up a

minization function, add an objective function to the project, select Minimize
sum as Target, and choose the previously defined design response in a new
tab.
Fig. 62
Set up an objective function for a minization
Command in parameter file

The resulting command in the Tosca Structure parameter file is then:
ID_NAME
TYPE
CS_REF
DEF_TYPE
LC_SET
NODE
END_
=
=
=
=
=
=
disp_x_abs
DISP_X_ABS
CS_1
SYSTEM
STATIC, 2,
10
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DRESP
User Manual 2 - 101
SIMULIA
Tosca Structure
Design Responses
4.4.4
Reaction force
REACTION_FORCE_ABS
F =
REACTION_FORCE_X,
REACTION_FORCE_Y,
REACTION_FORCE_Z
F =
Ke ui
Ke ui
REACTION_FORCE_X_ABS,
REACTION_FORCE_Y_ABS,
REACTION_FORCE_Z_ABS
F =
Ke ui
REACTION_MOMENT_ABS
F =
REACTION_MOMENT_X,
REACTION_MOMENT_Y,
REACTION_MOMENT_Z
F =
Ke ui
Ke ui
REACTION_MOMENT_X_ABS,
REACTION_MOMENT_Y_ABS,
REACTION_MOMENT_Z_ABS
F =
Ke ui
Where e are the elements connected to the nodes i on supported DOFs.

TOPO
SHAPE
BEAD
SIZING
OBJ_FUNC
CONSTRAINT
Table 11
Reaction forces (C = controller, S = sensitivity)
The reaction forces and the reaction moments can only be defined as a
DRESP (design response) in the sensitivity based bead and topology optimization.
Remarks
1. A reference coordinate system (CS_REF) cannot be used for the reaction
force responses defined using REACTION_FORCE_ABS and
REACTION_MOMENT_ABS.
2. The reaction force, reaction moment, internal force and/or internal moment
in a given DOF of a node applied in the optimization formulation has to
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Ku = F where K may be linear or non-linear.
SIMULIA
Tosca Structure
have stiffness in the DOF direction similar to the DOF direction of the reaction force or internal force used in the optimization formulation. Meaning
that at least one of the elements surrounding the node has to have stiffness
in the DOF direction similar to the reaction force or internal force direction
applied in the optimization formulation.
Hence, this criterion is also physical meaningful since a structure having no
stiffness in a given direction will always have zero reaction force in this
direction.
3. Differences between reaction forces can be defined using group operations.
4. Examples for combinations of reaction forces can be found in chapter
4.5.1.4 Group operations for reaction forces/moments.
4.4.4.1 Example of reaction force design response

Define a reaction force in Y-direction (REACTION_FORCE_Y) of the global
coordinate system (CS_0) of node 112072.
REACTION_FORCE on OBJ_FUNC_ITEM_1 or CONST-
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Apply New |
STRAINTS item.
Fig. 63
Defining the reaction force as constraint (choose magnitude

=ABS)
User Manual 2 - 103
SIMULIA
Tosca Structure
Design Responses
Fig. 64
Defining the reaction force as design response
Fig. 65
Reaction force design response setup

The resulting command in the Tosca Structure parameter file yields:
DRESP
ID_NAME
DEF_TYPE
TYPE
2 - 104 User Manual
= my_reac
= SYSTEM
= REACTION_FORCE_Y
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In order to set up a reaction force design response in Tosca Extension for

ANSYS/WB, add a design response to the project. Set the Category to Reaction Force/Moment and the Response Type to Y.
SIMULIA
Tosca Structure
NODE
LC_SET
GROUP_OPER
CS_REF
END_
4.4.5
=
=
=
=
112072
ALL,2,All
Max
CS_0
Internal force
INTERNAL_FORCE_ABS
F =
INTERNAL_FORCE_X,
INTERNAL_FORCE_Y,
INTERNAL_FORCE_Z
F =
Ke ui
Ke ui
INTERNAL_FORCE_X_ABS,
INTERNAL_FORCE_Y_ABS,
INTERNAL_FORCE_Z_ABS
F =
Ke ui
INTERNAL_MOMENT_ABS
F =
INTERNAL_MOMENT_X,
INTERNAL_MOMENT_Y,
INTERNAL_MOMENT_Z
F =
Ke ui
Ke ui
INTERNAL_MOMENT_X_ABS,
INTERNAL_MOMENT_Y_ABS,
INTERNAL_MOMENT_Z_ABS
F =
Ke ui
For the elements e attached to the nodes i.
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Ku = F where K may be linear or non-linear

.
TOPO
SHAPE
BEAD
SIZING
OBJ_FUNC
CONSTRAINT
Table 12
Internal forces (C = controller, S = sensitivity)
User Manual 2 - 105
SIMULIA
Tosca Structure
Design Responses
The internal forces and the internal moments can be defined as a DRESP
(design response) in the sensitivity based bead and topology optimization.
The internal forces as DRESPs are supported for Abaqus, ANSYS, Marc,
MSC Nastran.
a)
b)
Fig. 66
Internal forces are defined through node(s) and element(s).

a) Defining the internal axial forces of a bar/beam using one node
and one element. b) Defining the internal axial forces of a continuum element by summing up the forces in axial direction using a
node group and element group.
As previously shown the internal forces are defined by nodes and elements.
Meaning that the design response is defined in the following way:
ID_NAME
DEF_TYPE
TYPE
CS_DEF
GROUP_OPER
ND_GROUP
NODE
EL_GROUP
ELEM
LC_SET
=
=
=
=
=
=
=
=
=
=
.....
SYSTEM
.....
.....
MAX or
.....or
.....or
.....or
.....or
.....
SUM
use the
use the
use the
use the
NODE-definition
ND_GROUP-definition
ELEM-definition
ELEM_GROUP-definition
END_
Remarks
1. The reaction force, reaction moment, internal force and/or internal moment
in a given DOF of a node applied in the optimization formulation has to
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DRESP
SIMULIA
Tosca Structure
have stiffness in the DOF direction similar to the DOF direction of the reaction force or internal force used in the optimization formulation. Meaning
that at least one of the elements surrounding the node has to have stiffness
in the DOF direction similar to the reaction force or internal force direction
applied in the optimization formulation.
Hence, this criterion is also physical meaningful since a structure having no
stiffness in a given direction will always have zero reaction force in this
direction.
2. Internal forces are only supported for elements having node numbers. If
the element is not defined by nodes (e.g. some weld element) then the
internal forces of this element can not be applied in the optimization.
3. Both node(s) and element(s) always have to be defined for internal forces.
4. See also the tables of supported element types (chapter 11 Solver Specific
Features) for a list of elements which can be used for internal forces.
5. A reference coordinate system (CS_REF) can not be used for the internal
force responses defined using INTERNAL_FORCE_ABS and
INTERNAL_MOMENT_ABS.
6. Internal forces are supported for Abaqus, ANSYS, Marc and MSC Nastran.
7. Internal forces are not supported for PERMAS.
8. Examples for combinations of internal forces can be found in chapter
4.5.1.5 Group Operations for Internal Forces.
Define the sum of internal forces in the Y-direction (INTERNAL_FORCE_Y)

of
the
global
coordinate
system
(CS_0)
of
node
group
ND_INTERNAL_GROUP_LEFT connected to the element group
EL_INTERNAL_GROUP_LEFT.
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4.4.5.1 Example internal force
User Manual 2 - 107
SIMULIA
Tosca Structure
Design Responses

Apply New | INTERNAL_FORCE on OBJ_FUNC_ITEM_1 or CONSTRAINTS
item.
Defining internal forces as constraint
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Fig. 67
2 - 108 User Manual
SIMULIA
Tosca Structure
Fig. 68
Defining internal forces as design response

Tosca Extension for ANSYS/WB does not support this Tosca Structure feature at the moment.
The resulting command in the Tosca Structure parameter file is:
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Version 8.1.0 Rev. 1 - 05.2014
DRESP
ID_NAME
DEF_TYPE
TYPE
EL_GROUP
ND_GROUP
LC_SET
GROUP_OPER
CS_REF
END_
4.4.6
=
=
=
=
=
=
=
=
internal_force_response
SYSTEM
INTERNAL_FORCE_Y
EL_INTERNAL_GROUP
ND_INTERNAL_GROUP
ALL,1,All
Sum
CS_0
Eigenfrequency
DYN_FREQ
fj
User Manual 2 - 109
SIMULIA
Tosca Structure
Design Responses
DYN_FREQ_KREISSEL
kf j
1
--- ln
e ,
k j
30
by default k = ---------f min
Analysis types: Modal analysis

2 2
( 4 f M K ) = 0
TOPO
SHAPE
BEAD
SIZING
OBJ_FUNC
S*
C, S*
S*
CONSTRAINT
S*
S*
S*
Table 13
Eigenvalues (C = controller, S = sensitivity)

*Note that Kreisselmaier-Steinhauser formulation is only
allowed in objective function
Eigenvalues are the simplest dynamic responses in structural mechanics.

Typical optimization tasks for modal analysis would be to:
1. Maximize the first eigenfrequency (first natural mode)
2. Constrain an eigenfrequency to be higher or lower than a given value
4. Bandgap optimization: Force modes away from a certain frequency

Only the first eigenvalue optimization task (1.) is allowed by all optimization
types. The other definitions, 2.-4., are only possible with sensitivity based
optimization.
It is recommended to use the Kreisselmaier-Steinhauser formulation when
maximizing the first eigenfrequencies (especially for multiple eigenfrequencies) given by
kf j
30
1
--- ln
e , by default k = ---------
f min
k j
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3. Maximize or minimize an eigenfrequency at a certain mode
SIMULIA
Tosca Structure
The
Kreisselmaier-Steinhauser
formulation
is
defined
by
DYN_FREQ_KREISSEL in the design response. For this design response
mode tracking is not needed.
For the other optimization tasks mode tracking is often necessary because
the modes and thereby the eigenfrequencies may switch during the optimization.
4.4.6.1 Eigenvalue example

Define the Kreisselmaier-Steinhauser formulation for the first 5 eigenvalues of
the first load case.
1. Apply New | EIGENFREQUENCY on OBJ_FUNC_ITEM_1 or CONSTRAINTS item.
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2. In the LC_SET field enter a question mark "?".
User Manual 2 - 111
SIMULIA
Tosca Structure
Design Responses
3. Click MORE 5 times and enter sub-steps 1 to 5 and click OK.
Maximizing the first five eigenfrequencies using the Kreisselmaier-Steinhauser formulation.

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Fig. 69
2 - 112 User Manual
SIMULIA
Tosca Structure
Fig. 70
Defining the Kreisselmaier-Steinhauser formulation as design

response
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Add a design response to the project, select Eigenfrequency as Category and

DYN_FREQ_KREISSEL as Response Type.
In order to select the desired five eigenfrequencies, select Manual as Load
Case Selection, chose Modal as Analysis and set Step to 5.
Fig. 71
Design response definition and corresponding Load Case table

DRESP
ID_NAME
TYPE
DEF_TYPE
LC_SET
=
=
=
=
freq_kreissel
DYN_FREQ_KREISSEL
SYSTEM
MODAL,ALL,1-5
User Manual 2 - 113
SIMULIA
Tosca Structure
Design Responses
LC_SEL
END_
= MIN

Mode tracking is available in the sensitivity based optimization and defined
using three optimization parameters (OPT_PARAM):
Mode tracking is activated using the optimization parameter MODETRACKING= ON. The second item in MODETRACKING defines the node group
which is used for the mode tracking. The node group can improve performance when the node group is small. If no node group is defined all nodes in
the model will be applied as default. This is reasonable for small to medium
sized finite element models. By default the mode tracking applies for 5
modes. This can be changed by the item MODENUMBERS =
<number_modes>. This number should not be set too high otherwise the
CPU-time might have a significant increase.
Using the parameter MODETRACK_REFERENCE for the Modal Assurance
Criterion (MAC) allows the user to define the reference modes applied when
tracking the modes during the optimization iterations. If the parameter
MODETRACK_REFERENCE is set to INITIAL then the reference modes are
set to be the modes of the initial optimization iteration throughout the entire
optimization history. If the parameter MODETRACK_REFERENCE is set to
PREVIOUS then the reference modes are always set to be the modes of the
previous optimization iteration.
Typically, setting MODETRACK_REFERENCE to INITIAL is the most consistent comparison in the modetracking. However, some initial modes may
change significantly or completely disappear during the optimization iterations and thereby, the INITIAL comparison may fail. When INITIAL as setting
for MODETRACK_REFERENCE is failing then the only option is to apply
PREVIOUS even though the comparison might not be so consistent as INITIAL.
4.4.7
Equivalent stress
SIG_1
SIG_2
2 - 114 User Manual
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MODETRACKING
=<ON/OFF>, <NODE_GROUP>
MODENUMBERS
=<NUMBER_MODES>
MODETRACK_REFERENCE =INITIAL | PREVIOUS
SIMULIA
Tosca Structure
SIG_3
SIG_11
11
SIG_22
22
SIG_33
33
SIG_12
12
SIG_23
23
SIG_13
13
SIG_ABS_123
max ( 1 , 2 , 3 )
SIG_ABS_3
SIG_MISES
SIG_TRESCA
1--2
2
2
{ ( 1 2 ) + ( 2 3 ) + ( 1 3 ) }
2
max ( 1 2 , 2 3 , 3 1 )
SIG_BELTRAMI
SIG_GALILEI
SIG_KUHN
SIG_MARIOTTE
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SIG_SANDEL
2
[ 1 + 2 + 3
1---
2
2
2 -----------------2- ( 1 2 + 2 3 + 1 3 ) ]
1 + 2
SIG_SAUTER
1 2 + 2 3 + 3 1
SIG_DRUCKER_PRAGER
STRAIN_ENERGY
1 T
c = --- u Ku
2
User Manual 2 - 115
SIMULIA
Tosca Structure
Design Responses
STRAIN_ENERGY_
DENSITY
1 T
c = ------- u Ku
2V
DAMAGE_LC
user / program dependent
DAMAGE
user / program dependent
Contact and strain meassures
SIG_CONTACT_SHEAR
SIG_CONTACT_
SHEAR_X
SIG_CONTACT_
SHEAR_Y
SIG_CONTACT_TOTAL
STRAIN_ELASTIC
1 + 2
p + 1 + 2
2
2
2
2
- ( e ) + ( e ) + ( e )
-11
22
33
3
2
2
2
+2 ( e ) + ( e ) + ( e )
12
13
23
STRAIN_PLASTIC
1--2
2
2
2
2
- ( p ) + ( p ) + ( p )
-11
22
33
3
2
2
2
+2 ( p ) + ( p ) + ( p )
12
13
23
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SIG_CONTACT_PRESSU
RE
SIMULIA
Tosca Structure
STRAIN_TOTAL
2 2
2
2
- [ 11 + 22 + 33
-3
2
2
2
+2 ( 12 + 13 + 23 ) ]
ABQ_ND_PEEQ
1--2
PEEQ, see Abaqus documentation
Analysis types: Any analysis type with stress output or fatigue result
TOPO
OBJ_FUNC
SHAPE
BEAD
SIZING
CONSTRAINT
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Table 14
Equivalent stress (C = controller, S = sensitivity)
The equivalent stresses are the main input for the shape optimization controller algorithm. All values, whether nodal, from gauss points or elements, are
interpolated to the nodes. Equivalent stress is only allowed in the objective
function by controller based shape optimization.
Typical optimization tasks:
1. Minimize maximal von Mises stress (see vol.2 chapter 6.6.1, Minimization
of maximum equivalent stress)
2. Minimize maximal damage (fatigue analysis)
3. Minimize contact pressure in a contact region (see vol.2 chapter 6.7.2,
Minimization of contact pressure)
Equivalent stresses are always read for ALL_NODES to give the user the
most appropriate output. This will give some warnings for nodes which do not
User Manual 2 - 117
SIMULIA
Tosca Structure
Design Responses
have any equivalent stress values, e.g., nodes on elements which are not in
contact when evaluating SIG_CONTACT_... .
Remark:
Plastic strain values (TYPE = STRAIN_PLASTIC) are calculated by Tosca
Structure and may differ slightly from your solver results.
4.4.8
Stress in topology optimization
( vMises )
SIG_TOPO_MISES = Max -------------------------2 y
( f ( i ) y )
The vMises is the elemental centroidal von Mises stress, y is the reference
stress and f ( i ) is a factor for interpolating the stresses of the elements having intermediate densities (given by the topology optimization, see vol.2
chapter 4: Stress interpolation).
Only von Mises stress can be applied in topology optimization.
Analysis type: Static linear and non-linear (contact) analysis (no geometrical and material non-linearities in element group)
TOPO
OBJ_FUNC
CONSTRAINT
BEAD
SIZING
Weighted centroidal von Mises stress for topology optimization (C = controller, S = sensitivity)
Remarks
Stress applied in topology optimization cannot directly be compared to the
von Mises stress given as output from the finite element solver. Only for solid
elements ( = 1 ) the von Mises stresses given by Tosca Structure stresses
is equal to the von Mises stresses as output from the FE-solver (see vol.2
chapter 4: Stress interpolation).
Please note:
Topology optimization using stresses as DRESP is implemented as a prerelease feature at Tosca Structure version 7.2.0.
Consequently, this newly developed feature may not yet be applied to all possible practical scenarios. Thus, we appreciate your feedback since this feature is still under development.
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Table 15
SHAPE
SIMULIA
Tosca Structure
Stress calculation
The von Mises stress is calculated in the elemental centroid for avoiding
stress singularities which might be present in the initial model or appear in the
non-smoothed topology optimized structures.
singular
stresses
Fig. 72
Singular stresses caused by the initial model (left) and by a nonsmooth topology optimized structure (right)
Reference stress for objective function

The reference stress ref is defined in the objective function command or will
be automatically calculated by Tosca Structure for the objective function.
A reference stress for the objective function terms can be directly defined as
OBJ_FUNC
ID_NAME
= OBJ_FUNCTION_ID
DRESP
= DRESP_ID_1,<weight_fact_1>, <ref_stress_1>
DRESP
= DRESP_ID_2,<weight_fact_2>, <ref_stress_2>
...........
TARGET = MIN
END_
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where <reference stress 1> and <reference stress 2> correspond to ref . The reference stress values should not be chosen too low as
this might cause numerical singularities. This corresponds to
2
2
( vMises )
( vMises )
+
Min 1 Max -----------------------------Max

-------------------------------
2
( f ( i ) ref 1 ) 2
( f ( i ) ref 2 ) 2
If the user does not define a reference stress in the objective function command then Tosca Structure automatically determines a reference stress,
which is generated in the initial optimization iteration and is written to
TOSCA.OUT.
Constraint value
A limitation on the stresses can be formed for a DRESP of type
SIG_TOPO_MISES used in a constraint definition with the LE_VALUE
parameter:
User Manual 2 - 119
SIMULIA
Tosca Structure
Design Responses
CONSTRAINT
ID_NAME
DRESP
MAGNITUDE
LE_VALUE
=
=
=
=
STRESS_CONSTRAINT
DRESP_STRESS_ID
ABS
<stress_constraint>
END_
This corresponds to restricting the weighted centroidal von Mises stress by

the constraint value stress_constraint= con :
2
( vMises )
Max -----------------------------2- con con
( f ( i ) con )
Remarks
1. ref is equal to the reference value when the DRESP defined by
SIG_TOPO_MISES is applied in the objective function. The reference
stress ref can be changed by modifying the reference value in the objective.
2. con is equal to LE_VALUE (or GE_VALUE) when the DRESP defined by
SIG_TOPO_MISES is applied in a constraint.
3. A DRESP being TYPE = SIG_TOPO_MISES can only be applied once in
the objective function or as constraint!.
4. Note that a reference stress or constrained stress which is too low might
cause numerical singularities.
The factor f ( i ) describes a function for the interpolation of stresses depending of the density i of the element i.
The interpolation is needed because during the topology optimization the
densities of the elements are modified and can have a minimum value close
to zero. Stress values calculated by the solver for transition or soft elements
(i.e. elements with low density) have no real physical meaning for the
stresses and must be weighted by a factor to allow for a successful optimization convergence.
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Stress interpolation
SIMULIA
Tosca Structure
.
Different densities of several elements
during topology optimization
Void
Initial
Fig. 73
Optimized
Densities of elements during the optimization: Initial equal density

of all elements (bottom left), modified densities during the topology
optimization iterations (top) and final density values for the optimized model (bottom right)
The stress interpolation for intermediate densities is similar to the stiffness

material interpolation and can be illustrated as
Thus, the stress measure SIG_TOPO_MISES applied in topology optimization cannot be directly compared to the von Mises stresses seen as output
from the finite element solver. Only for solid elements ( = 1 ) the
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Version 8.1.0 Rev. 1 - 05.2014
E ( i )
------------- f ( i )
E0
User Manual 2 - 121
SIMULIA
Tosca Structure
Design Responses
SIG_TOPO_MISES corresponds to the von Mises stresses calculated by the

FE-solver.
Solid elements:
Von Mises stress =

constraint stress:
( vMises )
vMises
f ( i = 1 ) = 1 -------------------------2 = ------------------( f ( i ) y )
y2
2
vMises
-------------------- = 1 DRESP = vMises = con
2
con
Element group
The element group for the stress measure can consist of both design and
non-design elements.
Frequently, the initial model for the optimization contains non-physical modeling around loaded nodes and boundary conditions, respectively. The user
should avoid including stresses from stress singularities caused by external
loaded nodes or by boundary conditions. These singularities are eliminated
by excluding these elements from the group used for calculating the DRESP.
The user should exclude elements with loaded nodes and boundary conditions to avoid stress singularities.
Supported element types

Supported element types are 3D standard continuum elements which are
shown in Fig. 16:
Hexahedral 8 and 20 node elements
Tetrahedral 4 (not recommended!) and 10 node elements
Pentahedron 6 and 15 nodes elements
All linear isotropic materials are supported for the elements in the element
group. Anisotropic and non-linear materials both inside and outside the
design domain (DV_TOPO) are only supported if the stresses of these materials are not a part of the element group applied for calculation of the DRESP
of TYPE = SIG_TOPO_MISES.
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Fig. 74
SIMULIA
Tosca Structure
Pyramidal 5 and 13 node elements as well as shell elements are not supported.
Remark:
1. Shear and volume locking in the finite element yield wrong results not only
in the finite element analysis but can also cause optimization convergence
problems when such stress responses are included in the optimization
formulation. Especially, the linear 4 node tetrahedral elements should be
avoided. Instead it is recommended to use the quadratic10 node tetrahedral element or the linear 8 node hexahedral element.
Loadcases
Several loadcases can be defined for the stress measure.
Static linear analysis is supported. For static non-linear analysis only contact
is supported. Thus, geometrical non-linearities (like large deformation) and
non-linear materials are not supported.
4.4.8.1 Example: Stresses in objective function

We want to minimize the maximum von Mises stress. For a typical optimization task see chapter 5.6.6 Minimize the maximum stress with volume constraint.
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Not yet available with Tosca ANSA environment 13.2.x. Stresses as design
responses are only supported for ANSA version 13.3.0 and later.
User Manual 2 - 123
SIMULIA
Tosca Structure
Design Responses
Fig. 75
Design response SIG_TOPO_MISES
Fig. 76
Design response using SIG_Topo_Mises
Command in Parameter file

The design response for stresses for topology optimization is defined as follows:
DRESP
ID_NAME
TYPE
DEF_TYPE
EL_GROUP
LC_SET
END_
2 - 124 User Manual
=
=
=
=
=
TOPO_STRESS_DESIGN_ELEMENTS
SIG_TOPO_MISES
SYSTEM
<element_group>
<loadcases>
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Add a design response to the project first, then chose Stress/Strain as Category and SIG_Topo_Mises as Response Type.
SIMULIA
Tosca Structure
The design response for stresses is applied in the objective function as the
following:
OBJ_FUNC
ID_NAME = OBJ_FUNCTION_ID
DRESP
= SIG_TOPO_MISES,<weight_fact_1>, <ref_stress_1>
...........
TARGET = MIN
END_
4.4.8.2 Example: Stresses in constraint definition

Define a constraint on the Maximum von Mises stress. For a typical optimization task see chapter 5.6.7 Minimize the material volume with stress constraint.
Not yet available with Tosca ANSA environment 13.2.x. Stresses as design
responses are only supported for ANSA version 13.3.0 and later.
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Fig. 77
Design response SIG_TOPO_MISES

Set up a design response first with Stress/Strain as Category and
SIG_Topo_Mises as Response Type. Then add a constraint to the project
User Manual 2 - 125
SIMULIA
Tosca Structure
Design Responses
and select the perviously defined von Mises stress design response, set Type
to Absolute, Category to Less or equal and set the desired value.
Fig. 78
Using SIG_Topo_Mises design response in a constraint
Command in Parameter file

The design response for stresses for topology optimization is defined as the
following:
DRESP
ID_NAME
TYPE
DEF_TYPE
EL_GROUP
LC_SET
=
=
=
=
=
SIG_TOPO_MISES
SYSTEM
<element_group>
<loadcases>
END_
The constraint is then defined as:

CONSTRAINT
=
=
=
=
STRESS_CONSTRAINT
ABS
<stress constraint>
END_
Remarks
1. Each design response definition of type SIG_TOPO_MISES may only be
applied once in either the objective or constraint definition. If stresses
should be considered both in constraint or the objective (or several
stresses should be combined) for each use one separate design response
has to be defined.
2. Different optimization settings (STRESS_DRESP_OPT = ON) are applied for
updating the design variables (=relative densities) when DRESP is TYPE =
SIG_TOPO_MISES.
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ID_NAME
DRESP
MAGNITUDE
LE_VALUE
SIMULIA
Tosca Structure
When the stresses are applied as design response (DRESP) in a topology

optimization formulation the following default settings are modified:
The move limit (DENSITY_MOVE = 0.10 in OPT_PARAM) on the
design variables is decreased from 0.25 to 0.10.
The maximal number of optimization iterations (ITER_MAX = 80 in
STOP) is increased from 50 to 80.
3. The default settings are overwritten by setting STRESS_DRESP_OPT=OFF,
e.g.
OPT_PARAM
......
STRESS_DRESP_OPT = OFF
DENSITY_MOVE = 0.15
DENSITY_UPDATE = CONSERVATIVE
......
END_
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4.4.9
Center of gravity
CENTER_GRAVITY_X
x dV
x G = ---------------- dV
CENTER_GRAVITY_Y
y dV
y G = ---------------- dV
CENTER_GRAVITY_Z
xz dV
z G = ------------------- dV
Analysis independent design response
TOPO
OBJ_FUNC
SHAPE
BEAD
SIZING
User Manual 2 - 127
SIMULIA
Tosca Structure
Design Responses
TOPO
CONSTRAINT
Table 16
SHAPE
BEAD
SIZING
Center of gravity (C = controller, S = sensitivity)
Fig. 79
2 - 128 User Manual
The center of gravity and the moments of inertia can be calculated in the global coordinate system or/and a user defined local
Cartesian coordinate system. The calculation in the local coordinate system involves both a translation of the origin and a rotation of the coordinate system.
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The center of gravity for the three directions is defined by

CENTER_GRAVITY_X, CENTER_GRAVITY_Y and CENTER_GRAVITY_Z,
respectively. The center of gravity and the moments of inertia can be defined
as a DRESP (design response) and as a VARIABLE in the sensitivity based
topology, bead and sizing optimization. For shape optimization the center of
gravity and the moments of inertia can only be defined as a VARIABLE which
means that the values can only be used for output or control purposes.
Both the center of gravity and the moments of inertia can be defined as a
design response for the entire structure or for a part of the entire structure,
e.g. some specific components. This is done using the command
EL_GROUP.
The center of gravity and the moments of inertia are per default calculated in
the global coordinate system. However, the user has the option to calculate
the center of gravity and the moments of inertia in a local coordinate system.
The local coordinate system is defined in the design response using the command CS_REF. For the calculation of the center of gravity both the directions
and origin of the local coordinate system is used as reference whereas for the
moments of inertia the directions of the axes of the local coordinate system is
applied, see figure Fig. 79. The global coordinate system is applied if no local
coordinate system is defined in the design response (DRESP). The volume
for which the center of gravity is calculated is defined using EL_GROUP.
SIMULIA
Tosca Structure
Remarks
1. Only elements of the element group (EL_GROUP) listed in the tables of
supported element types (chapter 11 Solver Specific Features) will be
applied in the calculation of center of gravity.
2. The physical density defined in finite element input deck will be used in the
calculation for the center of gravity.
3. The moments of inertia for shell and membrane elements are calculated as
true 3D elements in Tosca Structure using the thickness defined in the
properties of the shell and membrane elements in the finite element deck.
Some finite element solvers and postprocessors calculate the moments of
inertia for shell and membrane elements as 2D elements without thickness.
calculation for the center of gravity and in the calculation for the moments
of inertia.
5. Internally, Tosca Structure calculates the center of gravity and the moments
of inertia using more digits than can be observed in the finite element input
deck. A slight difference (<1%) between the center of gravity and the
moments of inertia calculated using Tosca Structure and the finite element
solver might be present.
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6. When Tosca Structure calculates the center of gravity and the moments of
inertia only the elements shown in the tables of supported element types
(chapter 11 Solver Specific Features) are included in the calculation. This
might lead to a significant difference between the center of gravity and the
moments of inertia calculated by Tosca Structure and the center of gravity
and the moments of inertia calculated by the finite element solver, e.g. if
several beam elements are included in the calculation of the center of
gravity and the moments of inertia.
7. The coordinate system for the center of gravity and the moments of inertia
is always interpreted as a Cartesian (rectangular) coordinate system, even
if a cylindrical or spherical coordinate system was defined. To get close to a
non-Cartesian coordinate system you can define adequate "box
constraints" using several constraints (e.g. in x- and y-direction for a cylindrical coordinate system).
Definition
The design response (DRESP) for the center of gravity in the x-direction is
defined like
DRESP
User Manual 2 - 129
SIMULIA
Tosca Structure
Design Responses
ID_NAME
DEF_TYPE
TYPE
EL_GROUP
CS_REF
=
=
=
=
=
...
SYSTEM
CENTER_GRAVITY_X
...
...
END_
where the local coordinate definition (CS_REF) is optional. Default is global

coordinate system.
The design response (DRESP) for the center of gravity in the y-direction is
defined like
DRESP
ID_NAME
DEF_TYPE
TYPE
EL_GROUP
CS_REF
=
=
=
=
=
...
SYSTEM
CENTER_GRAVITY_Y
...
...
END_

coordinate system.
The design response (DRESP) for the center of gravity in the z-direction is
defined like
DRESP
=
=
=
=
=
...
SYSTEM
CENTER_GRAVITY_Z
...
...
END_

coordinate system.
Examples of commands for center of gravity
E.g. the design response (DRESP) for the center of gravity for the y-direction
of the entire structure (ALL_ELEMENTS) calculated in the global coordinate
system is defined like
DRESP
ID_NAME
DEF_TYPE
TYPE
2 - 130 User Manual
= DRESP_COG_Y_GLOBAL
= SYSTEM
= CENTER_GRAVITY_Y
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ID_NAME
DEF_TYPE
TYPE
EL_GROUP
CS_REF
SIMULIA
Tosca Structure
EL_GROUP
= ALL_ELEMENTS
END_
E.g., the definition of the design response (DRESP) for the center of gravity
for the y-direction of the substructure called EL_GROUP_2 is calculated in
the local coordinate system number 23 like the following:
DRESP
ID_NAME
DEF_TYPE
TYPE
EL_GROUP
CS_REF
=
=
=
=
=
DRESP_COG_X
SYSTEM
CENTER_GRAVITY_X
EL_GROUP_2
CS_23
END_
4.4.10 Moment of inertia

INERTIA_XX
INERTIA_YY
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INERTIA_ZZ
Ix =
( y2 + z2 ) dV
Iy =
( x2 + z2 ) dV
Iz =
( x2 + y2 ) dV
INERTIA_XY
I xy = I yx = xy dV
INERTIA_XZ
I xz = I zx = xz dV
INERTIA_YZ
I yz = I zy = yz dV
TOPO
OBJ_FUNC
SHAPE
BEAD
SIZING
User Manual 2 - 131
SIMULIA
Tosca Structure
Design Responses
TOPO
CONSTRAINT
Table 17
SHAPE
BEAD
SIZING
Moments of inertia (C = controller, S = sensitivity)
The moments of inertia can be applied as DRESP (topology, sizing and bead
optimization) and as VARIABLE (topology, sizing, shape and bead optimization). The moments of inertia are defined using INERTIA_XX, INERTIA_XY
(INERTIA_YX), INERTIA_XZ (INERTIA_ZX), INERTIA_YY, INERTIA_YZ
(INERTIA_ZY) and INERTIA_ZZ, respectively.
Mathematically, the moments of inertia about the origin of the coordinate system are given by the above integrals which can be calculated in a global or a
local coordinate system as shown in Fig. 79. The local coordinate system is
defined using CS_REF. The volume for which the moments of inertia are calculated is defined using EL_GROUP.
Remarks
1. Only the elements of the element group (EL_GROUP) listed in the tables of
supported element types (chapter 11 Solver Specific Features) will be
applied in the calculation of moments of inertia.
2. The product of inertia with respect to any two orthogonal axes is zero if
either of the axes is an axis of symmetry.
calculation of the moments of inertia.
DRESP
ID_NAME
DEF_TYPE
TYPE
EL_GROUP
CS_REF
=
=
=
=
=
...
SYSTEM
INERTIA_XX
...
...
END_
The design response (DRESP) for the moment of inertia about the line
through the origin, parallel to the Y-axis is defined like
DRESP
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through the origin, parallel to the X-axis is defined like
SIMULIA
Tosca Structure
ID_NAME
DEF_TYPE
TYPE
EL_GROUP
CS_REF
=
=
=
=
=
...
SYSTEM
INERTIA_YY
...
...
END_
through the origin, parallel to the Z-axis is defined like
DRESP
ID_NAME
DEF_TYPE
TYPE
EL_GROUP
CS_REF
=
=
=
=
=
...
SYSTEM
INERTIA_ZZ
...
...
END_
The design response (DRESP) for the moment of inertia describing the coupling between the rotation parallel to the X-axis and the rotation parallel to the
Y-axis yields
DRESP
ID_NAME
DEF_TYPE
TYPE
EL_GROUP
CS_REF
= ...
= SYSTEM
= INERTIA_XY
(Alternatively, TYPE =INERTIA_YX)
= ...
= ...
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END_
The design response (DRESP) for the moment of inertia describing the coupling between the rotation parallel to the X-axis and the rotation parallel to the
Z-axis yields
DRESP
ID_NAME
DEF_TYPE
TYPE
EL_GROUP
CS_REF
= ...
= SYSTEM
= INERTIA_XZ
(Alternatively, TYPE = INERTIA_ZX)
= ...
= ...
END_
User Manual 2 - 133
SIMULIA
Tosca Structure
Design Responses
The design response (DRESP) for the moment of inertia describing the coupling between the rotation parallel to the Y-axis and the rotation parallel to the
Z-axis yields
DRESP
ID_NAME
DEF_TYPE
TYPE
EL_GROUP
CS_REF
= ...
= SYSTEM
= INERTIA_YZ
(Alternatively, TYPE = INERTIA_YZ)
= ...
= ...
END_
Examples of commands
E.g. the design response (DRESP) for the moment of inertia of the entire
structure (ALL_ELEMENTS) about the line through the origin of the global
coordinate system, parallel to the Y-axis is defined like
DRESP
ID_NAME
DEF_TYPE
TYPE
EL_GROUP
=
=
=
=
DRESP_INERTIA_YY_GLOBAL
SYSTEM
INERTIA_YY
ALL_ELEMENTS
END_
DRESP
ID_NAME
DEF_TYPE
TYPE
EL_GROUP
CS_REF
END_
2 - 134 User Manual
=
=
=
=
=
DRESP_INERTIA_YY_LOCAL
SYSTEM
CENTER_GRAVITY_X
EL_GROUP_2
CS_23
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E.g. The definition of the design response (DRESP) for the moment of inertia
of the substructure called EL_GROUP_2 is calculated about the line through
the origin of the local coordinate system number 23, parallel to the Y-axis is
like the following
SIMULIA
Tosca Structure
4.4.11 Volume
VOLUME
Ve
where V e is the element volume. For topology optimization design elements

are scaled with the current relative density.
TOPO
OBJ_FUNC
CONSTRAINT
Table 18
SHAPE
BEAD
S
C, S
SIZING
S
Volume (C = controller, S = sensitivity)
For standard optimization problems the volume constraint is necessary, e.g. if

the topology optimization is used in order to minimize the compliance (thus to
maximize the stiffness) and no volume constraint is used, the optimizer simply fills up the whole design area with material.
4.4.11.1 Volume design response example

Define the volume design response for the element group DESIGN_ELEMS.
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Apply New | VOLUME on OBJ_FUNC_ITEM_1 or CONSTRAINTS.
User Manual 2 - 135
SIMULIA
Tosca Structure
Design Responses
Using this dialog, a volume constraint is defined. Note that MAGNITUDE =

REL should be chosen.
This defines the design response of the type VOLUME.

Fig. 80
2 - 136 User Manual
Design response setup for Volume
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In Tosca Extension for ANSYS/WB a Named Selection is used instead of an

element group. This predefined selection can be called later during an optimization setup.
Add a design response to the project, select Base as Category and Volume
as Response Type. Then choose the predefined Named Selection by setting
Scoping Method to Named Selection.
SIMULIA
Tosca Structure

DRESP
ID_NAME
DEF_TYPE
TYPE
EL_GROUP
GROUP_OPER
END_
=
=
=
=
=
volume
SYSTEM
VOLUME
DESIGN_ELEMS
Sum
4.4.12 Weight
WEIGHT
we
where w e is the element weight. For topology optimization design elements

are scaled with the current relative density.
TOPO
OBJ_FUNC
CONSTRAINT
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Table 19
SHAPE
BEAD
SIZING
S
Weight (C = controller, S = sensitivity)
The weight term is the same as the volume term except you have the possibility of constraining your optimization result to have a certain physical weight.
Tosca Structure requires that the density of all elements is defined in the input
deck. Additionally, only supported element types are used in the weight calculation.
4.4.12.1 Example of a weight design response

Definition of a weight design response
DESIGN_ELEMS and constraining it to 100 Kg.
for
the
element
group
User Manual 2 - 137
SIMULIA
Tosca Structure
Design Responses

Apply New | WEIGHT on OBJ_FUNC_ITEM_1 or CONSTRAINTS.
Using this dialog, a weight constraint is defined. Note that MAGNITUDE =

ABS should be chosen.
This defines the design response of the type WEIGHT.

In Tosca Extension for ANSYS/WB a Named Selection is used instead of an
element group. This predefined selection can be called later during an optimization setup.
2 - 138 User Manual
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Tosca Structure
Add a design response to the project, select Base as Category and Weight as
Response Type. Then choose the predefined Named Selection by setting
Scoping Method to Named Selection.
Fig. 81
Design response setup for Weight

DRESP
ID_NAME
DEF_TYPE
TYPE
EL_GROUP
GROUP_OPER
END_
=
=
=
=
=
weight
SYSTEM
WEIGHT
DESIGN_ELEMS
Sum
4.4.13 DENSITY_MEASURE
DENSITY_MEASURE
4
------------------Volume
Volume
Nel
4
( 1 ) dv --------
( 1 e )
N el e = 1 e
where e is the relative density in each element of the given user defined
element group and N el is the number of elements in the defined element
group, respectively.
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The DRESP DENSITY_MEASURE is defined in the following way:
User Manual 2 - 139
SIMULIA
Tosca Structure
Design Responses

TOPO
OBJ_FUNC
CONSTRAINT
Table 20
SHAPE
BEAD
SIZING
Density measure (C = controller, S = sensitivity)
The DRESP named DENSITY_MEASURE can be applied for measuring the

amount of intermediate densities. The DENSITY_MEASURE can be used in
the OBJ_FUNC or CONSTRAINT for minimizing and surpassing the number of
elements containing intermediate densities. This design response can be
used for additional penalization of intermediate elements and thereby, obtain
more clearly defined solid/void conceptual designs.
DENSITY_MEASURE is aimed at advanced dynamic applications like modal
eigenfrequency analysis and frequency response analysis.
value of DENSITY MEASURE
0.5
1.0
1.0
0.0
min
4 min ( 1 min ) 4 min
DRESP DENSITY_MEASURE yields the value 1.0 for the intermediate density
0.5 of all elements.
DRESP DENSITY_MEASURE yields the value 0.0 for the intermediate density
1.0 of all elements.
DRESP DENSITY_MEASURE yields the value 4 min ( 1 min ) 4 min for the
intermediate minimum density min of all elements.
Fig. 82
2 - 140 User Manual
DRESP_DENSITY_MEASURE depending on element density

(all elements having the same intermediate density).
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intermediate density of all elements
SIMULIA
Tosca Structure

The DRESP DENSITY_MEASURE is defined in the following way:
DRESP
ID_NAME
= DRESP_ DENSITY_MEASURE
DEF_TYPE
= SYSTEM
TYPE
= DENSITY_MEASURE
EL_GROUP
=
GROUP_OPER = SUM
END_
The DRESP DENSITY_MEASURE can then be applied in the objective function

or in the constraint in the following way:
OBJ_FUNC
ID_NAME = DENSITY_MEASURE_OBJ
DRESP
=
DRESP
= _ DENSITY_MEASURE, <weighting_factor>
TARGET
= MIN
END_
Or
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CONSTRAINT
ID_NAME
= DENSITY_MEASURE_constraint
DRESP
= DRESP_ DENSITY_MEASURE
MAGNITUDE = ABS
LE_VALUE
= 0.05
END_
REMARKS
1. The DRESP DENSITY_MEASURE is only for advanced applications. In
particular, it is aimed at advanced dynamic applications like modal eigenfrequency analysis and frequency response analysis
2. The weighting factor has to be carefully chosen when applying the DRESP
DENSITY_MEASURE in the objective function. Otherwise, only one of the
objective terms would be optimized.
User Manual 2 - 141
SIMULIA
Tosca Structure
Design Responses
3. The constraint value has to be carefully chosen when applying the DRESP
DENSITY_MEASURE as constraint. Otherwise, there might be no feasible
solution.
4. The constraint value for DRESP DENSITY_MEASURE cannot be lower than
4 minimum density (DENSITY_LOWER) which is default
4 0.001 ( 1 0.001 ) 0.004 .
5. Normally, the DRESP DENSITY_MEASURE yields a significant higher
number of optimization iterations.
4.4.14 Bead height

BEAD_HEIGHT
TOPO
SHAPE
BEAD
SIZING
OBJ_FUNC
CONSTRAINT
Bead height. (C = controller, S = sensitivity)

Only for controller based bead optimization
(BEAD_CONTROLLER).
The height of the bead stiffeners is formulated as a constraint of the controller

based optimization problem. The bead height is initially zero for all nodes and
the optimizer moves the nodes in the shell normal direction until they reach
the bead height.
The bead height is defined via the DRESP command which is then referenced in the CONSTRAINT command. A typical bead height constraint could
be defined as follows:
DRESP
ID_NAME
DEF_TYPE
ND_GROUP
TYPE
GROUP_OPER
END_
2 - 142 User Manual
=
=
=
=
=
DRESP_BEAD_HEIGHT
SYSTEM
DESIGN_NODES
BEAD_HEIGHT
MAX
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Table 21
SIMULIA
Tosca Structure
CONSTRAINT
ID_NAME
DRESP
MAGNITUDE
EQ_VALUE
END_
4.5
=
=
=
=
bead_height
dresp_bead_height
ABS
10.
Combined Terms
For getting the scalar value of a design response or a variable it is necessary
to combine values derived from model properties or analysis results. This
could be done getting the maximum or minimum value within a number of
load cases or a number of group entities or creating response combinations
like relative values, differences or mean values. In Tosca Structure combination of values can be performed in several ways:
1. The simplest way to combine terms is using a weighted sum for the objective function, or using a MINMAX formulation with the different weighting of
the design responses. See chapter 4.2 Objective Function for more information.
www.3ds.com/tosca
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2. Combining terms may also be done using an operator - a special design

response (DRESP) of the DEF_TYPE = OPER. This should only be done
with caution to avoid meaningless optimization tasks. You must also be
aware of the difference in the way sensitivity and controller based algorithms handle the operator.
Note that for weighted sums you may as well use the formulations used in
chapter 4.2 Objective Function.
3. Values of one type from several load cases can be combined directly using
load case selection and weighting for the design response (command
DRESP, item LC_SET).
4. Values of one type at several locations (nodes, elements) in the model can
in general be combined directly using group operations for the design
response (DRESP item GROUP_OPER).
Remark:
If several of these possibilities to combine values are applied, Tosca Structure
operates as follows:
1. First the value over all entities of the group for one load case is calculated.
This means that a loop over all entities of the group is executed and then
the value of the inner loop is calculated with the operator specified in
User Manual 2 - 143
SIMULIA
Tosca Structure
Combined Terms
GROUP_OPER parameter. If the operator is not defined by the user, a

default one will be used.
2. Second this value (already combined for the group entities) is calculated
for the different load cases specified in the LC_SET parameter. If no
LC_SET parameter is present, then all load cases and sub-steps (frequencies) will be used to determine the value.
3. Combination of design responses by operators is applied next.
4. Finally, the combination of design responses in the objective function is
applied.
4.5.1
Group operations for design responses

For extracting one scalar value from a field of analysis results for a number of
group entities into one design response it is necessary to combine these
results using an operator GROUP_OPER:
DRESP
ID_NAME
DEF_TYPE
TYPE
UPDATE
ND_GROUP
EL_GROUP
GROUP_OPER
=
=
=
=
= <group_entities_for_combination>
= <group_entities_for_combination>
= MAX | MIN | SUM | COUNT
END_
The following group operators exist:

MIN: extracts the minimum value within the group
SUM: sums up all values of the entities of the group

COUNT: counts the number of entities of the group (cannot be used for the
design response, only applicable for variables)
For the different types of terms, default settings for the operator exist. For all
displacement, forces, stresses, strains and other nodal values, the default
operator is MAX.
For all element related entities (except the stresses and strains) the default
operator is SUM.
Remarks:
1. It is recommended that the user specifies the operator directly in order to
make sure that the correct settings are used.
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MAX: extracts the maximum value within the group
SIMULIA
Tosca Structure
2. In Tosca ANSA environment, the operator can only be changed using the
commands from Module Buttons toolbar that deal with design responses
(variables).
3. Maximal 500 design responses are allowed. Therefore, the maximal
number of nodes for GROUP_OPER = MAX is restricted to 500, as internally there is created one design response for each node.
4. For sensitivity based optimization the objective function built from design
responses combining several entities (nodes) will be replaced by a subsitute expression built from the single design responses. For TARGET=MAX
this means that the sum of the single design responses is optimized. For
an example see chapter 4.5.1.3 Group Operations for Displacements.
5. Not all group operators make sense for all kind of design responses. An
overview which group operators are admitted for specific design responses
can be found in chapter 4.5.3 Design response combination.
4.5.1.1 Group Operations for Stresses

For a standard shape optimization definition, the maximum stress over all
load cases is selected within the design nodes as follows:
DRESP
ID_NAME
DEF_TYPE
TYPE
UPDATE
ND_GROUP
GROUP_OPER
=
=
=
=
=
=
DRESP_MAX_MISES
SYSTEM
SIG_MISES
EVER
DESIGN_NODES
MAX
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END_
4.5.1.2 Group Operations for Stiffness

For the standard topology optimization task the stiffness/compliance is
defined as the sum of the strain energy for all elements in the model. If more
than one load case is defined, the overall stiffness is then the sum of the stiffness of the referenced load cases. This can be defined as:
DRESP
ID_NAME
DEF_TYPE
TYPE
UPDATE
EL_GROUP
=
=
=
=
=
DRESP_SUM_ENERGY
SYSTEM
STRAIN_ENERGY
EVER
ALL_ELEMENTS
User Manual 2 - 145
SIMULIA
Tosca Structure
Combined Terms
GROUP_OPER
= SUM
END_
4.5.1.3 Group Operations for Displacements

The picture at Fig. 83 shows a structure loaded at the nodes 15, 16 and 17.
The y-displacement of these three nodes should be minimized or applied in a
set of constraints.
Fig. 83
A structure loaded with three loads in the nodes 15, 16 and 17,
respectively. The displacements of the three nodes should be
minimized or applied in a set of constraints using
GROUP_OPER=MAX or GROUP_OPER=SUM.
Use in Objective Function

Initially, a node group is defined containing the nodes 15, 16 and 17 (see Fig.
83) yielding
ID_NAME
TYPE
FORMAT
LIST_BEGIN
15, 16, 17
= DISP_NODES
= NODE
= LIST
END_
GROUP_OPER = MAX
Based upon the node group a design response for the displacements in ydirections are defined in a DRESP using GROUP_OPER=MAX yielding
DRESP
ID_NAME
DEF_TYPE
2 - 146 User Manual
= DRESP_DISP_MAX
= SYSTEM
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GROUP_DEF
SIMULIA
Tosca Structure
TYPE
LC_SET
ND_GROUP
GROUP_OPER
=
=
=
=
DISP_Y
STATIC,1,
DISP_NODES
MAX
END_
Internally, Tosca Structure generates three DRESPs. One DRESP for the displacement of node 15, one DRESP for the displacement of node 16 and one
DRESP for the displacement of node 17.
If one then applies the DRESP in the objective yielding:
OBJ_FUNC
ID_NAME
DRESP
TARGET
= MIN_DISP_MAX
= DRESP_DISP_MAX
= MIN
END_
Tosca Structure then sums up the three displacements like the following:
minimize { 0 } = minimize { u 15 + u 16 + u 17 }
Remark:
If you want to minimize the maximum of the three displacements you need to
define an objective function with target MIN_MAX operating on three design
responses (one for each node).
minimize { 0 } = max { u 15 ;u 16 ;u 17 }
GROUP_OPER = SUM
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Based upon the node group a design response for the displacements in ydirections are defined in a DRESP using GROUP_OPER=SUM yielding
DRESP
ID_NAME
DEF_TYPE
TYPE
LC_SET
ND_GROUP
GROUP_OPER
END_
=
=
=
=
=
=
DRESP_DISP_SUM
SYSTEM
DISP_Y
STATIC,1,
DISP_NODES
SUM
Internally, Tosca Structure generates one DRESP consisting of the sum of the
displacements of the nodes 15, 16 and 17.
If one then applies the DRESP in the objective yielding:
User Manual 2 - 147
SIMULIA
Tosca Structure
Combined Terms
OBJ_FUNC
ID_NAME
DRESP
TARGET
END_
= MIN_DISP_SUM
= DRESP_DISP_SUM
= MIN
Tosca Structure then sum up the three displacements like the following;
Alternative definition of objective function
Alternatively, one could also define three DRESPs for each node like the following:
DRESP
ID_NAME
DEF_TYPE
TYPE
NODE
LC_SET
GROUP_OPER
=
=
=
=
=
=
DRESP_DISP_1
SYSTEM
DISP_Y
15
STATIC,1
MAX or SUM
=
=
=
=
=
=
DRESP_DISP_2
SYSTEM
DISP_Y
16
STATIC,1
MAX or SUM
=
=
=
=
=
=
DRESP_DISP_3
SYSTEM
DISP_Y
17
STATIC,1
MAX or SUM
END_
DRESP
ID_NAME
DEF_TYPE
TYPE
NODE
LC_SET
GROUP_OPER
END_
ID_NAME
DEF_TYPE
TYPE
NODE
LC_SET
GROUP_OPER
END_
And then add the three design response in the objective function:
OBJ_FUNC
ID_NAME
DRESP
DRESP
2 - 148 User Manual
= MIN_DISP_SUM
= DRESP_DISP_1
= DRESP_DISP_2
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DRESP
SIMULIA
Tosca Structure
DRESP
TARGET
= DRESP_DISP_3
= MIN
END_
Meaning that the objective function minimizes the following;
Remark:
Consequently, it can be concluded that all three ways of defining the optimization leads to the same objective function. In this case it is strongly recommended to combine the displacements using GROUP_OPER = SUM which
results in a much better performance.
Use in Constraints
83) yielding
GROUP_DEF
ID_NAME
TYPE
FORMAT
LIST_BEGIN
15, 16, 17
= DISP_NODES
= NODE
= LIST
END_
GROUP_OPER = MAX
Based upon the node group a design response for the displacements in ydirections are defined in a DRESP using GROUP_OPER=MAX yielding
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DRESP
ID_NAME
DEF_TYPE
TYPE
LC_SET
ND_GROUP
GROUP_OPER
=
=
=
=
=
=
DRESP_DISP_MAX
SYSTEM
DISP_Y
STATIC,1,
DISP_NODES
MAX
END_
Internally, Tosca Structure generates three DRESPs. One DRESP for the displacement of node 15, one DRESP for the displacement of node 16 and one
DRESP for the displacement of node 17.
If one then applies the DRESP in a constraint yielding:
CONSTRAINT
ID_NAME
DRESP
= CONSTRAINT_MAX
= DRESP_DISP_MAX
User Manual 2 - 149
SIMULIA
Tosca Structure
Combined Terms
MAGNITUDE
LE_VALUE
END_
= ABS
= <value>
Tosca Structure then generates three displacement constraints like the following;
u 15 u
u 16 u
u 17 u
GROUP_OPER = SUM
Based upon the node group a design response for the displacements in ydirections are defined in a DRESP using GROUP_OPER=SUM yielding
DRESP
ID_NAME
DEF_TYPE
TYPE
LC_SET
ND_GROUP
GROUP_MAX
END_
=
=
=
=
=
=
DRESP_DISP_SUM
SYSTEM
DISP_Y
STATIC,1,
DISP_NODES
SUM
displacements of the nodes 15, 16 and 17.
CONSTRAINT
ID_NAME
DRESP
MAGNITUDE
LE_VALUE
END_
=
=
=
=
CONSTRAINT_MAX
DRESP_DISP_MAX
ABS
<value>
Tosca Structure then generates a single displacement constraint like the following;
u 15 + u 16 + u 17 u
2 - 150 User Manual
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Tosca Structure
Alternative definition of constraints

DRESP
ID_NAME
DEF_TYPE
TYPE
NODE
LC_SET
GROUP_OPER
END_
=
=
=
=
=
=
DRESP_DISP_1
SYSTEM
DISP_Y
15
STATIC,1
MAX or SUM
=
=
=
=
=
=
DRESP_DISP_2
SYSTEM
DISP_Y
16
STATIC,1
MAX or SUM
=
=
=
=
=
=
DRESP_DISP_3
SYSTEM
DISP_Y
17
STATIC,1
MAX or SUM
DRESP
ID_NAME
DEF_TYPE
TYPE
NODE
LC_SET
GROUP_OPER
END_
DRESP
ID_NAME
DEF_TYPE
TYPE
NODE
LC_SET
GROUP_OPER
END_
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And then add the three design response in three constraints:

CONSTRAINT
ID_NAME
DRESP
MAGNITUDE
LE_VALUE
END_
CONSTRAINT
ID_NAME
DRESP
MAGNITUDE
LE_VALUE
END_
CONSTRAINT
ID_NAME
DRESP
=
=
=
=
CONSTRAINT_1
DRESP_DISP_1
ABS
<value>
=
=
=
=
CONSTRAINT_2
DRESP_DISP_2
ABS
<value>
= CONSTRAINT_3
= DRESP_DISP_3
User Manual 2 - 151
SIMULIA
Tosca Structure
Combined Terms
MAGNITUDE
LE_VALUE
END_
= ABS
= <value>
Tosca Structure then generates three displacement constraints like the following;
u 15 u
u 16 u
u 17 u
Consequently, it can be concluded that there is fundamental difference in the

constraints if a node group (ND_GROUP) consisting of more than one node
is applied and the choice of GROUP_OPER.
4.5.1.4 Group operations for reaction forces/moments

Group operations for reaction forces
The structure for defining a DRESP for reaction forces(s) or reaction
moment(s):
DRESP
=
=
=
=
=
=
=
.....
SYSTEM
.....
MAX or SUM
.....or use the NODE-definition
.....or use the ND_GROUP-definition
.....
END_
1. GROUP_OPER is default GROUP_OPER = MAX.

2. Other options of MAX and SUM are invalid.
3. A node group (ND_GROUP) has to be applied in the DRESP when more
than one node is required.
4. Maximal 500 DRESPs can be defined. Therefore, the maximal number of
nodes for GROUP_OPER = MAX is 500 or less as for each group member a
design response is created.
5. The maximal number of nodes for GROUP_OPER = SUM is unlimited.
6. GROUP_OPER = SUM is not allowed for absolute values.
2 - 152 User Manual
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ID_NAME
DEF_TYPE
TYPE
GROUP_OPER
ND_GROUP
NODE
LC_SEL
SIMULIA
Tosca Structure
The picture at Fig. 84 shows a structure where the reaction forces in the ydirection of the three nodes 31, 32, 33 should be applied in a set of constraints.
Fig. 84
A structure loaded with three loads. The reaction forces of the

three nodes 31, 32 and 33 should be applied in a set of constraints using GROUP_OPER=MAX or GROUP_OPER=SUM.
Use in Constraints
84) yielding
GROUP_DEF
ID_NAME
TYPE
FORMAT
LIST_BEGIN
31, 32, 33
= REAC_NODES
= NODE
= LIST
END_
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GROUP_OPER = MAX
Based upon the node group a design response for the reaction force in ydirections are defined in a DRESP using GROUP_OPER=MAX yielding
DRESP
ID_NAME
DEF_TYPE
TYPE
LC_SET
ND_GROUP
GROUP_OPER
=
=
=
=
=
=
DRESP_REAC_MAX
SYSTEM
REACTION_FORCE_Y
STATIC,1,
REAC_NODES
MAX
END_
User Manual 2 - 153
SIMULIA
Tosca Structure
Combined Terms
Internally, Tosca Structure generates three DRESPs. One DRESP for the
reaction force of node 31, one DRESP for the reaction force of node 32 and
one DRESP for the reaction force of node 33.
CONSTRAINT
ID_NAME
DRESP
MAGNITUDE
LE_VALUE
END_
=
=
=
=
CONSTRAINT_MAX
DRESP_REAC_MAX
ABS
<value>
Tosca Structure then generates three reaction force constraints like the following;
R 31 R*
R 32 R*
R 33 R*
GROUP_OPER = SUM
Based upon the node group a design response for the reaction force in ydirections are defined in a DRESP using GROUP_OPER=SUM yielding
=
=
=
=
=
=
DRESP_REAC_SUM
SYSTEM
REACTION_FORCE_Y
STATIC,1,
REAC_NODES
SUM
reaction forces of the nodes 31, 32 and 33.
CONSTRAINT
ID_NAME
DRESP
MAGNITUDE
LE_VALUE
END_
=
=
=
=
CONSTRAINT_MAX
DRESP_REAC_MAX
ABS
<value>
Tosca Structure then generates a single reaction force constraint like the following;
R 31 + R 32 + R 33 R*
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DRESP
ID_NAME
DEF_TYPE
TYPE
LC_SET
ND_GROUP
GROUP_OPER
END_
SIMULIA
Tosca Structure
Alternative definition of constraints function

DRESP
ID_NAME
DEF_TYPE
TYPE
NODE
LC_SET
GROUP_OPER
END_
=
=
=
=
=
=
DRESP_REAC_1
SYSTEM
REACTION_FORCE_Y
31
STATIC,1
MAX or SUM
=
=
=
=
=
=
DRESP_REAC_2
SYSTEM
REACTION_FORCE_Y
32
STATIC,1
MAX or SUM
=
=
=
=
=
=
DRESP_REAC_3
SYSTEM
REACTION_FORCE_Y
33
STATIC,1
MAX or SUM
DRESP
ID_NAME
DEF_TYPE
TYPE
NODE
LC_SET
GROUP_OPER
END_
DRESP
ID_NAME
DEF_TYPE
TYPE
NODE
LC_SET
GROUP_OPER
END_
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And then add the three design response in three constraints:

CONSTRAINT
ID_NAME
DRESP
MAGNITUDE
LE_VALUE
END_
CONSTRAINT
ID_NAME
DRESP
MAGNITUDE
LE_VALUE
END_
CONSTRAINT
ID_NAME
DRESP
=
=
=
=
CONSTRAINT_1
DRESP_REAC_1
ABS
<value>
=
=
=
=
CONSTRAINT_2
DRESP_REAC_2
ABS
<value>
= CONSTRAINT_3
= DRESP_REAC_3
User Manual 2 - 155
SIMULIA
Tosca Structure
Combined Terms
MAGNITUDE
LE_VALUE
END_
= ABS
= <value>
Tosca Structure then generates three reaction force constraints like the following;
R 31 R*
R 32 R*
R 33 R*
4.5.1.5 Group Operations for Internal Forces
Fig. 85
A structure loaded with three loads. The internal forces of the two
nodes 65 and 66 and elements 33, 34, 37 and 38 should be
applied in a set of constraints using GROUP_OPER=MAX or
GROUP_OPER=SUM.
Use in Constraints
Initially, a node group is defined containing the nodes 65 and 66 (see Fig. 85)
yielding
GROUP_DEF
ID_NAME
TYPE
FORMAT
LIST_BEGIN
2 - 156 User Manual
= FORCE_NODES
= NODE
= LIST
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The picture at Fig. 85 shows a structure where the internal forces in the ydirection of the two nodes 65 and 66 for elements 33, 34, 37 and 38 should
be applied in a set of constraints.
SIMULIA
Tosca Structure
65, 66
END_
and a element group is defined containing the elements 33, 34, 37 and 38
(see Fig. 85) yielding
GROUP_DEF
ID_NAME
= FORCE_ELEM
TYPE
= ELEM
FORMAT
= LIST
LIST_BEGIN
33, 34, 37, 38
END_
GROUP_OPER = MAX
Based upon the node group and the element group a design response for the
internal force in y-directions are defined in a DRESP using
GROUP_OPER=MAX yielding
DRESP
ID_NAME
DEF_TYPE
TYPE
LC_SET
ND_GROUP
EL_GROUP
GROUP_OPER
=
=
=
=
=
=
=
DRESP_FORCE_MAX
SYSTEM
INTERNAL_FORCE_Y
STATIC,1,
FORCE_NODES
FORCE_ELEM
MAX
END_
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Internally, Tosca Structure generates two DRESPs. One DRESP for the internal force of node 65 for element 33 and 34, and one DRESP for the internal
force of node 66 for element 37 and 38.
CONSTRAINT
ID_NAME
DRESP
MAGNITUDE
LE_VALUE
END_
=
=
=
=
CONSTRAINT_MAX
DRESP_FORCE_MAX
ABS
<value>
Tosca Structure then generates two internal force constraints like the following;
F 65 F*
F 66 F*
User Manual 2 - 157
SIMULIA
Tosca Structure
Combined Terms
GROUP_OPER = SUM
Based upon the node group a design response for the internal force in ydirections are defined in a DRESP using GROUP_OPER=SUM yielding
DRESP
ID_NAME
DEF_TYPE
TYPE
LC_SET
ND_GROUP
EL_GROUP
GROUP_OPER
END_
=
=
=
=
=
=
=
DRESP_FORCE_SUM
SYSTEM
INTERNAL_FORCE_Y
STATIC,1,
FORCE_NODES
FORCE_ELEM
SUM
internal forces of the nodes 65 and 66 for the elements 33, 34, 37 and 38.
CONSTRAINT
ID_NAME
DRESP
MAGNITUDE
LE_VALUE
END_
=
=
=
=
CONSTRAINT_MAX
DRESP_FORCE_MAX
ABS
<value>
Tosca Structure then generates a single internal force constraint like the following;
F 65 + F 66 F*
Alternatively, one could also define two DRESPs for each node like the following:
GROUP_DEF
ID_NAME
TYPE
FORMAT
LIST_BEGIN
33, 34
= FORCE_ELEM_1
= ELEM
= LIST
END_
DRESP
ID_NAME
DEF_TYPE
TYPE
2 - 158 User Manual
= DRESP_FORCE_1
= SYSTEM
= INTERNAL_FORCE_Y
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Alternative definition of constraints function
SIMULIA
Tosca Structure
NODE
EL_GROUP
LC_SET
GROUP_OPER
END_
=
=
=
=
65
FORCE_ELEM_1
STATIC,1
MAX or SUM
GROUP_DEF
ID_NAME
TYPE
FORMAT
LIST_BEGIN
37, 38
END_
= FORCE_ELEM_2
= ELEM
= LIST
DRESP
ID_NAME
DEF_TYPE
TYPE
NODE
EL_GROUP
LC_SET
GROUP_OPER
=
=
=
=
=
=
=
DRESP_FORCE_2
SYSTEM
INTERNAL_FORCE_Y
66
FORCE_ELEM_2
STATIC,1
MAX or SUM
END_
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And then add the two design response in two constraints:

CONSTRAINT
ID_NAME
DRESP
MAGNITUDE
LE_VALUE
END_
=
=
=
=
CONSTRAINT_1
DRESP_FORCE_1
ABS
<value>
CONSTRAINT
ID_NAME
DRESP
MAGNITUDE
LE_VALUE
END_
=
=
=
=
CONSTRAINT_2
DRESP_FORCE_2
ABS
<value>
Tosca Structure then generates two internal force constraints like the following;
F 65 F*
F 66 F*
User Manual 2 - 159
SIMULIA
Tosca Structure
Combined Terms

4.5.2
Load case combination and selection

Design responses extracted from finite element analysis may depend on a
number of load cases. For getting a scalar value as design response it is necessary to select results from the load cases (LC_SET) and combine the
selected results using an operator (LC_SEL).
If LC_SEL is not set explicitly, a default value is used according to the type of
the design response. Using Tosca Structure.gui LC_SEL no longer needs to
be defined manually.
If no LC_SET parameter is present, then all load cases and sub-steps (frequencies) will be used to determine the value. As operator, the operator specified by LC_SEL or the default parameter will be used.
4.5.2.1 Load case specification (LC_SET)

If more than one load case or sub-step exists, the user may wish to choose
the load case that is to be taken into consideration. Also, for modal analysis
where more than one eigenfrequency is calculated, a selection of the eigenfrequencies of interest is necessary.
The specification of a load case/sub-step or a mode is done using the definition of the related analysis type, the load case number and the sub-step (if
applicable).
Analysis type
For the analysis the following types are supported:
MODAL: modal analysis

NONLINEAR: nonlinear statics
FREQUENCY: frequency response
As an alternative definition all present analysis types can be selected with
ALL.
Load case
The selection of a load case is performed with the selection of the number of
the load case. If the CAE solver does not support the numbering of load
cases, the optimization environment starts with number 1 for the first load
case and then the following load cases are assigned the numbers in increasing order.
As an alternative definition, all present load cases can be selected with ALL.
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Tosca Structure
Nevertheless, for better control it is recommended to define single design

responses for each load case and combine them later, e.g., in the objective
function definition.
Substep
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The selection of a sub-step is performed with the selection of the number of

the sub-step. If the solver does not support numbers for sub-steps, the optimization environment starts with number 1 for the first sub-step, and then the
following sub-steps are assigned the numbers in increasing order.
As an alternative definition, all present sub-steps can be selected with ALL.
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Combined Terms
Load case and sub-step selection in Tosca ANSA environment
Selection of LC_SET entry for a design response
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Fig. 87
Selection of a load case in Tosca Structure.gui
If more than one FE input file is used, then the numbering of load cases is not
necessarily unique because the numbering of load cases might start with 1 in
each input file. For avoiding this problem, the GUI offers the possibility to
select the name of the file that contains the load case to be used in the design
response definition. The load cases in the first referenced file in the
FEM_INPUT command (see chapter 3.4 Loading FE Data and FEM_INPUT)
will then get their original numbers. If there is a second file referenced in the
FEM_INPUT command, then 10000 will be added to its load case numbers;
e.g., load case 11 in the second file will be referenced as load case 10011. If
a third file is referenced, 20000 will be added to its load case numbers, and
so on.
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Combined Terms

The Load Case selection is done within a design responses Details View
window. Either the Load Case is set to All or to Manual. With Manual
selected, a new table containing further Load Case information needs to be
filled out.
Load Case selection in the Details View window
4.5.2.2 Selection criteria for load cases (LC_SEL)

If more than one load case or sub-step is used in the definition of a design
response, the question is how to combine the load cases or sub-steps. For
the optimization, there is a big difference if the design response is determined
for the minimum value over all load cases or for the maximum value. For
example, if the design response represents the modal frequency, the minimum value will be the first eigenvalue and the maximum value will be the
highest value stored in the result database. If this design response is then
used in the objective function, the optimization result will be totally different.
As LC_SEL values, the following values are available:
MIN - determines the minimum value over all load cases/sub-steps
MAX - determines the maximum value over all load cases/sub-steps
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SUM - sums up the values over the load cases/sub-steps

Please note:
Depending on your design response default values for loadcase combination
are selected. Thus, it is not necessary to select them manually. Manual selection of the LC_SEL parameter is not supported by Tosca Structure.gui, Tosca
ANSA environment and Tosca Extension for ANSYS/WB.
Manual definition of LC_SEL is no longer supported. Default values depending on the type of design response are used instead.
Manual definition of LC_SEL is no longer supported. Default values depending on the type of design response are used instead.
Manual definition of LC_SEL is not supported. Default values depending on
the type of design response are used instead.
Remarks
1. For the different types of design responses Tosca Structure has default
settings for the LC_SEL Item. All nodal based results like stresses, strains,
displacements, forces, ... are used with the operator MAX. Element based
results like the strain energy are used with the LC_SEL operator SUM.
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2. For sensitivity based optimization: If a design response with MAX or MIN

operator is used in the constraint or objective function definition, then
Tosca Structure creates a new design response for each load case/substep, that are then used in the constraint or objective function definition.
The name of the design response can be seen and tracked in the
TOSCA.OUT file and also in the optimization_report.csv file.
4.5.3
Design response combination
TOPO
SHAPE
OBJ_FUNC
S*
CONSTRAINT
S*
Table 22
BEAD
SIZING
S*
S*
Combined terms (C = controller, S = sensitivity)
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Combined Terms
(*only weighted sums (including differences))
Creating response combinations like relative values, differences or mean values requires operations on a number of previously extracted design
responses. For sensitivity based topology optimization, only weighted sums
are admitted in objective function and constraint definitions. For controller
based shape optimization, a large variety of other operators are admissible.
All operators are available to create new responses for monitoring of optimization results. Weighted sums operate on one to 10 variables defined by the
item VARIABLE. All other operators combine (operate on) one to four variables whereas the order of the variables is significant. For a complete list of
available operators refer to the detailed description of the DRESP command.
DRESP
ID_NAME
DEF_TYPE
VAR_OPER
VAR_A
VAR_B
=
=
=
=
=
.....
OPER
SUB or
.....
.....
SUB_ABS or ...
END_
and
DRESP
ID_NAME
= .....
DEF_TYPE
= OPER
VAR_OPER
= COMBINE
VARIABLE
= ....., .....
VARIABLE
= ....., .....
....................
Remark:
1. Please note: maximal 500 Design responses are allowed.
2. For sensitivity based topology optimization design responses can only be
combined using DEF_TYPE = OPER if they refer to the same loadcases.
Combination of design responses with OPER cannot be done for two separate loadcases. Nevertheless for shape optimization design responses for
different loadcases may be combined.
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END_
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4.5.3.1 Combined responses in sensitivity based optimization

Displacements
TYPE
The allowable types for
displacements and rotations
DISP_X
DISP_Y
DISP_Z
ROT_X
ROT_Y
ROT_Z
GROUP_OPER
The allowable
definition types for
displacements
and rotations
VAR_OPER
The allowable
operators for
displacements
and rotations
MAX
MIN
SUM
SUB
SUB_ABS
COMBINE
DISP_ABS
MAX
SUB
SUB_ABS*
ROT_ABS
MAX
SUB_ABS*
MAX
MIN
---
DISP_X_ABS
DISP_Y_ABS
DISP_Z_ABS
ROT_X_ABS
ROT_Y_ABS
ROT_Z_ABS
* For these VAR_A and VAR_B have to have the same DRESP type. E.g.
the DRESP type for VAR_A and VAR_B is TYPE = DISP_ABS yielding
u =
( u x1 u x2 ) + ( u y1 u y2 ) + ( u z1 u z2 )
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Remarks
1. For TYPE=DISP_ABS with VAR_OPER=SUB both VAR_A and VAR_B are
TYPE=DISP_ABS. For this case the displacement of DRESP is calculated
as following:
DRESP = u = l def l ini

with
l def =
( ( x pos + u x ) + ( y pos + u y ) + ( z pos + u z ) )
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Combined Terms
as deformed length and
I ini =
( ( x pos ) + ( y pos ) + ( z pos ) )
as initial length.
Thereby n pos = n pos1 n pos2 , for n = x,y,z
and u n = u n1 u n2 , for n = x, y, z ,
where pos1 and pos2 are the coordinates of the nodes and u the
displacements.
The DRESP can also be negative and gives the stretch between two nodes
(i.e. the difference between the two notes in deformed and undeformed
configuration).
2. GROUP_OPER is default GROUP_OPER = MAX.
3. A node group (ND_GROUP) has to be applied in the DRESP when more
than one node is required.
4. Maximal 500 DRESPs can be defined. Therefore, the maximal number of
nodes for GROUP_OPER = MAX is 500 or less as in this case one design
response is created for each group member.
5. If possible, define design responses for displacements for single nodes
(allows better control). Often 1 representative node is sufficient for the task.
6. The maximal number of nodes for GROUP_OPER = SUM us unlimited.
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7. Design responses combined using VAR_OPER should refer to the same

group.
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Reaction forces
TYPE
reaction forces
REACTION_FORCE_X
REACTION_FORCE_Y
REACTION_FORCE_Z
REACTION_MOMENT_X
REACTION_MOMENT_Y
REACTION_MOMENT_Z
REACTION_FORCE_ABS
REACTION_MOMENT_ABS
REACTION_FORCE_X_ABS
REACTION_FORCE_Y_ABS
REACTION_MOMENT_X_ABS
REACTION_MOMENT_Y_ABS
GROUP_OPER
The allowable
reaction forces
VAR_OPER
The allowable
operators for
reaction forces
MAX
MIN
SUM
SUB
SUB_ABS
COMBINE
MAX
SUB_ABS*
MAX
MIN
---
* For these VAR_A and VAR_B have to have the same DRESP type.
E.g. the DRESP type for VAR_A and VAR_B is
TYPE = REACTION_FORCE_ABS yielding
R =
( R x1 R x2 ) + ( R y1 R y2 ) + ( R z1 R z2 )
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Internal forces
TYPE
internal forces
INTERNAL_FORCE_X
INTERNAL_FORCE_Y
INTERNAL_FORCE_Z
INTERNAL_MOMENT_X
INTERNAL_MOMENT_Y
INTERNAL_MOMENT_Z
INTERNAL_FORCE_ABS
INTERNAL_MOMENT_ABS
GROUP_OPER
The allowable
internal forces
VAR_OPER
The allowable
operators for
internal forces
MAX
MIN
SUM
SUB
SUB_ABS
COMBINE
MAX
SUB_ABS*
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Combined Terms
TYPE
internal forces
INTERNAL_FORCE_X_ABS
INTERNAL_FORCE_Y_ABS
INTERNAL_MOMENT_X_ABS
INTERNAL_MOMENT_Y_ABS
GROUP_OPER
The allowable
internal forces
MAX
MIN
VAR_OPER
The allowable
operators for
internal forces
---
E.g. The DRESP type for VAR_A and VAR_B is
TYPE = INTERNAL_FORCE_ABS yielding
2
( F x1 F x2 ) + ( F y1 F y2 ) + ( F z1 F z2 )
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F =
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Modal eigenfrequencies
GROUP_OPER
The allowable
definition types
TYPE
DYN_FREQ
MAX
MIN
VAR_OPER
The allowable
operators
SUB
SUB_ABS
COMBINE
Frequency spectrum responses
TYPE
frequency response
FS_DISP_X_ABS
FS_DISP_Y_ABS
FS_DISP_Z_ABS
FS_DISP_ABS
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FS_PHASE_X
FS_PHASE_Y
FS_PHASE_Z
FS_VELOCITY_X
FS_VELOCITY_Y
FS_VELOCITY_Z
FS_ACCEL_X
FS_ACCEL_Y
FS_ACCEL_Z
GROUP_OPER
The allowable
frequency
response
VAR_OPER
The allowable
operators for
frequency
response
MAX
MIN
SUB_ABS*
MAX
MIN
---
E.g. the DRESP type for VAR_A and VAR_B is TYPE = FS_DISP_X_ABS
yielding
A x =
( u R, x1 u R, x2 ) + ( u I, y1 u I, y2 )
4.5.3.2 Combining design responses (Tosca ANSA environment)

A linear combination of already existing design responses is a new design
response that is created by the commands New | COMBINED_TERM applied
on OBJ_FUNC_ITEM_1 item (for the use as the objective) or New |
COMBINED_ITEM applied on CONSTRAINTS item (for the use as a constraint):
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Combined Terms
Objective:
Constraint:
In the figure above, the new design response is

COMBINED_ITEM_1 = 0.6 DRESP_1 + 0.8 DRESP_2.
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In the window that appears, the combined design responses and their weighing factors are entered:
SIMULIA
Tosca Structure
Pressing "?" key in a VARIABLE_<n> field opens the list of all defined design
responses:
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In this window, an already existing design response can be chosen by double

clicking its name, or a new design response can be defined by clicking
Action button or right click in the ID-field and choosing New | DRESP. This
command opens the window where a design response can be defined, e.g.,
as follows:
Note that the window DRESP/VARIABLE that lists all available design
responses is also opened by the button DRESP/VARIABLE found in
OBJ_FUNC/CONSTRAINTS panel of Modules Buttons toolbar.
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Combined Terms
4.5.3.3 Combining displacements and rotations
Fig. 89
A displacement called DRESP_1 is defined in the y direction of

the global coordinate system and a displacement called
DRESP_2 is defined in z direction of a local coordinate system.
Fig. 89 shows two displacements in different coordinates system and different

directions called DRESP_1 and DRESP_2 which can be combined to a
DRESP which canbe applied in the optimization like the following:
DRESP
ID_NAME
= .....
DEF_TYPE
= OPER
VAR_OPER
= COMBINE
VARIABLE
= ....., .....
VARIABLE
= DRESP_1, 0.6
VARIABLE
= DRESP_2, -0.8
VARIABLE
= ....., .....
....................
END_
Remarks
2. Displacements of different coordinate systems can be combined and

weighted.
3. Rotations can also be combined and weighted.
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1. Different directions of displacements can be combined and weighted.
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4.5.3.4 Combining reaction forces and internal forces
Fig. 90
An internal force called DRESP_1 is defined in the y direction of

the global coordinate system and a reaction force called
DRESP_2 is defined in z direction of a local coordinate system.
Figure Fig. 90 shows two forces defined in different coordinates system and
different directions called DRESP_1 and DRESP_2 which can be combined
to a DRESP which can be applied in the optimization like the following:
DRESP
ID_NAME
= .....
DEF_TYPE
= OPER
VAR_OPER
= COMBINE
VARIABLE
= ....., .....
VARIABLE
= DRESP_1, 0.6
VARIABLE
= DRESP_2, -0.8
VARIABLE
= ....., .....
....................
END_
Remarks
2. Different directions of internal forces and reaction forces can be combined

and weighted.
3. Internal forces and reaction forces of different coordinate systems can be
combined and weighted.
4. Reaction force moments and internal force moments can also be combined
and weighted.
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Combined Terms
4.5.3.5 Combining absolute values of responses

Combining absolute values of response is done by operator type VAR_OPER
= SUB_ABS. To get the absolute value of the difference of two terms
(DRESP_1 and DRESP_2) the design response definition is as follows:
DRESP
ID_NAME
DEF_TYPE
VAR_OPER
VAR_A
VAR_B
END_
=
=
=
=
=
.....
OPER
SUB_ABS
DRESP_1
DRESP_2
4.5.3.6 Controller based combined terms

For the controller based shape optimization, basically any operator is allowed
for the definition of the objective function, but here one must be cautious
because the operation is only performed on the scalar nodal values. This is
explained in the following two examples:
Example 1:
We want to apply the von Mises stress in the optimization relative to the von
Mises in the first iteration ( 0 ):
i
i, rel = -----0
VARIABLE
ID_NAME
DEF_TYPE
TYPE
ND_GROUP
LC_SET
GROUP_OPER
UPDATE
END_
VARIABLE
ID_NAME
DEF_TYPE
TYPE
ND_GROUP
LC_SET
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=
=
=
=
=
=
=
von_mises
SYSTEM
SIG_MISES
ALL_NODES
ALL,1,All
Max
EVER
=
=
=
=
=
von_mises_first
SYSTEM
SIG_MISES
ALL_NODES
ALL,1,All
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Now, if we use this term in the objective function all nodal von Mises stresses
will be divided by the von Mises stress from the first iteration.
To define the above statement use the following commands:
SIMULIA
Tosca Structure
GROUP_OPER
UPDATE
END_
DRESP
ID_NAME
DEF_TYPE
VAR_OPER
VAR_A
VAR_B
END_
= Max
= FIRST
=
=
=
=
=
relative_von_mises
OPER
DIV
von_mises
von_mises_first
Example 2:
In a second example, the sum of the von Mises stress from two load cases,
say LC1 and LC2, should be used as the design response:
sum = LC1 + LC2
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The above is NOT a sum of the stress tensors upon which the von Mises criteria is calculated. It is simply a sum of the two resulting values of the von
Mises stress for each node.
The scalar summation can be done using following commands:
DRESP
ID_NAME
DEF_TYPE
TYPE
ND_GROUP
LC_SET
GROUP_OPER
END_
DRESP
ID_NAME
DEF_TYPE
TYPE
ND_GROUP
LC_SET
GROUP_OPER
END_
DRESP
ID_NAME
DEF_TYPE
VAR_OPER
VAR_A
VAR_B
=
=
=
=
=
=
von_mises_LC1
SYSTEM
SIG_MISES
ALL_NODES
ALL,1,All
Max
=
=
=
=
=
=
von_mises_LC2
SYSTEM
SIG_MISES
ALL_NODES
ALL,2,All
Max
=
=
=
=
=
scalar_sum_von_mises
OPER
ADD
von_mises_LC1
von_mises_LC2
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Logging and Monitoring
END_
4.5.3.7 Other operators for controller based shape optimization

The operators
VAR_OPER = FILTER
VAR_OPER = CUT_OFF
VAR_OPER = NORM
VAR_OPER = NORM_FIRST
refer to a vector and require additional parameters. They can be used to filter
values of a vector, cut them at a certain value or normalize them (standard
normalization or with reference to maximum of first iteration). Additional
parameters are specified in detail in the DRESP command in vol.3 Commands Manual.
VAR_OPER = NROOT
VAR_OPER = NPOWER
allow to calculate the nth root or power of a single value. For details refer to
the DRESP command in vol.3 Commands Manual.
4.6
Logging and Monitoring
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All defined design responses are logged to the log-file TOSCA.OUT. The
design responses used in objective function or constraints are also written in
the file optimization_report.csv. In Tosca Structure.gui these can be monitored graphically during and after optimization using the Convergence
Plot button in Tosca Structure.gui.
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often defines the shape and the topology of new components using the experience and the results gained from existing designs. This results in an evolution process that might lead to an optimum design after several manual
design iterations and a long process development time.
Nowadays it is necessary to shorten the development process of new components, and at the same time develop fundamentally new designs. Therefore,
optimization tools are necessary for replacing the natural evolution process
by an automatic procedure.
With Tosca Structure, it is possible to carry out topology and shape optimization in the existing CAE environment.
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Fig. 91
5.1
Topology optimization of a control arm
General Information
Topology optimization is a tool to generate a new design proposal and is often
used within the concept phase for a determining a new conceptual design for
a component.Starting with the design area (which represents the maximum
allowed area for the component) and with the boundary conditions, such as
loads, fixtures and manufacturing conditions, the optimization system will
determine a new material distribution by removing and adding material in the
design area. This design proposal should fulfill all mechanical requirements
and often represents a weight-optimal design proposal.
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The Optimization Task
eigenfrequencies;
weight, volume;
center of gravity;
moment of inertia.
that the design proposal can be produced, e.g., with casting or stamping. Different casting constraints can be defined, like member size constraints, freezing of parts, symmetry and different coupling constraints.
As result, the optimization creates a design proposal with the information
regarding the material layout. This design proposal has to be interpreted and
has to be used for a more detailed analysis. For supporting this step, the
Tosca Structure system supports the generation of a verification model within
Tosca ANSA environment. This means that a new model based on the results
of the topology optimization can be created easily without the necessity of
applying the loads and boundary conditions manually to the verification
model. All load cases and boundary conditions of the original optimization
model are also transferred automatically to the verification model.
With the results of the verification run, it is possible to perform a normal FE
postprocessing step within the postprocessing environment suitable for your
solver, or a CAD model can be generated that then can be transferred back to
your CAD system.

In Tosca Structure, two principle algorithms exist for solving topology optimization problems. The main difference is the method for solving the problem,
and also the type of design responses which can be used to formulate the
optimization problem. The two algorithms are:
the controller based optimality criteria approach
the general, sensitivity based approach
Both algorithms have the special application area and both are useful for different types of optimization tasks.
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5.2
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Tosca Structure
5.2.1
Controller versus sensitivity based topology optimization

Depending on the optimization task defined by the user, Tosca Structure
decides which algorithm is the best to solve the problem. The two main algorithms (the controller based algorithm for standard problems and the sensitivity based algorithm for extended problems) have different methods to find the
solution.
Some of the main differences between sensitivity based optimization algorithm and controller based algorithm are the following:
1. Elements with intermediate densities (gray elements). The sensitivity
based algorithm has some elements in the final design containing intermediate densities (gray elements), whereas the controller based algorithm
leads to the elements being either void (density very close to zero) or solid
(density equal to one) in the final design.
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2. Number of optimization iterations. The controller based algorithm uses

15 optimization iterations by default. For the sensitivity based optimization
algorithm, the number of iterations is unknown before the optimization
starts, but normally the number of optimization iterations is around 30 to
45.
3. Analysis types. The sensitivity based algorithm supports the responses of
linear static (non-conservative forces) and linear eigenfrequency (not
allowed to be prestressed) finite element analysis. On the other hand, the
controller based algorithm also supports non-linear static analysis such as
contact simulation, even when the contact zones are on the surfaces of the
design space. The sensitivity based algorithm supports geometrical nonlinearities (NLGEOM) and contact for Abaqus and ANSYS. Furthermore,
some non-linear materials are also supported. Other non-linearities in the
sensitivity based algorithm are not supported. Furthermore, prescribed
displacements are allowed in the CAE model for static topology optimization. However, prescribed displacements are not allowed for modal and
frequency response analysis. Generally, laminate materials can not be
designed in topology optimization. However, laminate materials as design
elements are allowed for MSC Nastran and Abaqus.
4. Objective and constraint types. The sensitivity based algorithm can have
one objective function and several constraints where the constraints are all
inequality constraints. The objective and the constraints can be based
upon the stiffness, displacements, reaction forces, internal forces, eigenfrequencies and material volume (material weight). On the other hand, the
controller based algorithm has the compliance as objective and the material volume as an equality constraint.
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5. Algorithms. For sensitivity based topology optimization task is a general

optimization algorithm integrated. This algorithm uses the sensitivities of
the design variables with regard to the objective function and the
constraints. Tosca Structure uses an algorithm based on the Method of
Moving Asymptotes from Krister Svanberg (Sweden).
It is not necessary to calculate the sensitivities for the Tosca Structure
controller-based strategy. The controller uses the strain energy and the grid
point stresses as input data.
Allowed objective functions and constraints
In topology optimization, a variety of combinations of objective functions and
constraints can be selected. Standard formulation using the efficient controller based optimality criteria algorithm is
Objective function
Maximize stiffness
Table 23
Constraint
Volume constraint
Feasible objective functions and constraints for controller

based optimality criteria algorithm
All other types of objective functions and constraints can be applied using the
sensitivity based algorithm.
The following table describes which terms and response types are valid for
the objective function and the constraints.
Objective function or Constraint
Displacement (absolute or relative)

von Mises Stress
Moment of inertia
Rotations
Reaction forces (absolute or relative)
Reaction moments (absolute or relative)
Internal forces (absolute or relative)
Internal moments (absolute or relative)
Eigenfrequencies
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Objective function or Constraint

Material Volume
Total stiffness
Table 24
Feasible objective functions and constraints for sensitivity

based algorithm
Several constraints and several terms for the objective function can be specified.
5.2.2

The following describes the general procedure for defining an optimization
task. These procedures are supported by Task Manager in Tosca ANSA environment (TAE) as well as the command tree in Tosca Structure.pre screen of
Tosca Structure.gui (GUI). For more information about Tosca Structure.gui
see vol.1 chapter 2.1.2. The CAE analysis model must previously be completely defined.Alternatively the entire optimization setup including the CAE
analysis model can be completed within ANSYS Workbench using the Tosca
Extension for ANSYS/WB.
Analysis Model
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1. Question: Which file(s) contains the FE- model for the optimization?
Procedure: Link file(s) to optimization task.
TAE: MODEL_LINK | FILE, select Edit, then choose your model file.
GUI: Choose your model file in FEM_INPUT.
WB: Right click the Geometry cell of the static or modal system and select
Import Geometry. Add mesh and load cases later in the Mechanical
apllication.
Design Area
2. Question: Which part of the FE model should be selected as the design
space?
Procedure: Assign an element group to the design area.
TAE: DESIGN_AREA, select Edit, then choose a predefined group or
select a new group.
GUI: Choose or define the element group for the selected design area
(volume 3: GROUP_DEF) and define the design variables (volume 3:
DV_TOPO).
WB: Add a Topology | Design Area and assign a part of the geometry graphically or by Named Selection.
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3. Question: Are there elements in the design space which have to have
certain restrictions (e.g. symmetry and manufacturing restrictions)? How
can these restrictions be described?
Procedure: Define design variable constraints for element group.
TAE: DESIGN_AREA | DV_CONSTRAINTS, select New | <type of restriction>, choose predefined group or select new group for this restriction. If
needed, define link conditions using Modules Buttons toolbar.
GUI: Choose or define element groups with restrictions (volume 3:
GROUP_DEF). Define the restrictions using DVCON_TOPO command.
WB: Click Topology and choose a desired restriction. Then assign a part
of the geometry.
4. Question: Are there certain symmetry conditions that should be fulfilled?
Procedure: Create a symmetry coupling condition.
TAE: DESIGN_AREA | DV_CONSTRAINTS, select New |
SYMMETRY_CONTROL.
GUI: Create a LINK_TOPO condition and reference it in the restriction
command (volume 3: DVCON_TOPO).
WB: Select Topology | Symmetry and fill out the corresponding input
boxes.
5. Question: Which terms describe the values to be optimized? Should these

values be minimized or maximized or otherwise combined using the
minmax formulation (only available for sensitivity based algorithm)? Are
any special weighting factors or target values required?
Procedure: Choose the terms for optimization (design responses) and the
target type.
TAE: OBJ_FUNC_ITEM_1, select New | <term for optimization>; choose
Edit for choice of target type (min, max, minmax).
GUI: Define the design response (volume 3: DRESP) and assign it to the
objective function (volume 3: OBJ_FUNC).
WB: Select Optimization | Design Response and define the available options for this Design Response. Then add a Optimization |
Objective Function and assign the predefined Design Response.
Constraint
6. Question: Which terms describe the constraint? What value should the
constraint have?
Procedure: Choose the term for the constraint and set the target value or
upper/lower boundary.
TAE: CONSTRAINT, select New | <term for constraint>.
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constraint (volume 3: CONSTRAINT).
WB: Select Optimization | Design Response and define the available options for this Design Response. Then add a Optimization |
Constraint and assign the predefined Design Response.
Optimization Task
7. Question: Are all of the command definitions listed above complete and
ready for the optimization job?
Procedure: If necessary, make the additional definitions and prepare the
optimization job.
TAE: Automatically prepared by task manager.
GUI: Reference all definitions above in OPTIMIZE.
WB: All active (not Suppressed) definitions will be used automatically in
the Optimize command and the following optimization.
8. Question: Are you using controller or sensitivity based optimization
strategy?
Procedure: Choose the corresponding strategy.
TAE: Chosen in the beginning when the task is created
(TOPOLOGY_OPTIMIZATION_CONTROLLER or
TOPOLOGY_OPTIMIZATION_SENSITIVITY).
GUI: Set the correct value to either TOPO_CONTROLLER or
TOPO_SENSITIVITY in OPTIMIZE subcommand STRATEGY.
WB: Choose the desired Strategy in the Analysis Settings in the
Tree Outline.
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9. Question: Should the stop condition be modified?
Procedure: Modify stop condition
TAE: GLOBAL_STOP_CONDITION, select Edit and change the number of
iterations.
GUI: STOP.
WB: An iteration based stop condition can be defined as Max design
cycles in Analysis Settings in the Tree Outline.
Completion
10.Question: Is all required data specified?
Procedure: If yes, finish the definition of the optimization problem and
save your definition.
TAE: OUTPUT, choose Edit, enter the jobname
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Design Area
GUI: Save as <jobname>.par

WB: Save the current Workbench project.
The essential commands required for the optimization model in topology optimization are described in the following.
The definitions for the optimization job are assembled in a parameter file. The
exact syntax of the commands can be looked up in vol.3 Commands Manual.
Fig. 92 gives an overview of a standard optimization task and the relation
between the several commands. Only commands which are referenced in the
OPTIMIZE command will be included in the optimization.
Fig. 92
5.3
Block structure of topology optimization commands
Design Area
5.3.1
Design variables
For each optimization problem, the design variables represent the values to
be changed during the optimization. The densities of the elements are the
design variables for the topology optimization in Tosca Structure. The densities change during the optimization in order to fulfill the optimization goals.
The density of each individual element in the design space is a design variable in topology optimization. The Youngs modulus of each element is coupled with the density (see e.g. vol.2 chapter 5.10, References).
Valid design elements are 2D and 3D elements, including shell elements.
Bars can be used as design variables, but not within mixed groups. The list of
valid element types for the topology optimization is given in vol.2 chapter 11,
Solver Specific Features for the different FE solvers.
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During an optimization, only part of the model may be changed. This part is
defined as design area.
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Design variable definition in Tosca ANSA environment
Fig. 93
DV_TOPO definition in the Tosca ANSA environment
In order to choose the design element group, the command Edit should be
applied on the item DESIGN_AREA. Then, pressing "?" key in GROUP_DEF
field (after the field EL_GROUP is set to GROUP_DEF) opens the window SET
HELP where all existing groups are listed; if needed, a new element group
can be created by using New command of this window.
Design variable definition in Tosca Structure.gui
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The DV_TOPO command is used to assign a previously defined element

group to be the design element group for the topology optimization. The element group has to be a group of elements which are allowed as design elements for the topology optimization.
Fig. 94
DV_TOPO definition in Tosca Structure.gui
The resulting command is the DV_TOPO command. For further details please
refer to DV_TOPO in the command manual.
DV_TOPO
ID_NAME
= dv_design_elem
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Design Area
EL_GROUP
= design_elem
END_
Definition of a design area in Tosca Extension for ANSYS/WB

Add a Design Area to the project by clicking Topology | Design Area
in the TOSCA toolbar. The part of the geometry that is assigned will be optimized. It is also possible to assign a predefined Named Selection.
Fig. 95
Add and define a Design Area in Tosca Extension for ANSYS/WB
5.3.1.1 Results from previous runs as initial material distribution

In some cases the user may want to use results of already performed optimizations as start solution for the current optimization task. This is possible with
the option INITIAL_DV_FIELD within the DV_TOPO command (currently not
supported from the Tosca ANSA environment). If this option is used then the
material distribution stated in the result file will be used instead of a homogeneous material distribution in the design area.
ID_NAME
=dv_design_elem
EL_GROUP
=design_elem
INITIAL_DV_FIELD =<my_initial_mat_distribution.ONF>
END_
The RESTART File containing the initial material distribution must be located
in the start directory of the optimization job. The format of the RESTART File
has to be ONF (Optmization Neutral File). The initial material distribution is
extracted from the datablock 740 with the title MAT_PROP_NORMALIZED.
When using a material distribution of a previous optimization run (file
TP_XXX.onf ) for the new optimization it is recommended to rename the file
(e.g. to INITIAL_MAT.onf) . Otherwise name conflicts with the running optimization (with newly generated material distribution files TP_YYY.onf) may lead
to confusion in the postprocessing: the start file TP_XXX.onf may be considered and shown as last iteration (if XXX is larger as the last iteration in the
actual optimization).
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Depending on the state used as initial material distribution and depending on

the differences in the optimization definition between the used solution and
the current task the convergence can be speeded up significantly. If the
changes are too big then the usage of the initial distribution may lead to a
higher number of iteration.
The restart is not available for the controller based approach due to the fact
that this approach is already very efficient and the use of previously defined
material distributions does not lead to a speedup of the optimization process.
5.3.2
Manufacturing conditions and geometrical restrictions

For the topology optimization with Tosca Structure, it is possible to define
constraints (DVCON_TOPO) that have a direct influence on the individual
design variables(DV_TOPO). This allows the manufacturing restrictions or
geometrical design aspects to be taken into consideration in the topology
optimization. The different restrictions are listed below:
Frozen area
Element fixing by exclusion from the optimization group.
Element fixing by freezing elements (FROZEN).
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Manufacturing control - Prevention of undercuts in the model.

Casting - the remaining structure can be produced by casting
(MID_PLANE = POINT)
Forging - the remaining structure can be produced by forging
(MID_PLANE = NONE)
Stamping - the remaining structure can be produced by stamping
(MID_PLANE = STAMP)
Definition or automatic determination of the middle plane
(MID_PLANE = AUTO)
Tightness of resulting structures (MID_PLANE = AUTO_TIGHT)
Symmetry control
Area linking (LINK_TOPO)
Symmetry restriction(LINK_TOPO)
Member size control
Minimum member size control (MIN_MEMBER)
Maximum member size control (MAX_MEMBER)
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Design Area

Sometimes it is required to maintain material in certain parts of the design
area, such that they remain unchanged in the optimized model. Element
groups describing these parts can be defined as frozen area. This option is
used to exclude the so-called frozen elements from being modified during the
optimization, even though these elements are included in the design space.
This is the case, e.g., when the elements are used in order to fix the component and therefore should be preserved independently of their internal loads.
The inclusion into the design space may be necessary, e.g., to control the target volume (see constraints absolute volume or relative volume, Bd.1,
Chapter 5.5.1).
Defining a frozen area in Tosca ANSA environment
Manufacturing constraints are defined using DV_CONSTRAINTS item. Each of
these restrictions relates to an element group that is either the design area or
a subset of it. For the definition of the frozen area, only an element group is
necessary. No further properties have to be set.
Workflow for the definition of FROZEN_AREA

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Fig. 97
Frozen areas due to functional requirements
Defining a frozen area in Tosca Structure.gui
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The DVCON_TOPO command has to be selected in Tosca Structure.pre

screen when defining the design variable constraints. The name of the element group that is to be frozen follows after the obligatory ID_NAME field. If
the element group is not already defined, it is necessary to define it in
advance using GROUP_DEF command.
Choose Type = Frozen.
Fig. 98
Definition of a FROZEN design variable constraint for an existing

element group
The resulting command looks like:

DVCON_TOPO
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Design Area
ID_NAME
EL_GROUP
CHECK_TYPE
= frozen_area
= frozen_grp
= FROZEN
END_
This constraint for the design variables is activated when it is referenced in

the OPTIMIZE command.
Definition of a frozen area in Tosca Extension for ANSYS/WB
Add a Frozen Area to the project by clicking Topology | Frozen Area.
Select and assign a geometry or surface; predefined Named Selection are
possible, too. Edges, vertices or nodes are not available to choose.
Fig. 99
Add and define a Frozen Area
The manufacturing constraints are helpful and necessary to ensure that the
design is manufacturable, and thus the results of the topology optimization
are acceptable and the transfer of the results is easy.
In many cases where bending and torsion loads are applied, the topology
optimization results in models with hollow areas or models with undercuts
that make the manufacturing close to infeasible.
In order to convert the result of non-restricted topology optimization into a
manufacturable design, a lot of manual changes are necessary. These
changes might modify the mechanical properties dramatically. The solution
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for this problem is to include the manufacturing constraints directly in the

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Fig. 100 Difference between two optimization results: without manufacturing constraints (left) and with casting constraint to prevent undercuts (right)
The formation of cavities and undercuts during the topology optimization can
be prevented by using the casting constraint in the design variable constraint
definition. This simplifies significantly the transfer of topology optimization
results into manufacturable components. Solutions are limited as in the case
of all other kinds of restrictions. Usually, it is better to carry out the optimization without manufacturing restrictions first, and then to perform a second
optimization with manufacturing restrictions.
For a definition of a demold restriction, two element groups are needed. The
first group ("casting group") consists of the elements where the restriction is
active; it should be a subset of the design element group. The second one is
the "check group": when it is checked if an element is allowed to be removed,
this test is performed with respect to the elements in the check group.The
check group should include all elements of the casting group.
The check if a removal of an element results in a hole or an undercut requires
that the check direction is specified. Since only one check direction for an element is allowed, casting groups of two different demold restrictions must not
intersect. There are four types of the check for undercuts and cavities:
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Design Area
1. Using a pull direction without the middle plane (MID_PLANE = NONE).

Only the pull direction is defined. A fictitious middle plane lies outside of the
component so that pulling takes place in only one direction.
2. Using a pull direction with a fixed middle plane (MID_PLANE = POINT)
A middle plane is defined by a point and the pull direction (vector perpendicular to the middle plane). It is checked that the component is demoldable in both directions away from the middle plane.
3. Using a pull direction and the automatically defined middle plane
(MID_PLANE = AUTO).
Tosca Structure determines the optimal position of the middle plane for
each area.
4. Using the normal direction to the surface (MID_PLANE = SURFACE)
For each element, the direction is the normal at the surface point nearest to
the element (only the surface of the elements from the casting group is
considered).
= deformation angle
r = base radius
Fig. 101 Pull cone with a deformation angle centered at element enlarged
by base radius r.
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A pull direction vector (PULL_DIR) has to be defined for the types 1-3. The
deformation angle (ANGLE) defines the necessary angle needed for ejection.
Values between 0 and 20 are permitted. Checking the pull direction is made
with the help of a pull cone starting at the centroid of the respective element.
That the pull direction is maintained is checked using the pull cone with a certain base radius.This radius is based on the average element size and is usually determined from the model.
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Tosca Structure
The specification of this RADIUS is optional and is only necessary for models
that have elements of very different sizes. If a value is specified, it should be
larger than approximately 50% of the average element edge length.
Initial model (design space) for

topology optimization
Forward and backward

deformation with auto middle
plane
Topology optimization with no

pull direction
Upward deformation with no

middle plane
Members of the specified element group are only modified if they can be
removed from the model in the pull direction, so that internal cavities and
recesses cannot be formed.
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Fig. 102 Engine mount with and without manufacturing restrictions
User Manual 2 - 195
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Design Area
Remarks
1. The check type SURFACE is useful for models where the pull direction is not
already known.
Fig. 103 CHECK_TYPE "SURFACE"
3. Defining a pull restriction causes many restrictions for 2D models. If the

topology optimization with pull direction is to be carried out on 2D models,
the option SPEED=SLOW should be set using the command OPT_PARAM
for the controller based optimality criteria. If the sensitivity based algorithm
is used, the settings for the DENSITY_UPDATE and the DENSITY_MOVE
may have to be adjusted to smaller or more conservative values to ensure
convergence of the algorithm.
4. For a more strict avoidance of undercuts an additional material filter
(FILTER_MAT = YES) can be switched on which is applied after each optimization cycle. The optimization result is changed based on purely
geometric aspects. This may influence the objective values and even the
convergence in a negative way. Thus apply only, if the standard casting
restriction does not lead to sufficient results.
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2. The specified check group is the group of elements against which a

removal of an element is examined. This group has always to contain at
least all elements of the DVCON group. The elements outside of the
DVCON group are treated as a barrier if there are elements in the check
group that do not belong to the DVCON group. This means that the
elements in the optimization group cannot be removed "through" these
other elements.
For example, in the optimization of an engine bracket, a part is retained in
the analysis model. The check group is to be restricted to the engine
bracket because during its manufacture, the engine block is not significant
for its deformation. If the engine bracket is attached to the engine, the
engine block must be included in the CHECK_GROUP, otherwise elements
from the optimization space are removed that have been pulled by the
engine block.
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Demold constraint definition in Tosca ANSA environment
For the definition of the DEMOLD_CONTROL feature, the above mentioned

settings should be entered in DEMOLD_CONTROL dialog. If necessary, new
element groups can be defined for the fields EL_GROUP and CHECK_GROUP.
In addition, a new coordinate system can be defined if necessary, in order to
define a pull direction different from the directions of the global coordinate
system axes.
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Fig. 104 Workflow for definition of a DEMOLD_CONTROL
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Design Area
Demold constraint definition in Tosca Structure.gui
Fig. 105 Casting constraint definition

Defining a demold constraint in Tosca Extension for ANSYS/WB
Fig. 106 Add and define a Demold Control to the optimization
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Add a Demold Control to the project by clicking Topology | Demold

Control. All relevant options like direction, mid plane, etc. are set in the corresponding input box in the Details View window.
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Tosca Structure
Remark
1. This constraint for the design variables is only active if the definition is
referenced in the OPTIMIZE command. This is done using the parameter
DVCON = cast_restrictrion in OPTIMIZE command.
5.3.2.3 Tightness constraint for the resulting structure
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Fig. 107 Check type "CAST" (left) in comparison to check type

"AUTO_TIGHT" (right)
The manufacturing constraints for tightness represent a possibility to prevent the remaining structure from having holes and breakouts in the defined
restriction area.
The elements are removed in a similar way to the option AUTO. This means
that the elements are removed in the pull direction or in the opposite direction. However, at least one layer of elements will be present in the middle
plane. The resulting "middle plane" is not necessarily planar. It might be a
curved surface.
The tightness is only checked within the restriction area. It is not possible to
ensure a tight connection to elements outside the restriction group in the area
of the boundary.
The midplane thickness is controlled by the RADIUS parameter (midplane
thickness = 2*RADIUS).
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Design Area
Remarks
1. For 2D models, the definition of a manufacturing constraint leads to a
significant reduction of the possible solution space. If this option is used in
combination with 2D models, an additional definition for the step width
should be added using the OPT_PARAM command (the parameter
SPEED=SLOW has to be defined).
2. Breakouts might occur if there are thin walls parallel to the pull direction.
These areas should be excluded from the restriction group.
Fig. 108 Workflow for definition of a tightness restriction

For the definition of the tightness restriction, the above mentioned settings
should be entered in DEMOLD_CONTROL dialog with the field MID_PLANE set
to AUTO_TIGHT. If needed, new groups for the fields EL_GROUP and
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CHECK_GROUP can be defined. In addition, a new coordinate system can be

defined if necessary, in order to define a pull direction different from the directions of the global coordinate system axes.
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Design Area
Definition of a tightness restriction in Tosca Structure.gui
Fig. 109 Tightness constraint definition

Definition of a tightness restriction in Tosca Extension for ANSYS/Workbench
Fig. 110 Define a tightness restriction within a Demold Control
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Add a Topology | Demold Control to the project first. Within the

Details View window of the added Demold Control the option Mid
plane has to be set on Auto tight.
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5.3.2.4 Stamping restriction
Fig. 111 Stamping restriction for a cranehook

The stamping restriction means the following: If one element is removed from
the structure, all elements positioned either behind or in front of the element
(with respect to the pull direction) are removed too. The stamping restriction
is a variant of the demold manufacturing constraint, with MID_PLANE parameter set to STAMP.
Remark
1. The speed (step width) should not be set too high if the stamping restriction
is activated for the optimization. An unsuitable choice leads to supports
being unattached to the rest of the structure.
Thin trusses in the resulting structure are often undesirable, depending on the
manufacturing process. Defining a minimum thickness avoids the creation of
small substructures in the final result.
The minimum member size control technique also ensures the mesh independence of the results. A coarse mesh and a fine mesh lead to the same
optimized topology if the minimum member sizes for both cases are set to the
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5.3.2.5 Minimum truss thickness (minimum member size)
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Design Area
same absolute size. Please note that the size in both cases should be larger
than the average element edge length.
Fig. 112 Optimized engine support with and without MINIMUM member
size restriction
Remarks
1. It is not possible to ensure the accurate minimum thickness of the structures. For some cases, the results contain parts with a diameter smaller
than the defined minimum member size.
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2. The CPU-time for the calculation increases quadratically with the minimum
member size. To save calculation time, the restriction should only be
defined in the areas of the model where thin parts should be avoided. To
identify these areas, the first step is to perform an optimization without
restrictions.
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Defining a minimum member size in Tosca ANSA environment
Fig. 113 Workflow for defining a minimum member size restriction
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For the definition of the minimum member size, the element group and the
desired minimum thickness should be entered in MEMBER_SIZE_CONTROL
dialog, using MEMBER_SIZE = MIN.
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Design Area
Defining a minimum member size in Tosca Structure.gui
Fig. 114 Minimum member size definition

The minimum member size is defined using the DVCON_TOPO command:
DVCON_TOPO
ID_NAME
EL_GROUP
CHECK_TYPE
THICKNESS
=
=
=
=
<Name of DVCON object>

<Element group to be restricted>
MIN_MEMBER
<minimum thickness of structures>
no restriction
minimum member size
maximum member size
Fig. 115 Minimum / maximum member size control
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Defining a minimum membersize in Tosca Extension for ANSYS/WB

Add a Membersize Control by clicking Topology | Membersize
Control. Within the corresponding Details View window the desired
minimum membersize can be set as Thickness if the Check Type is set to
MIN_MEMBER.
Fig. 116 Defining a minimum membersize within Membersize Control
5.3.2.6 Maximum truss thickness (maximum member size)

The definition of a maximum truss thickness is often necessary in order to
design the components produced by casting. With this restriction, thick parts
are avoided by splitting them into several thinner parts.
Normally, the maximum member size control is also a minimum member size
control. In the restriction area, the resulting structure contains trusses mainly
of the given defined diameter. Generally, no thinner trusses exist. Usually, the
combination of a maximum member size control and a minimum member size
control is not required.
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Fig. 117 Plate designed with and without maximum member size control
User Manual 2 - 207
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Tosca Structure
Design Area
Defining a maximum member size in Tosca ANSA environment
For the definition of the maximum member size, the element group and the
desired maximum thickness as well as the minimum thickness and the minimum distance between trusses (DISTANCE field) should be entered in
MEMBER_SIZE_CONTROL dialog, using MEMBER_SIZE = MAX.
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Fig. 118 Workflow for definition of a maximum membersize restriction
SIMULIA
Tosca Structure
Definition of maximum member size in Tosca Structure.gui
Fig. 119 Maximum member size definition

The maximum member size is defined using the DVCON_TOPO command:
DVCON_TOPO
ID_NAME
EL_GROUP
CHECK_TYPE
THICKNESS
MIN_THICKNESS
DISTANCE
END_
=
=
=
=
=
=

MAX_MEMBER
<maximum thickness of structures>
<minimum thickness of structures>
<maximum thickness of structures>
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Definition of a maximum membersize in Tosca Extension for ANSYS/Workbench

Add a Membersize Control by clicking Topology | Membersize
Control. Select MAX_MEMBER as Check Type and insert the desired
membersize as Thickness. More options like Distance or MinThickness are available in the Details View window, too.
Fig. 120 Defining a Maximum Membersize
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Design Area
Remarks
1. The maximum member size restriction will usually not create thin parts in
the area of boundary conditions and loads in the optimized structure. A
reduction in these areas may result in collapsing the structure.
2. The specified maximum diameter should not be smaller than twice the
average element edge length because smaller values will create elements
only connected by one or two nodes (point or line contact).
3. The CPU-time for the calculation increases quadratically with the maximum
member size. To save calculation time, the restriction should only be
defined in the areas of the model where the thick parts are present. To
identify these areas, the first step is to perform an optimization without
restrictions.
4. The maximum member size constraint can only be used with the sensitivity
based algorithm. Maximum member size constraints with the controller
algorithm are not supported.
5.3.2.7 Symmetry conditions

Different symmetry conditions can be defined for an optimization in Tosca
Structure. They can be used for obtaining symmetrical results using non-symmetrical meshes, saving the processing time for the FE-calculation. Furthermore, symmetrical load cases can often be reduced in the FE model.
The following symmetry conditions are available with Tosca Structure:
reflection symmetry
point symmetry
rotational symmetry
link condition (coupling of arbitrary areas of the model)
Fig. 121 Beam without symmetry (left) and with reflection symmetry (right)
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cyclic symmetry (replication of an area with a given distance)
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Fig. 122 Example of point symmetry (left) and rotational symmetry (right)
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Fig. 123 Example of cyclic symmetry (left) and a link condition (right)
User Manual 2 - 211
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Tosca Structure
Design Area
Fig. 124 Workflow for definition of a symmetry condition

Following settings should be entered in the dialog SYMMETRY_CONTROL in
order to define a symmetry condition:
1. Reflection symmetry (TYPE = PLANE_SYM): the symmetry plane is identified by a point (ORIGIN_1..ORIGIN_3) and the normal direction
(DIRECTION_1..DIRECTION_3).
2. Rotation symmetry (TYPE = ROTATION_SYM): the rotation axis is defined
by a point (ORIGIN_1..ORIGIN_3) and the direction
(DIRECTION_1..DIRECTION_3); the field ANGLE is the rotation angle.
3. Cyclic symmetry (TYPE = CYCLIC_SYM): the translation direction is
defined by a point (ORIGIN_1..ORIGIN_3) and the direction
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Tosca Structure
(DIRECTION_1..DIRECTION_3); the field TRANSLATION is the translation distance. Note that although the origin has no influence, it should be
specified because Tosca Structure requires that the direction is an axis of a
coordinate system. In this case, this coordinate system is created automatically by Tosca ANSA environment.
In each case, EL_GROUP is the element group that the symmetry condition
applies to.
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Defining the symmetry condition in Tosca Structure.gui
Fig. 125 Symmetry definition using LINK_TOPO and DVCON_TOPO

Symmetries are defined with the command LINK_TOPO and are applied to an
element group using the DVCON_TOPO command. The LINK_TOPO command is used to define the type of symmetry, the coordinate system and, if
necessary, the rotation angle (in case of rotation symmetry) or the translation
distance (in case of cyclic symmetry). The symmetry definition can also be
extended to frozen areas by selecting the corresponding checkbox.
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Design Area
The frozen elements of one area are also considered as frozen for the linked
areas if Frozen checkbox is checked.
LINK_TOPO
ID_NAME
CS
TYPE
TRANSLATION
ANGLE
= <Name of LINK_TOPO object>

= <Name of the reference coordinate
system>
= <Type of symmetry>, <axis>
= <Translation for cyclic symmetry>
= <Segment angle for rotation symmetry>
END_
DVCON_TOPO
ID_NAME
EL_GROUP
CHECK_TYPE
CHECK_LINK
=
=
=
=
<Name of DVCON_TOPO object>

LINK_TOPO
<Name of LINK_TOPO definition>
END_
More than one symmetry condition can be defined for an element group.
Geometrically, different combinations have to be feasible.
Defining a symmetry condition in Tosca Extension for ANSYS/Workbench
Fig. 126 Define a symmetry condition

Remark
1. The FE meshes do not have to be symmetric. The restriction can also be
applied to unstructured meshes or to tetrahedron meshes. The elements
should have nearly the same size because the result is the resolution of the
coarsest part of the mesh. It is possible that the linked elements are not
determined correctly if the size of the elements differs too much.
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Add a Symmetry Control to the project by clicking Topology | Symmetry Control. Options like the type of symmetry or directions can be set in
the corresponding Details View window.
SIMULIA
Tosca Structure
5.3.2.8 Combination of manufacturing restrictions

Each geometrical restriction reduces the possibilities of the solution. Thus, it
is necessary to add only the restrictions needed for solving the problem. It is
still possible to find a solution if too many restrictions are defined, but the
result will most probably be suboptimal compared to the optimal design.
Therefore, the first step for the user is to perform an optimization without
restrictions to obtain knowledge about the restrictions needed for the specific
problem.
It is not possible to combine all manufacturing constraints at random. The
user has to be careful when combining the restrictions.
The DVCON_TOPO constraints are processed in a fixed order (independent
of the definition order in the parameter file):
1. minimum member size;
2. symmetry;
3. casting restriction;
4. maximum member size.
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It is possible within this order that one constraint weakens the modification of
another restriction.
E.g., a combination of reflection symmetry and a casting restriction defined by
a pull direction which is not parallel to the reflection symmetry axis is questionable geometrically and the user is not allowed to specify such a restriction.
Fig. 127 Illegal combination of pull direction with reflection symmetry

Examples for possible combinations:
Reflection symmetry can be combined with a pull direction on the condition
that the pull direction is perpendicular or parallel to the symmetry plane.
Rotation symmetry and the definition of a pull direction: this combination is
possible if the pull direction is parallel to the axis of rotation.
Two reflection symmetries can be combined if the planes are perpendicular.
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Tosca Structure
Design Area
The combination of a maximum member size and a pull direction is not recommended for the controller based algorithm. It is possible that the optimization does not converge, depending on the finite element mesh.
Minimum member size control and maximum member size control can be
combined if the radius of the minimum member size is larger than the
radius of the maximum member size (!). This can be done because the
minimum member size control is processed before the maximum member
size control. The optimizer creates thick supports that are broken up in the
second step. Parallel double supports can often be seen with this combination. The choice of a radius for the maximum member size which is larger
than the radius of the minimum member size does not influence the combination.
Fig. 128 Feasible combinations of pull directions and symmetry
5.3.2.9 Tips on defining restrictions with Tosca Structure.gui

The DVCON_TOPO ID name has to be referenced in the OPTIMIZE command in order to activate the restriction.
OPTIMIZE
= name_of_dvcon_entry
END_
The element group for a certain restriction should be a subset of the design
element group. If this is not the case, Tosca Structure will stop the optimization.
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...
DVCON
...
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Tosca Structure
5.4
Objective Function
The objective function describes the optimization target. In general, one scalar value (sometimes combined from other scalars) is to be maximized or
minimized.
5.4.1
Overview
The OBJECTIVE FUNCTION is the function, which value can be maximized
or minimized during the optimization. This function depends on the results of
the FE analysis. Therefore, the values of interest must be derived from the FE
results in order to define an objective function and functional constraints. The
results of the FE analysis (total displacement, energy, etc.) for determining
the objective function and functional constraints are called design
responses. A single value from the design response must be specified for the
definition of the objective function using the command DRESP (DESIGN
RESPONSE). For Details about design responses refer to vol.2 chapter 4.4,
Design Responses. General comments about the definition of objective functions can be found in vol.2 chapter 4.2, Objective Function.
5.4.2
Minimization or maximization of an objective
Compliance terms for

objective
Material volume terms

for objective
Eigenfrequency terms
for objective
+C k
+ ( V V )
+f k

--- ln
k
j = 1 e
kf j
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The following tables describe which design response types are valid as the
terms of an objective function that is to be minimized or maximized:
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Tosca Structure
Objective Function
Displacement terms for

objective
Reaction force terms

for objective
Internal force terms for

objective
+u i
+R i
+F i
+ i
+M i
+M i
+ u i
+ R i
2
+ F i
2
+ u x + u y + u z
+ R x + R y + R z
+ F x + F y + F z
+ ( u i ,1 u i ,2 )
+ ( R i ,1 R i ,2 )
+ ( F i ,1 F i ,2 )
+ ( u i ,1 u i ,2 )
+ ( R i ,1 R i ,2 )
Von Mises stress terms

for objective
+ ( F i ,1 F i ,2 )
Center of gravity
terms for objective
Moment of inertia
terms for objective
+i i
+I ij
In this table, the indices i and j indicate a direction of an axis (x, y or z) of the
global or a local coordinate system. The compliance, eigenfrequencies, displacements and forces can be based upon results from different load cases.
The reference values marked with "*" are defined in DRESP parameter of
OBJ_FUNC command. By default, the reference values are zero. The reference values can be set individually for each term in the objective function.
The weight factors are defined by the user in DRESP parameter of
OBJ_FUNC command. The weight factors are set individually for each term of
the objective function. By default, the weight factors are set to 1.
In the example below, the weight factor is set to 1.5 and the reference value is
set to 4.0:
OBJ_FUNC
...
DRESP
...
END_
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= id_dresp, 1.5, 4.0
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( vMises )
+Max ----------------------------2- ref
( f ( i ) ref )
SIMULIA
Tosca Structure
Remarks
1. A minimization optimization task can be converted into a maximization optimization task (or vice versa) by changing the sign of the weighting factors
in the definition of the objective function.
5.4.3
Multidisciplinary objective (minmax formulation)

The following tables describe which terms and response types are valid in the
Min-Max formulation
Compliance terms in
Min-Max

in Min-Max
in Min-Max
( C k C k )
( V V )
1
-----------------
fk fk
Displacement terms in Min-Max
( u i u i )
( )
( R i R i )
(M M )
2
( u i u i )
2
( R i R i )
( u x + u y + u z u )
((u u ) u )
( R x + R y + R z R )
((R R ) R )
2
( ( u i ,1 u i ,2 ) u i )
( ( R i ,1 R i ,2 ) R i )
i ,1
i ,2
i ,1
i ,2
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Reaction force terms in Min-Max
User Manual 2 - 219
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Tosca Structure
Constraints
Von Mises stress terms

in Min-Max
Center gravity terms

in Min-Max
Moment of inertia
terms in Min-Max
i C i C
I ij I ij
( vMises )
Max ----------------------------2- ref
( f ( i ) ref )
where the index i and j are indicating one of the x-y-z-directions. The compliance, eigenfrequencies, displacements and reaction forces can be from different load cases.
The REFERENCE values marked with the star "*" are defined by the use in
the DRESP command in OBJ_FUNC. Normally, the reference values are zero.
Hence, by default all reference values are set to zero. The reference can be
set individually for each term in the objective function.
The WEIGHT factors are defined by the user in the DRESP command in
OBJ_FUNC. The weight factors can be different for each individual term in the
objective function. By default the weighting factors are all set to one. Hence,
by default all weighting factors are set to one.
The reference value and weight factor can be changed, e.g. to 2.5 and 14.0
for response id_dresp in the following way:
OBJ_FUNC
...
DRESP
...
= id_dresp, 2.5, 14.0
The main difference between the scheme in vol.2 chapter 5.4.2 and the present scheme is the way the frequency terms are defined in the objective.
5.5
Constraints
Constraints are fundamental parts of the definition for an optimization task,
see also vol.2 chapter 4.3. The purpose of having constraints is to ensure that
the optimized design is feasible. The following two tables describe which
design response types are valid as constraints. These design responses can
be constrained using equality constraint, lower equal constraint or greater
equal constraint as explained in vol.2 chapter 4.3. Note, that the equality constraint is only allowed for the controller based topology optimization. The
lower equal or greater equal constraints are allowed for the sensitivity based
approach as explained in vol.2 chapter 5.2.1. The constraint values can be
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END_
SIMULIA
Tosca Structure
defined as absolute values or relative with respect to the corresponding values of the optimization start model. Moreover, for the sensitivity based
approach new combinations using VAR_OPER or GROUP_OPER for the
DRESP can also be applied in the constraints as described in vol.2 chapter
4.3:

constraints

for constraints
C k C k
V V
[ V V ]
[ C l C l ]
for constraints
f k f k
f l f l
f k f l f
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[ f k f l f ]
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Tosca Structure
Constraints

constraints

for constraints
Internal force terms

for constraints
u i u i
R i R i
F i F i
u i u i
R i R i
F i F i
i i
M i M i
M i M i
i i
M i M i
M i M i
2
u i u i
R i R i
2
F i F i
2
[ u i u i ]
[ R i R i ]
[ F i F i ]
u x + u y + u z u
2
R x + R y + R z R
F x + F y + F z F
2
[ u x + u y + u z u ]
2
2
2
2
2
2
[ R x + R y + R z R ] [ F x + F y + F z F ]
u i ,1 u i ,2 u i
R i ,1 R i ,2 R i
F i ,1 F i ,2 F i
u i ,1 u i ,2 u i
R i ,1 R i ,2 R i
F i ,1 F i ,2 F i
( u i ,1 u i ,2 ) u i
( R i ,1 R i ,2 ) R i
[ ( u i ,1 u i ,2 ) u i ]
2
( F i ,1 F i ,2 ) F i
2
[ ( R i ,1 R i ,2 ) R i ] [ ( F i ,1 F i ,2 ) F i ]
2
i ,1 u i ,1 + i ,2 u i ,2 + u i
Von Mises stress terms for

constraints
( vMises )
Max ----------------------------2- ref ref
( f ( i ) ref )
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Center of gravity
terms for
constraints
Moment of inertia
terms for
constraints
i i i i
I ij I ij
i i i i
I ij I ij
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i ,1 u i ,1 + i ,2 u i ,2 + u i
SIMULIA
Tosca Structure
Remark
1. Constraints defined using relative values always refer to the design
response of the start model for the optimization. Please note that the
element densities in the optimization start model may be modified
compared to your original model (e.g. when no volume constraint is
present they are set to 50% of the original density). Take this into account
when defining, e.g., relative displacement or frequency constraints. This
behaviour can be controlled by the user with the parameter
DENSITY_INITIAL in the OPT_PARAM command.
5.5.1
Multiple material constraints and constitutive laws

Multiple material constraints and constitutive laws are allowed in the design
domain. I.e., different sub domains of the total design domain can be subject
to different material volume constraints. Furthermore, different sub domains
are allowed to have different constitutive material laws.
Remarks
1. The DRESP WEIGHT_TOPO_FILL is not allowed when the design area
contains different materials.
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Fig. 129. shows the design domain consisting of three different materials.
Two volume constraints are applied in the design domain. The elements on
the left side have the volume constraint of 20%, and the elements on the right
side have the volume constraint of 40%.
Fig. 129 Design domain consisting of three different materials. The stiffness of the structure is optimized under two material volume constraints.
User Manual 2 - 223
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Tosca Structure
Constraints
The design element group contains all elements:

DV_TOPO
ID_NAME
EL_GROUP
= DESIGN_VARIABLES
= ALL_ELEMENTS
END_
Then, using the groups ELEM_LEFT (left part of the model) and
ELEM_RIGHT (right part of the model), two separate design responses are
defined:
DRESP
ID_NAME
DEF_TYPE
TYPE
EL_GROUP
GROUP_OPER
=
=
=
=
=
DRESP_VOL_TOPO_LEFT
SYSTEM
VOLUME
ELEM_LEFT
SUM
=
=
=
=
=
DRESP_VOL_TOPO_RIGHT
SYSTEM
VOLUME
ELEM_RIGHT
SUM
END_
DRESP
ID_NAME
DEF_TYPE
TYPE
EL_GROUP
GROUP_OPER
END_
Afterwards, these design responses are applied in the relative volume constraints:
ID_NAME
DRESP
MAGNITUDE
LE_VALUE
=
=
=
=
VOLUME_CONSTRAINT_LEFT
DRESP_VOL_TOPO_LEFT
REL
0.2
=
=
=
=
VOLUME_CONSTRAINT_RIGHT
DRESP_VOL_TOPO_RIGHT
REL
0.4
END_
CONSTRAINT
ID_NAME
DRESP
MAGNITUDE
LE_VALUE
END_
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CONSTRAINT
SIMULIA
Tosca Structure
Remark
1. It is not allowed for the element groups with different volume constraints to
have common elements. In other words, each element can be used in no
more than one volume constraint.
The compliance is minimized in the objective in order to maximize the stiffness:
DRESP
ID_NAME
DEF_TYPE
TYPE
EL_GROUP
GROUP_OPER
=
=
=
=
=
DRESP_SUM_ENERGY
SYSTEM
STRAIN_ENERGY
ALL_ELEMENTS
SUM
END_
OBJ_FUNC
ID_NAME
DRESP
TARGET
= MAXIMIZE_STIFFNESS
= DRESP_SUM_ENERGY
= MIN
END_
Finally, the commands defined above are referenced in OPTIMIZE command:

OPTIMIZE
ID_NAME
DV
OBJ_FUNC
CONSTRAINT
CONSTRAINT
=
=
=
=
=
TOPOLOGY_OPTIMIZATION
DESIGN_VARIABLES
MAXIMIZE_STIFFNESS
VOLUME_CONSTRAINT_LEFT
VOLUME_CONSTRAINT_RIGHT
END_
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Fig. 130 shows the results of the optimization.

Abaqus
Nastran
ANSYS
Marc
PERMAS
User Manual 2 - 225
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Tosca Structure
Typical Tasks for Static Analysis
Fig. 130 The solution for the optimization problem shown in Fig. 129.
5.6

This section deals with the typical optimization tasks for the static, nonlinear
static and temperature static analysis types. Only some very common tasks
are described here; for complex optimization tasks, it is useful and necessary
to combine, e.g., the static compliance as the objective with the displacement
constraints and modal frequency constraints resulting from a modal analysis.
Please refer to Tosca Structure example manual for these cases.
5.6.1
Minimizing compliance under volume constraint

This standard optimization task corresponding to maximizing the stiffness is
defined as the minimization of the compliance that is the reciprocal value of
the stiffness.
Formulation of the optimization problem
min
U
i = 1, n
i = 1, n Vol
= vol_restrict
with U being the strain energy, Vol the element volume and vol_restrict the
value of the volume constraint.
Necessary definitions
The user has to define two design responses in order to set up the optimization problem:
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The optimization problem can be solved with the controller based approach
(which needs about 15 iterations to solve the problem) and with the sensitivity
approach (where the number of iterations is not previously known).
The controller based approach works with equality constraints, so that the
problem looks like:
SIMULIA
Tosca Structure
1. The design response for the sum of the strain energy over all elements (if
not all elements are selected, then the problem will not represent the maximization of the total stiffness).
2. The design response for the relative volume defined as the sum of volumes
of elements multiplied with their relative densities and divided through the
original volume.
3. The strain energy can be used as an objective function term. The answer
to the question whether to minimize or to maximize the sum of the strain
energy depends on the loading types and boundary conditions, respectively. If the loads for the model are applied as external forces or pressure,
then the objective function has to be minimized. If only prescribed displacements are assigned and no external forces, then the objective function has
to be maximized. If simultaneously prescribed displacements and external
loading are assigned then a new energy stiffness measure
ENERGY_STIFF_MEASURE is available for stiffness optimization using
sensitivity based topology optimization.
4. The relative material volume is used in the equality constraint, so that the
optimization results the stiffest model that has the specified material
volume (and thus weight). Without the constraint, the stiffest structure will
use as much material as possible.
The commands in the parameter file for this problem look like:
DRESP
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ID_NAME
DEF_TYPE
TYPE
UPDATE
EL_GROUP
GROUP_OPER
=
=
=
=
=
=
DRESP_SUM_ENERGY
SYSTEM
STRAIN_ENERGY
EVER
ALL_ELEMENTS
SUM
=
=
=
=
=
=
DRESP_VOL_TOPO
SYSTEM
VOLUME
EVER
ALL_ELEMENTS
SUM
END_
DRESP
ID_NAME
DEF_TYPE
TYPE
UPDATE
EL_GROUP
GROUP_OPER
END_
OBJ_FUNC
ID_NAME
= maximize_stiffness
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DRESP
TARGET
= DRESP_SUM_ENERGY
= MIN
END_
CONSTRAINT
ID_NAME
DRESP
MAGNITUDE
EQ_VALUE
=
=
=
=
volume_constraint
DRESP_VOL_TOPO
REL
0.45
=
=
=
=
=
topology_optimization
design_variables
maximize_stiffness
volume_constraint
TOPO_CONTROLLER
END_
OPTIMIZE
ID_NAME
DV
OBJ_FUNC
CONSTRAINT
STRATEGY
END_
Remark
1. The same optimization task can be solved using the sensitivity based
topology optimization. Then, the relative material volume constraint should
be set to "less or equal", i.e., LE_VALUE parameter should be used instead
of EQ_VALUE parameter.
Defining the stiffness optimization task in Tosca ANSA environment
Please refer to vol.2 chapter 5, Topology Optimization section where an
example similar to this one is described.
Realization with the Tosca Structure.gui
5.6.2
Minimizing displacement/rotation under volume constraint

Aim of this optimization task is to get a structure with a minimum deflection or
rotation. In case that the displacement at a node with a load is to be minimized, the problem is identical to the maximization of the stiffness.
The optimization problem can be solved with the sensitivity based approach.
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Please refer to vol.2 chapter 5, Topology Optimization section where an

example similar to this one is described.
SIMULIA
Tosca Structure
The sensitivity based approach works with an inequality constraint, and the
optimization problem is
min ( u i )
i = 1, n Vol vol_restrict
with u i being the displacement in a given coordinate or the total displacement, Vol the element volume and vol_restrict the value of the volume constraint.
The user has to define two design responses in order to set up the optimization problem:
1. The design response for the displacement of the given node. The displacement in a given direction (x, y or z) or the absolute value of the displacement is chosen according to the value of TYPE parameter. Please refer to
vol.2 chapter 4.4.3, Displacement and rotation for details.
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2. The design response for the relative volume defined as the sum of volumes
of elements multiplied with their relative densities and divided through the
original volume.
3. The objective function is the minimization of the displacement design
response. If more than one node is used in the design response definition,
an individual design response is created for each node. In this case, a
large number of nodes leads to many objective function terms. The target
of the objective function is to minimize the nodal displacement of a single
node, or, if more than one node is specified in the displacement design
response, the target should be set to the minimization of the largest
displacement. Please check the TOSCA.OUT file for the list of generated
design responses.
4. The relative material volume is used in the inequality constraint, so that the
optimization results the stiffest model that has the material volume (and
thus weight) less than a certain value. Without the constraint, the stiffest
structure will use as much material as possible.
The commands in the parameter file for this problem look like:
DRESP
ID_NAME
DEF_TYPE
TYPE
= DRESP_DISP_X
= SYSTEM
= DISP_X
User Manual 2 - 229
SIMULIA
Tosca Structure
UPDATE
NODE
GROUP_OPER
LC_SET
LC_SEL
=
=
=
=
=
EVER
557
MAX
STATIC,2,ALL
MAX
=
=
=
=
=
=
DRESP_VOL_TOPO
SYSTEM
VOLUME
EVER
ALL_ELEMENTS
SUM
END_
DRESP
ID_NAME
DEF_TYPE
TYPE
UPDATE
EL_GROUP
GROUP_OPER
END_
OBJ_FUNC
ID_NAME
DRESP
TARGET
= DRESP_DISP_X
= MIN
END_
CONSTRAINT
ID_NAME
DRESP
MAGNITUDE
LE_VALUE
=
=
=
=
volume_constraint
DRESP_VOL_TOPO
REL
0.45
=
=
=
=
=
design_variables
maximize_stiffness
volume_constraint
TOPO_SENSITIVITY
END_
ID_NAME
DV
OBJ_FUNC
CONSTRAINT
STRATEGY
END_
The following example deals with the minimization of displacements of more

than one node:
DRESP
ID_NAME
DEF_TYPE
TYPE
UPDATE
NODE
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=
=
=
=
=
DRESP_DISP_X_1
SYSTEM
DISP_X
EVER
557
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OPTIMIZE
SIMULIA
Tosca Structure
GROUP_OPER
LC_SET
LC_SEL
= MAX
= STATIC,2,ALL
= MAX
END_
DRESP
ID_NAME
DEF_TYPE
TYPE
UPDATE
NODE
GROUP_OPER
LC_SET
LC_SEL
=
=
=
=
=
=
=
=
DRESP_DISP_X_2
SYSTEM
DISP_X
EVER
1997
MAX
STATIC,1,ALL
MAX
=
=
=
=
=
=
DRESP_VOL_TOPO
SYSTEM
VOLUME
EVER
ALL_ELEMENTS
SUM
=
=
=
=
maximize_stiffness
DRESP_DISP_X_1
DRESP_DISP_X_2
MINMAX
=
=
=
=
volume_constraint
DRESP_VOL_TOPO
REL
0.45
=
=
=
=
=
design_variables
maximize_stiffness
volume_constraint
TOPO_SENSITIVITY
END_
DRESP
ID_NAME
DEF_TYPE
TYPE
UPDATE
EL_GROUP
GROUP_OPER
END_
OBJ_FUNC
ID_NAME
DRESP
DRESP
TARGET
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END_
CONSTRAINT
ID_NAME
DRESP
MAGNITUDE
LE_VALUE
END_
OPTIMIZE
ID_NAME
DV
OBJ_FUNC
CONSTRAINT
STRATEGY
User Manual 2 - 231
SIMULIA
Tosca Structure
END_
Defining the displacement optimization task in Tosca ANSA environment

The definition of the optimization task proceeds as in the examples described
in Getting Started manual (see vol.2 chapter 5, Topology Optimization), with
the displacement design response defined using New | DISPLACEMENT
command applied on OBJ_FUNC item in Task Manager.
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Fig. 131 Defining the displacement objective function
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Fig. 132 Selecting the nodes for the displacement design response
User Manual 2 - 233
SIMULIA
Tosca Structure
Defining the displacement optimization task in Tosca Structure.gui

In this example, the displacement design response is defined and referenced
in OBJ_FUNC command:
The objective function is defined as the minimization problem of the design

response defined above.
Definition of a displacement optimization task in Tosca Extension for
ANSYS/Workbench
Add a Design Response to the project by clicking Optimization |
Design
Response. Choose Displacement
as Category in the
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Fig. 133 Definition of the displacement design response
SIMULIA
Tosca Structure
Details View window. Further options like the direction (Respone Type)
can be selected and the desired node(s) has to be defined.
Fig. 134 Create a displacement constraint within a Design Response
5.6.3
Constraint for difference between two displacements
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Aim of this optimization task is to obtain the structure with maximal stiffness
subject to the constraint on the difference of the displacements of two nodes.
This relative displacement constraint is used in the stiffness optimization task
of the shift fork model (see Fig. 135).
Fig. 135 Shift fork model with displacement plot

The two arms of the shift fork have unequal displacements. This is caused by
the different lengths of the arms. In order to get a working component, the displacements of the two arms have to be nearly identical. If the displacements
are different, then the gear wheel is not able to be moved with the shift-fork.
User Manual 2 - 235
SIMULIA
Tosca Structure

The optimization problem will be solved with the sensitivity based topology
optimization. The optimization task is formulated as
min ( U )
u 1 u 2 u max Difference
Vol vol_restrict
with U being the sum of the strain energy over all elements, u 1 and u 2 the
displacements of the nodes in a given direction (x, y or z), Vol the relative
material volume, vol_restrict the value of the volume constraint and
u maxDifference the constraint value.
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Five design responses are needed in this example.
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Tosca Structure
Defining a displacement constraint in Tosca ANSA environment
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Fig. 136 Definition of the constraint as combined term within the Tosca
ANSA environment
First, create a COMBINED_ITEM design response with VAR_OPER =
SUB_ABS. Then, create the individual design responses for each of the two
displacements. In order to do it, press "?" key in VARIABLE_1 field and press
New button in the appeared dialog, then choose TOSCA_DRESP. In the dialog,
choose TARGET = NODE, TYPE = DISP_Z (in case of the displacement in zdirection), then enter the node ID (NID field) and the load case(s) (LC_SET
field). Click OK and then double click on the name of the design response in
TOSCA HELP window so that this design response is entered in VARIABLE_1
field of the COMBINED_ITEM design response. Repeat the steps for the second displacement entered in VARIABLE_2 field.
For more details, see Fig. 136.
User Manual 2 - 237
SIMULIA
Tosca Structure
Defining a displacement constraint in Tosca Structure.gui

1. Define the design response for the displacement of the first node. Also the
direction has to be specified with the appropriate selection of the type. For
a list of existing types, please refer to vol.2 chapter 4.4.3, Displacement
and rotation. (The total absolute value can not be used as design
response.)
2. Define the design response for the displacement of the second node,
similar to the first one.
3. Define the design response with the difference of the nodal displacement
from the two nodes. To do this, create a DRESP command and choose
DefType = Operator, Operator = SUB_ABS.
Defining a displacement constraint in Tosca Extension for ANSYS/Workbench
Differences between displacments (OPER) are not available yet.
Common steps for Tosca ANSA environment and Tosca Structure.gui
1. A second constraint for the relative material volume has to be defined.
Only a few elements will be removed in the short arm in order to obtain
equal displacements of the two arms. In most cases the intention is to have
a structure with a given weight and the maximum stiffness.
2. The objective function has to be defined as minimization of the compliance
of the whole model. This is defined as the sum of the strain energy of all
elements (ALL_ELEMENTS element group).
The commands in the parameter file for this problem look like follows:
ID_NAME
TYPE
DEF_TYPE
LC_SET
GROUP_OPER
ND_GROUP
=
=
=
=
=
=
DISP_TIP_RIGHT
DISP_Z
SYSTEM
STATIC,1,
Max
TIP_RIGHT
=
=
=
=
=
=
DISP_TIP_LEFT
DISP_Z
SYSTEM
STATIC,1,
Max
TIP_LEFT
END_
DRESP
ID_NAME
TYPE
DEF_TYPE
LC_SET
GROUP_OPER
ND_GROUP
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DRESP
SIMULIA
Tosca Structure
END_
DRESP
ID_NAME
DEF_TYPE
VAR_OPER
VAR_A
VAR_B
=
=
=
=
=
DISP_DIFFERENCE
OPER
SUB_ABS
DISP_TIP_RIGHT
DISP_TIP_LEFT
=
=
=
=
=
=
DRESP_SUM_ENERGY_LC1
STRAIN_ENERGY
SYSTEM
STATIC,1
SUM
ALL_ELEMENTS
END_
DRESP
ID_NAME
TYPE
DEF_TYPE
LC_SET
GROUP_OPER
EL_GROUP
END_
OBJ_FUNC
ID_NAME
TARGET
DRESP
= MY_OBJ_FUNC
= MIN
= DRESP_SUM_ENERGY_LC1
END_
CONSTRAINT
ID_NAME
MAGNITUDE
DRESP
LE_VALUE
=
=
=
=
DISP_DIFF_CONSTRAINT
ABS
DISP_DIFFERENCE
0.1
=
=
=
=
=
DRESP_VOL_TOPO
VOLUME
SYSTEM
SUM
ALL_ELEMENTS
=
=
=
=
VOL_CONSTRAINT
REL
DRESP_VOL_TOPO
0.3
Version 8.1.0 Rev. 1 - 05.2014
DRESP
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END_
CONSTRAINT
ID_NAME
TYPE
DEF_TYPE
GROUP_OPER
EL_GROUP
END_
ID_NAME
MAGNITUDE
DRESP
LE_VALUE
User Manual 2 - 239
SIMULIA
Tosca Structure
END_
5.6.4
Minimization of a reaction or internal force
Fig. 137 Box model with spot-weld elements; 2 load cases (Force 1 and
Force 2) are applied
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The aim of this optimization is to minimize the internal force of spot-weld elements. Both the relative material volume constraint and a displacement constraint are used. A simple box model with 16 spot-weld elements is optimized.
SIMULIA
Tosca Structure
Fig. 138 Displacement plots for load cases 1 and 2

The box is loaded with 2 forces on the two sides. The edges of the bottom
rectangle are fixed.
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The optimization problem can be formulated in different ways.

The first possible formulation is to minimize the maximum spot-weld force
under a volume constraint. The second formulation is to minimize the volume
while restricting the forces in the spot-weld elements. Additionally, a displacement constraint is applied.
The second formulation is presented in the following
( m in Vol )
F node F Limit
node=1m
u node u Limit
node=1k
with Vol being the relative material volume of the design area, F node the
nodal force in an element in a given direction, F Limit the constraint force,
u node the nodal displacement and u Limit the restriction for the nodal displacement.
Four design responses are needed in order to set up the optimization task.
1. The first design response is the relative material volume of the design
area. This relative material volume design response is then used in the
objective function that is to be minimized.
2. The second design response is the maximum internal force over the nodes
of a given node group belonging to the elements mentioned in the given
element group.
User Manual 2 - 241
SIMULIA
Tosca Structure
3. The third and fourth design responses are the displacements of the loaded
nodes that are then used in constraints. These design responses are
defined as the total displacements for each load case and the appropriate
loaded node.
Defining an internal force constraint in Tosca ANSA environment
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Create a constraint with New | INTERNAL_FORCE_CONSTRAINT command

applied
on
CONSTRAINTS
item,
choose
TARGET
=
NODE_AND_ELEMENT_GROUP, ND_GROUP_DEF = ND_GROUP_DEF,
EL_GROUP_DEF = EL_GROUP_DEF. Then, press "?" key in
ND_GROUP_DEF field and choose the appropriate node group; repeat for
EL_GROUP_DEF where an element group shall be chosen, see Fig. 139.
Internally in Tosca Structure, a separate design response for each pair (node,
element) is created, where the node belongs to the chosen node group and to
the element (that itself belongs to the chosen element group). In the example,
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32 nodes are connected to the cweld elements. Since there are two load
cases, 64 design responses are produced in Tosca Structure.
Fig. 139 Defining the internal force constraint in Tosca ANSA environment
User Manual 2 - 243
SIMULIA
Tosca Structure
Fig. 140 Defining the internal force constraint in Tosca Structure.gui

Definining a reaction force constraint in Tosca Extension for ANSYS/WB
Define a Reaction Force constraint within a Design Response. Add a
Design Response first by clicking Optimization | Design Response,
then select Reaction Force/Moment as Category and the desired direction as Response Type. Assign a node to the design response.
2 - 244 User Manual
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Defining an internal force constraint in Tosca Structure.gui
SIMULIA
Tosca Structure
Call this Design Response in a Constraint (Note: If you change the

name of the Design Response by using the F2 button, it might be easier to
use the Design Response later). Therefore add a Constraint to the
project first, by clicking Optimization | Constraint.
Remark
1. Internal forces are not available in the ANSYS Workbench Extension and
thus the setup is performed using reaction forces.
Fig. 141 Defining the Category of a Design Response
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Fig. 142 Call the predefined Design Response in a Constraint
User Manual 2 - 245
SIMULIA
Tosca Structure
Result and Convergence
Fig. 144 Internal force constraint values during the optimization process
2 - 246 User Manual
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Fig. 143 Objective function (relative material volume) during the optimization process
SIMULIA
Tosca Structure
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Fig. 145 Displacement constraint values during optimization process
Fig. 146 Result of the optimization under force constraints in the spot weld
elements
The result of the optimization is shown in Fig. 146.
Definition summary (incomplete)
DRESP
ID_NAME
= DRESP_VOLUME
User Manual 2 - 247
SIMULIA
Tosca Structure
TYPE
DEF_TYPE
GROUP_OPER
EL_GROUP
=
=
=
=
VOLUME
SYSTEM
Sum
ALL_ELEMENTS
END_
OBJ_FUNC
ID_NAME
TARGET
DRESP
= MINIMIZE_VOLUME
= MIN
= DRESP_VOLUME, ,
END_
GROUP_DEF
ID_NAME
TYPE
FORMAT
LIST_BEGIN
5291, 4055, 5295,
5501, 4026, 5505,
5186, 4685, 5190,
5396, 4656, 5400,
= CWELD_NODES
= NODE
= LIST
4051,
4030,
4681,
4660,
5299,
5509,
5194,
5404,
4047,
4034,
4677,
4664,
5303,
5513,
5198,
5408,
4043,
4038,
4673,
4668
END_
GROUP_DEF
ID_NAME
TYPE
FORMAT
LIST_BEGIN
100000-100015
= CWELD_ELEMENTS
= ELEM
= LIST
END_
ID_NAME
TYPE
DEF_TYPE
GROUP_OPER
EL_GROUP
ND_GROUP
=
=
=
=
=
=
DRESP_INT_FORCE_ABS
INTERNAL_FORCE_ABS
SYSTEM
Max
CWELD_ELEMENTS
CWELD_NODES
=
=
=
=
CONSTRAINT_INT_FORCE_ABS
DRESP_INT_FORCE_ABS
ABS
15
END_
CONSTRAINT
ID_NAME
DRESP
MAGNITUDE
LE_VALUE
END_
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DRESP
SIMULIA
Tosca Structure
DRESP
ID_NAME
DEF_TYPE
TYPE
NODE
LC_SET
GROUP_OPER
=
=
=
=
=
=
DRESP_DISP_LC11
SYSTEM
DISP_ABS
3900
ALL,11,All
Max
=
=
=
=
=
=
DRESP_DISP_LC12
SYSTEM
DISP_ABS
4530
ALL,12,All
Max
=
=
=
=
MAX_DISP_LC11
ABS
DRESP_DISP_LC11
0.003
=
=
=
=
MAX_DISP_LC12
ABS
DRESP_DISP_LC12
0.003
=
=
=
=
=
=
=
=
DESIGN_VARIABLES
MINIMIZE_VOLUME
MAX_DISP_LC11
DVCON_FROZEN
TOPO_SENSITIVITY
MAX_DISP_LC12
CONSTRAINT_INT_FORCE_ABS
END_
DRESP
ID_NAME
DEF_TYPE
TYPE
NODE
LC_SET
GROUP_OPER
END_
CONSTRAINT
ID_NAME
MAGNITUDE
DRESP
LE_VALUE
END_
CONSTRAINT
ID_NAME
MAGNITUDE
DRESP
LE_VALUE
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END_
OPTIMIZE
ID_NAME
DV
OBJ_FUNC
CONSTRAINT
DVCON
STRATEGY
CONSTRAINT
CONSTRAINT
END_
OPT_PARAM
User Manual 2 - 249
SIMULIA
Tosca Structure
ID_NAME
= MY_PARAMETERS
OPTIMIZE
= TOPOLOGY_OPTIMIZATION
STOP_CRITERION_DENSITY = 0.001
END_
5.6.5
Minimization of the volume under displacement constraint

If the structure with the minimal volume (weight) subject to displacement constraints (corresponding to a restriction on the mechanical stiffness) is sought,
the optimization task is formulated as follows:
min Vol
i = 1, n
u j u restrict,j
j =1...m
Fig. 147 Model of a support structure with fixtures (right) and 4 loads (left)
Two design responses are needed:
1. The first design response is the design response representing the relative
material volume of the design area. This design response is the objective
function that is to be minimized.
2. The second design response is the displacement of the loaded node. The
absolute displacement is used in this case. Alternatively, the displacement
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where Vol is the relative material volume of an element in the design area, u j
is the nodal displacement and u restrict ,j is the restriction for the nodal displacement of the node j.
A model for the minimization of the relative material volume under the displacement of the loaded node is presented in the example below:
SIMULIA
Tosca Structure
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in the direction of the load (in the example it is Z-direction of a local coordinate system) can be used. The restriction to one direction reduces the
number of load cases generated by the optimization system because using
absolute displacement leads to the need of 3 additional load cases in order
to calculate the sensitivities while the displacement in Z-direction only
requires one additional pseudo-load case for the calculation of the sensitivities. The constraint is then defined as an inequality constraint with an
absolute value for the displacement value.
User Manual 2 - 251
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Tosca Structure
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Fig. 148 Objective function (relative material volume) during the optimization process
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Fig. 149 Displacement constraint value during optimization process
Fig. 150 Result of the optimization with displacement constraint

The result of the optimization is shown in Fig. 150.
User Manual 2 - 253
SIMULIA
Tosca Structure
Definition summary (incomplete)

DRESP
ID_NAME
DEF_TYPE
EL_GROUP
GROUP_OPER
TYPE
=
=
=
=
=
DRESP_VOLUME
SYSTEM
design_elem
Sum
VOLUME
END_
OBJ_FUNC
ID_NAME
DRESP
TARGET
= MINIMIZE_VOLUME
= DRESP_VOLUME, ,
= MIN
END_
DRESP
ID_NAME
TYPE
DEF_TYPE
GROUP_OPER
NODE
=
=
=
=
=
MAX_DISPLACEMENT
DISP_ABS
SYSTEM
Max
300
END_
CONSTRAINT
ID_NAME
DRESP
MAGNITUDE
LE_VALUE
= DISPLACEMENT_CONSTRAINT
= MAX_DISPLACEMENT
= ABS
= 8.5
5.6.6
Minimize the maximum stress with volume constraint

This chapter describes an example using the following model:
Boundary conditions: fully clamped
Non-design elements
Loading
Design elements
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END_
SIMULIA
Tosca Structure
Design elements are shown in blue, the elements in red are defined as nondesign elements due to loads and boundary conditions.
The optimization target is to minimize the maximum von Mises stress with a
volume constraint of 30%.
Initial model
Optimized model
The following diagram shows the difference between the maximum elemental
centroidal von Mises stress calculated by the FE solver and the stress interpolated by Tosca Structure.
Stress
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Max elemental centroidal

von Mises stress from
Tosca Structure

von Mises stress from
solver
Optimization Iteration
Fig. 151 Comparing the interpolated von Mises Stress in the topology optimization and the von Mises stress calculated by the solver.
User Manual 2 - 255
SIMULIA
Tosca Structure
5.6.7
Minimize the material volume with stress constraint

This chapter describes an example using the following model:
Boundary conditions: fully
Non-design elements
Loading
Design elements
Design elements are shown in blue, the elements in red are defined as nondesign elements due to loads and boundary conditions.
The optimization setup is to minimize material volume having a constraint on
theMaximum von Mises stress..
Optimized model
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Initial model
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Tosca Structure
The following diagram shows the difference between the maximal elemental
centroidal Von Mises stress from solver and from Tosca Structure:.
Stress

Von Mises stress from
Tosca Structure

Von Mises stress from
solver
Optimization Iteration
Fig. 152 Comparing the interpolated von Mises Stress in the topology optimization and the von Mises stress calculated by the solver.
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5.7
Typical Optimization Tasks for Modal

Analysis
Often the design target is to increase the first eigenfrequencies in an eigenfrequency spectrum. It is important to consider more than the first natural
eigenfrequency as illustrated in Fig. 153 (b) when increasing the natural frequencies using optimization. Otherwise, the first and secondary mode might
switch during the optimization as shown in Fig. 153 (a).
For some optimization problems it can be desirable that a sudden eignefrequency is increased whereas the other eigenfrequencies are allowed to
decrease as shown in Fig. 153 (a).
In chapter 5.7.1 Maximization of the first eigenfrequencies is described how
several lowest eigenfrequencies are increased (Fig. 153 (b)) and chapter
5.7.2 Maximizing the eigenfrequency of a certain eigenmode addresses how
a specific eigenfrequency in an eigenfrequency spectrum is optimized using
mode tracking (Fig. 153 (a)).
In vol.2 chapter 5.7.3 is described how a band gap in the eigenfrequency
spectrum can be designed. A band gap in the eigenfrequency spectrum contains no eigenfrequencies.
User Manual 2 - 257
SIMULIA
Tosca Structure
Typical Optimization Tasks for Modal Analysis
In chapter 5.7.4 Constraining an eigenfrequency is shown how an eigenfrequency can be applied in a constraint, e.g. when maximizing the stiffness
under the condition that the first eigenfrequency is above 100 Hz or when
minimizing the mass under the condition that the eigenfrequencies are be
below or above certain specified values.
Fig. 153 Optimizing all the lowest eigenfrequencies using the Kreisselmaier-Steinhauser formulation (b) and the single lowest eigenfrequency using mode tracking (a)

The following shows how several lowest eigenfrequencies are increased.
It is important to consider more than the first natural eigenfrequency as illustrated in Fig. 153 (b) when increasing the natural frequencies using optimization. At least the next two first natural frequencies should be considered in the
optimization.
All natural eigenfrequencies requested in the FE model are applied in the
optimization if ALL option is applied in the LC_SET parameter.
During the optimization, the various natural frequencies are automatically
weighted by their distance from the lowest natural frequency, i.e., when the
other natural frequencies approach the first natural frequency during the optimization, the more they will be weighted. Generally, the first natural frequency
is always maximized.
The design response is defined using the Kreisselmaier-Steinhauser formulation as described in chapter 4.4.6 Eigenfrequency.
Any number of natural frequencies in the design response can be specified
using the DRESP command.
In this example, all calculated natural frequencies are considered for the
objective function using the Kreisselmaier-Steinhauser formulation, and the
definition is as follows:
DRESP
ID_NAME = all_lowest_eigenfrequencies
DEF_TYPE = SYSTEM
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TYPE = DYN_FREQ_KREISSEL
LC_SET = MODAL, ALL, ALL
END_
OBJ_FUNC
ID_NAME = maximize_eigenfrequencies
DRESP = all_lowest_eigenfrequencies
TARGET = MAX
END_
If one has requested 10 eigenfrequencies in the finite element input model

but only the first 5 eigenfrequencies are to be used in the optimization definition, then the design response for 5 eigenfrequencies is defined as follows:
DRESP
ID_NAME = all_lowest_eigenfrequencies_1_5
DEF_TYPE = SYSTEM
LC_SET = MODAL, ALL, 1-5
END_
OBJ_FUNC
ID_NAME = maximize_eigenfrequencies_1_5
DRESP = all_lowest_eigenfrequencies_1_5
TARGET = MAX
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Defining an eigenfrequency objective function in Tosca ANSA environment

To add a new objective term for the eigenfrequency optimization, apply New
| EIGENFREQUENCY command on OBJ_FUNC item. It opens the following
dialog:
Fig. 154 Defining a design response for first 5 eigenfrequencies in Tosca

ANSA environment
Defining an eigenfrequency design response in Tosca Structure.gui

Create a new design response and then set DefType = System, Category =
Base and Type = DYN_FREQ_KREISSEL. Choose the load cases by pressing Add LC button and setting Analysis Type to MODAL, entering the load
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In this dialog, choose TYPE = DYN_FREQ_KREISSEL and then select the

appropriate load cases in LC_SET field either directly (note that the 3rd
parameter is the list of required eigenfrequencies, starting with 1 for the lowest one) or by pressing "?" key in LC_SET field and using the window that
appears.
SIMULIA
Tosca Structure
case ID and the numbers of eigenmodes (e.g., 1-5) in Eigenmode/Subcase

field.
Fig. 155 Defining an eigenfrequency design response for first 5 eigenfrequencies in Tosca Structure.gui
Add a Design Response first by clicking Optimization | Design

Response. In the corresponding Details View window, choose Eigenfrequency as Category and for example DYN_FREQ_KREISSEL as Response Type.
The choice All as Load Case | Selection considers all eigenfrequencies for the optimization. If desired differently, select Manual as Load Case
| Selection. More information can be entered by filling out the Tabular
Data. Therefore create a new tab within the Load Cases window, choose
Modal as Analysis, 1 as Steps and 1 as Substep/Mode. Add additional
rows for each of the remaining desired modes (2,3,4,5). In this case only the
first five eigenfrequencies will be considered during an optimization. Click
Apply.
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Defining an design response with certain eigenfrequencies in Tosca Extension for ANSYS/Workbench
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Fig. 156 Defining a Design Response with the first five eigenfrequencies
Maximizing the eigenfrequency of a certain eigenmode

Often it is needed to increase a specific eigenfrequency in the eigenfrequency spectrum belonging to a certain eigenmode as illustrated in Fig. 153
(a). In this case, a specific eigenfrequency is defined using TYPE =
DYN_FREQ, see also chapter 4.4.6 Eigenfrequency.
When optimizing a specific eigenfrequency, the order of the eigenfrequencies
might change during the optimization iterations as shown in Fig. 153 (b).
Consequently, the eigenfrequencies might have to be tracked during the optimization iterations.
The tracking is done using mode tracking as described in chapter 4.4.6.2
Mode tracking and chapter 5.8.2.1 Mode tracking.
By default the modes are not tracked during the optimization. Mode tracking
is activated in OPT_PARAM command:
DRESP
ID_NAME = single_lowest_eigenfrequency_1
DEF_TYPE = SYSTEM
TYPE = DYN_FREQ
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LC_SET = MODAL, ALL, 1

END_
OBJ_FUNC
ID_NAME = maximize_single_eigenfrequency
DRESP = single_lowest__1
TARGET = MAX
END_
OPT_PARAM
ID_NAME = opt_params
OPTIMIZE = maximize_single_eigenfrequency
MODETRACKING = ON
MODENUMBERS = 8
END_
For this example, at least 8 eigenfrequencies should be requested in the finite

element input model defined by the user.
Defining the OPT_PARAM command in Tosca Extension for ANSYS/WB
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Certain parameters of the OPT_PARAM command mentioned above are also

available in the Analysis Settings of the Mechanical application.
Fig. 157 Define additional optimization parameters in the Analysis Settings, e.g. Modetracking and Number of Modes
User Manual 2 - 263
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Defining an objective function for a minimization of a specific eigenfrequency in Tosca ANSA environment
To add a new objective term for the optimization, apply New | command on
OBJ_FUNC item. It opens the following dialog:
Fig. 158 Defining a design response for the first eigenfrequency in Tosca
ANSA environment
Defining a design response for a specific eigenfrequency in Tosca Structure.gui

Base and Type = DYN_FREQ. Choose the load cases by pressing Add LC
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In this dialog, choose TYPE = DYN_FREQ and then select the appropriate
load cases in LC_SET field either directly (note that the 3rd parameter is the
eigenfrequency number, so that 1 corresponds to the smallest eigenfrequency) or by pressing "?" key in LC_SET field and using the window that
appears.
SIMULIA
Tosca Structure
button and setting Analysis Type to MODAL, entering the load case ID and
the numbers of eigenmodes (e.g., 1) in Eigenmode/Subcase field.
Fig. 159 Defining an eigenfrequency design response for the first eigenfrequency in Tosca Structure.gui
Eigenfrequency Design Responses are based on a Modal system that

identifies the eigenfrequencies of a model first.
Add a Design Response by clicking on the Optimization | Design
Response button. Then choose Eigenfrequency as Category. In this
example, select DYN_FREQ as Response Type.
Now select Manual as Load Cases. To add the needed tabular data, create
a new tab, choose Modal as Analysis, 1 as Steps and 1 as Substep/
Mode. In this case only the very first eigenfrequency is considered.
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Defining a design resonse for a specific eigenfrequency in Tosca Extension

for ANSYS/Workbench
User Manual 2 - 265
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Fig. 160 Set up a Design Response with certain eigenfrequency
Fig. 161 Define an Objective Function and call a predefined Design

Response
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Then call the predefined Design Response within an Objective Function. Therefore click Optimization | Objective Function, select
Maximize sum as Target and call the Design Response that contains
the eigenfrequency.
SIMULIA
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5.7.3
Maximization of the band gap

Sometimes it is desirable that the first eigenfrequencies are as far away as
possible from a certain value. E.g., if an engine mainly works at 150 Hz, there
should be an as large as possible interval called a band gap around 150 Hz in
the eigenfrequency spectrum containing no eigenfrequencies. When the
band gap is maximized, some eigenfrequencies are decreased and other
eigenfrequencies are increased.
In the following optimization definition, the structure should be designed so
that the first four eigenfrequencies are as far away as possible from 150 Hz
in order to avoid the resonance at this frequency.
This is done by defining the first four eigenfrequencies as single design
responses with TYPE = DYN_FREQ and applying the eigenfrequencies in
the objective function using a min-max-formulation as follows:
DRESP
ID_NAME = eigenfrequency_1
DEF_TYPE = SYSTEM
TYPE = DYN_FREQ
END_
DRESP
DEF_TYPE = SYSTEM
TYPE = DYN_FREQ
END_
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DRESP
DEF_TYPE = SYSTEM
TYPE = DYN_FREQ
END_
DRESP
DEF_TYPE = SYSTEM
TYPE = DYN_FREQ
END_
OBJ_FUNC
DRESP = eigenfrequency_1, 1.0, 150.0
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TARGET = MINMAX
END_
Defining an objective function for a band gap maximization in Tosca ANSA

environment
Fig. 162 Defining a design response and a reference value for the first
eigenfrequency in Tosca ANSA environment
Defining an objective function for a band gap maximization in Tosca Structure.gui
First, one needs to create 4 design responses as follows. Create a new
design response and then set DefType = System, Category = Base and Type
= DYN_FREQ. Choose the load cases by pressing Add LC button and setting Analysis Type to MODAL, entering the load case ID and the numbers of
eigenmodes (1 for first term, 2 for the second one, etc.) in Eigenmode/Subcase field.
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Four design responses are created and added as the objective function terms
using the command New | EIGENFREQUENCY on OBJ_FUNC item. See vol.2
chapter 5.7.2, Maximizing the eigenfrequency of a certain eigenmode for
details. The reference value (REF_VALUE = 150) should be set for each
objective function term. The only difference between the terms is the mode
number represented by the third parameter in LC_SET field (1 for the first
design response, 2 for the second one, etc.).
SIMULIA
Tosca Structure
Once the design responses are defined, create an OBJ_FUNC command and
choose the design responses and their reference values (set RefValue = 150
for each design response).
Defining an objective function for a band gap maximization in Tosca Extension for ANSYS/Workbench
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For a band gap maximization with four eigenfrequencies there are four
Design Responses needed, one for every eigenfrequency. All Design
Responses have to be inserted in one Objective Function tab.
The Reference Value in the objective function tab should be set (to 150
e.g.) for each listed Design Response in the tab.
Fig. 164 Add four Design Responses to one Objective Function
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5.7.4
Constraining an eigenfrequency
Constraints for eigenfrequencies are allowed in the topology optimization
tasks such as stiffness optimization or minimizing the mass. The conditions
that the first eigenfrequency is above 100 Hz and the second eigenfrequency
is above 250 Hz are used in the example. For each condition, a separate
eigenfrequency design response is to be defined as follows:
DRESP
DEF_TYPE = SYSTEM
TYPE = DYN_FREQ
END_
DRESP
DEF_TYPE = SYSTEM
TYPE = DYN_FREQ
END_
CONSTRAINT
ID_NAME = con_eigen_1
DRESP = eigenfrequency_1
MAGNITUDE = ABS
GE_VALUE = 100.0
END_
ID_NAME = con_eigen_2
DRESP = eigenfrequency_2
MAGNITUDE = ABS
GE_VALUE = 150.0
END_
OPTIMIZE
...
CONSTRAINT = con_eigen_1
CONSTRAINT = con_eigen_2
...
END_
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CONSTRAINT
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Tosca Structure
Defining an eigenfrequency constraint in Tosca ANSA environment

To add a new eigenfrequency constraint, apply New | EIGENFREQUENCY
command on CONSTRAINTS item.
Fig. 165 Defining the constraints on the first and the second eigenfrequencies in Tosca ANSA environment
In CONSTRAINT_ITEM dialog, choose MAGNITUDE = ABS, VALUE =
GE_VALUE, VALUE = 100. Choose the appropriate load case in LC_SET
field either directly or by pressing "?" key in the text field and using the window that appears.
Defining a design response for a specific eigenfrequency in Tosca Structure.gui
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Base and Type = DYN_FREQ. Choose the load cases by pressing Add LC
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button and setting Analysis Type to MODAL, entering the load case ID and
the numbers of eigenmodes (e.g., 1) in Eigenmode/Subcase field.
Defining a design response for a specific eigenfrequency in Tosca Extension for ANSYS/Workbench
Fig. 167 Defining an eigenfrequency design response for a specific eigenfrequency in Tosca Extension for ANSYS/Workbench
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Add a Design Response to your project. By selecting Def Type = System, Category
=
Eigenfrequency and Response
Type
=
DYN_FREQ, the Design Response is set up for an eigenfrequency task.
Set the Load Case selection to Manual and select the desired eigenfrequency in the Steps/Mode field in a new created tab.
SIMULIA
Tosca Structure
5.8
Settings
Different settings can be made to control speed and convergence behaviour
of the topology optimization algorithms. Default values are available which
have been tried and tested on many occasions.
Other algorithm settings for the various optimization algorithms can be
selected using the OPT_PARAM command.
5.8.1
Parameters for standard linear static topology optimization

This chapter describes the possibilities for improving the performance of the
controller-based optimization algorithm using OPT_PARAM command.
5.8.1.1 Increments of volume modification (SPEED)

The user can specify a speed level for modifying the element properties in the
topology optimization. Per default, the number of iterations is set to a fixed
number of 15. The increments for the volume modification are calculated
implicitly. The control of the element properties modification is defined with
the SPEED parameter whereby the user, depending on the objective function
and selected constraint, can choose between the speed levels VERY_SLOW,
SLOW, MODERATE, MEDIUM, FAST and ITER (default set to 15).
For example:
OPT_PARAM
ID_NAME
OPTIMIZE
...
SPEED
...
= optimization_control
= id_of_optimize
= SLOW
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END_
The definition "SPEED=ITER, <number_of_iterations> " sets the number of

iterations (to 15 cycles by default). The number of iterations can be increased
manually or decreased to a minimum number of 10 iterations. A reduction in
the number of iterations can lead to undesired effects in the optimization.
Changing optimization speed can cause a different truss configuration in the
solution. Even if the results look a bit different the results are usually topologically identical.
Topologically identical means that the number and configuration of trusses
can be slightly different, depending on the starting values and the optimization parameters. The resulting structures have the same stiffness (the sum of
the strain energy is almost equal for the different results).
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Settings
5.8.1.2 Volume reduction in first iteration (START_DELETE)

This option can only be used if the speed is not set to "SPEED=ITER". By
default, 5% of the optimization element group volume is removed in the first
iteration of Tosca Structure.topology. Depending on the model being optimized, increasing this starting value may accelerate the optimization. This
can be done without influencing the solution, especially, for models where relatively low stresses are present in large areas. The value is changed using
the START_DELETE parameter. The volume to be removed in the first iteration is specified either by the absolute value as in
START_DELETE = ABS, 200
or by the relative value as in

START_DELETE = PERC, 0.2
Remark
1. Too many elements may be removed in the first iteration if the starting
value is too high. Tosca Structure.topology may not be able to identify the
original force flux if the distribution of forces changes significantly, and the
corresponding elements may consequently be deleted.
5.8.1.3 Tips on speed control

Remark
1. Changing the default settings may in some circumstances lead to coarse
structures due to a higher optimization speed.
In topology optimization, the given mass is distributed within the design area.
During this iterative process, elements with the original mass co-exist with the
original stiffness. But elements also exist that have no mass and no stiffness
as well as elements with an intermediate mass and an unknown stiffness. For
these elements, the relation between density and stiffness must be determined. Several methods can be found in publications determining this relation. One of the most common is the SIMP approach (Simple Isotropic
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5.8.1.4 Relation between relative density and stiffness
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Material with Penalization) which can be reduced to a simple exponential

relation between density and the stiffness of an element.
Fig. 168 Power law for different penalty exponents p.
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p
0
E ijkl = f ( ) in this case with f ( ) = E ijkl -----
0
with E0 ijkl as material stiffness tensor of the original material of density 0
and E ijkl as material stiffness tensor of the unknown material with the corresponding density .
This relation was very controversial but it has proven to be successful in practice. In 1999, BENDSE and SIGMUND have presented the physical theoretical proof for the penalty exponents p 3 and for materials with a lateral
contraction coefficient = 1 3 .
For the integrated algorithms, the penalty factor can be modified using the
OPT_PARAM command. Tosca Structure uses values between 2 and 3 as the
default values depending on the algorithms.
OPT_PARAM
ID_NAME
OPTIMIZE
...
MAT_PENALTY
...
= id_of_optimize
= 2.5
END_
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Settings
5.8.2
Settings for the general sensitivity based optimization

It is possible to apply a simple mode tracking function for the modal analysis
using the modal assurance criterion (MAC) including a mass weighting.
The mode tracking feature can not be guaranteed to work properly for all
examples due to the large material changes during topology optimization.
The modes of the different eigenfrequencies are compared in the modal
assurance criterion (MAC) for identifying if the eigenfrequencies from optimization iteration to optimization iteration have been switching yielding
where the initial modes are equal to the modes of the first iteration. The
modes in the first optimization iteration are used for identifying the eigenfrequencies through the optimization iterations. The MAC matrix is equal to the
unity matrix if the initial modes are equal to the modes in a given optimization
iteration. However, this is only the case in the first optimization iteration due to
the optimization changes. The largest components of the MAC matrix are
determined in each optimization iteration for determining if any mode switching should be present. If significant off-diagonal terms exist in the MAC matrix,
it indicates that the mode switching is present. The MAC matrix is printed in
the TOSCA.OUT file. Then the user can see how close to 1 the components
of the MAC matrix are and whether mode switching is present. If all the values in the MAC matrix are significantly below 1, it indicates that the applied
mode set does not contain enough modes for mode tracking.
According to the above equation, mode tracking can lead to a significant
increase in CPU-time. First, all modes of the eigenfrequencies have to be
cross-checked with each other. Sometimes a high number of cross-checks is
required. Second, more eigenfrequencies have to be calculated by the finite
element solver.
Mode tracking is defined in OPT_PARAM command as in the example below:
OPT_PARAM
ID_NAME
OPTIMIZE
MODETRACKING
MODENUMBERS
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=
=
=
=
opt_params
id_of_optimize
ON
15
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MAC i ,j
( { } i [ Mass ] { reference } j )
= ----------------------------------------------------------------------------------------------------------------------------------( { } i [ Mass ] { } i ) ( { reference } j [ Mass ] { reference } j )
SIMULIA
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END_
Setting the command MODETRACKING equal to ON activates the mode tracking. Default for MODETRACKING is OFF. Consequently, mode tracking will
only be applied if the user requests mode tracking. The value of MODENUMBERS specifies how many eigenfrequencies should be used in the mode
tracking. The default value of mode tracking is 5. In the above example,
MODENUMBERS is set to 15 meaning that 15 eigenfrequencies will be used
for the mode tracking. If, e.g., one maximizes the first eigenfrequency, this
eigenfrequency will be compared to the 15 specified eigenfrequencies in the
MODETRACKING command. It is important that the modal analysis file specified by the user also leads to an analysis having the same or more eigenfrequencies than specified in the MODENUMBERS command. For this example,
the user should specify at least 15 eigenfrequencies in the finite element file.
Sometimes it happens that many local modes having a low eigenfrequency
appear during the optimization iterations. Normally, this will lead to high number for MODENUMBERS which is not desirable because of high CPU-time.
However, this can be partly circumvented by setting a number in the input
finite element file avoiding the lower eigenfrequencies to be calculated. E.g.,
if it is known that the initial eigenfrequency is around 200 Hz, then it should be
specified in the finite element input file that the eigenfrequencies over 50 Hz
only are to be calculated.
To improve the performance, it is additionally possible to restrict mode tracking to a certain group of nodes in the model (e.g., every fifth node on the surface of the model) or nodes where lumped and rigid masses are attached. In
this case, the node group is referenced in the MODETRACKING parameter
as follows:
OPT_PARAM
ID_NAME
OPTIMIZE
MODETRACKING
MODENUMBERS
=
=
=
=
opt_params
id_of_optimize
ON, node_group
15
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END_
When a node group is applied in the mode tracking, then the modal assurance criterion (MAC) yields
MAC i ,j
( { } i { reference } j )
= --------------------------------------------------------------------------------------------( { } i { } i ) ( { reference } j { reference } j )
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Settings
where the modes are not scaled with the mass. Therefore, the nodes of the
applied group are often chosen to be the nodes of frozen elements, lumped
or rigid masses.
Remarks
1. The finite element input file specified by the user should contain a modal
analysis containing at least as many eigenfrequencies as the value of
MODENUMBERS parameter.
2. A general rule for keeping the MODENUMBERS low and thereby saving
CPU-time is to specify a lower bound for the calculated eigenfrequencies in
the finite element file. Choosing 25% of the expected eigenfrequency as
the lower bound usually suffices. E.g., if the initial eigenfrequency of
interest in the first optimization iteration is around 100 Hz, then it can be
specified that only the eigenfrequencies over 25 Hz are to be calculated.
3. The mode tracking feature can not be guaranteed to work for all examples.
4. Mode tracking is not recommended for the Kreisselmaier-Steinhauser
formulation.
5. Mode tracking can increase the CPU-time significantly both for finite
element solver and Tosca Structure. Restrict mode tracking to a smaller
representative group of nodes to gain performance.
The relative density of each element is the design variable in topology optimization.
In the initial optimization iteration the design space has a homogenous material distribution, meaning that each element contains the same relative material volume.
Initially, all the elements get the density causing the material volume constraint to be exactly fulfilled if a material volume constraint is defined for the
optimization problem.
When no volume constraint is present in the optimization problem but the relative material volume is used in the objective function, each element has an
initial relative density of 50%. However, if the constraints (e.g., displacement
constraints) require a significantly higher relative material volume than 50%
for being fulfilled and this is known before the optimization, then the initial relative material volume in the design space can be set to a larger value (e.g., to
90%) using the command DENSITY_INITIAL:
OPT_PARAM
ID_NAME
= opt_params
OPTIMIZE
= id_of_optimize
DENSITY_INITIAL= 0.9
END_
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5.8.2.2 Initial values of density
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Similarly, if it is known before the optimization that the relative material volume of significantly less than 50% is required in order to fulfill the constraints,
the initial relative material volume can be set to a lower value (e.g., to 10%):
OPT_PARAM
ID_NAME
= opt_params
OPTIMIZE
= id_of_optimize
DENSITY_INITIAL= 0.1
END_
In both cases, it will lead to lower number of optimization iterations.

The default value of DENSITY_INITIAL is 0.5. DENSITY_INITIAL should
always be greater than zero and lower than or equal to one.
Remark
1. The DENSITY_INITIAL parameter can be used to stabilize non linear or
contact problems in combination with volume constraints. Setting a higher
material volume in iteration 0 leads to an initially infeasible volume
constraint requiring more optimization iterations. Nevertheless the higher
initial stiffness improves the convergence behavior of the finite element
solver in the first optimization iterations.
2. Relative values in constraints always refer to the design response of the
start model for the optimization. In topology optimization this start model is
the model with eventually adapted element densities which may differ from
the initial model (e.g. when no volume constraint is present they are set to
50% of the original density). Take this into account when defining, e.g.,
relative displacement or frequency constraints. This behaviour can be
controlled by the user with the parameter DENSITY_INITIAL in the
OPT_PARAM command.
During a topology optimization process, the given mass is distributed within

the design area. At the end of the optimization, the resulting structure consists of hard (filled) and soft (void) elements. The soft elements have a negligible influence on the stiffness of the resulting structure but they are still
relevant for the number of degrees of freedom of the structure.
In Tosca Structure, the SOFT_DELETE option offers the possibility of removing soft elements based on different criteria, The free nodes are also removed
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5.8.2.3 Removing soft elements for increasing performance
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Settings
from the calculation model. The deleted elements are reactivated if needed,
in case that the force flow changes during the optimization.
Fig. 169 Mesh of a bending beam with hard (red) and soft (blue) elements
(The elements in the holes have been deleted by soft_delete
algorithm)
Remarks:
1. SOFT_DELETE is turned on after the 5th iteration, and only if the relative
change of the objective is less than a certain limit. This is done in order to
prevent unstable configurations that might occur in the first iterations from
remaining unchanged.
2. SOFT_DELETEcan be used to stabilize geometrically non-linear models
where solver instabiities can occur due to degenerated or fully collapsed
void elements.
SOFT_DELETE based on neighouring elements
In Tosca Structure, this SOFT_DELETE option offers the possibility of removing the soft elements which only have soft neighboring elements. To use this
feature, an element group must be specified. The average element edge
length (radius) can be specified by the user as an optional parameter. This is
only necessary if the sizes of mesh elements vary strongly.
ID_NAME
OPTIMIZE
= id_of_optimize
...
SOFT_DELETE = ALL_ELEMENTS, <radius>
SOFT_DELETE_METHOD = STANDARD ( AGGRESSIVE ),
<threshold>
...
END_
Remarks
1. If the average element edge length is not specified, the system will determine this value automatically. If the edge length varies considerably within
the mesh, this can influence the function of this feature.
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2. Postprocessing has to be performed on the original (complete) model.

3. If it occurs that there is a group of hard elements separated from the rest of
material by layers of soft elements, these soft elements will not be removed
by SOFT_DELETE for SOFT_DELETE_METHOD = STANDARD. This is
done in order to prevent solvers from being started with inconsistent input
files. Additionally, some soft elements may remain if they connect hard
elements that otherwise would be able to move with respect to each other
(i.e. those that have a common edge but not a common face).
4. An optional threshold can be defined. Default threshold for SOFT_DELETE
using STANDARD or AGGRESSIVE is 0.05.
SOFT_DELETE based upon maximum elemental shear strain
If the elements in the soft delete area are deleted based upon the maximum
elemental shear strain then the following has to be defined:
OPT_PARAM
.....
SOFT_DELETE_METHOD = MAX_SHEAR_STRAIN, <t_shear>
SOFT_DELETE
= <element_group>
.....
END_
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Meaning if an individual element shear strain is larger than the threshold

<t_shear> then the element is removed. Traditionally, the shear threshold
<t_shear> for MAX_SHEAR_STRAIN is positive. The threshold value must
be set by the user. Default settings are not available as the value strongly
depends on different model parameters (material properties).
In the following example the elements having an elemental shear strain larger
than 0.80 should be removed considering all elements in the structure:
OPT_PARAM
.....
SOFT_DELETE_METHOD = MAX_SHEAR_STRAIN, 0.80
SOFT_DELETE
= ALL_ELEMENTS
.....
END_
SOFT_DELETE based upon minimum elemental principal strain

If the elements in the soft delete area are deleted based upon the minimum
elemental principal strain then the following has to be defined:
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Settings
OPT_PARAM
.....
SOFT_DELETE_METHOD = MIN_PRINCIPAL_STRAIN, <t_min_prin>
SOFT_DELETE
= <element_group>
.....
END_
Meaning if an individual element minimal principal strain is lower than the

threshold <t_min_prin> then the element is removed.
Traditionally, the minimum principal threshold <t_min_prin>
for
MIN_PRINICIPAL_STRAIN is negative. The threshold value must be set by
the user. Default settings are not available as the value strongly depends on
different model parameters (material properties).
In the following example the elements having an elemental minimal principal
strain lower than -0.80 should be removed considering all elements in the
structure:
OPT_PARAM
.....
SOFT_DELETE_METHOD = MIN_PRINCIPAL_STRAIN, -0.80
SOFT_DELETE
= ALL_ELEMENTS
.....
END_
SOFT_DELETE based upon maximum elastoplastic strain

If the elements in soft delete are deleted based upon the maximum effective
elastoplastic strain then the following has to be defined in soft delete:
.....
SOFT_DELETE_METHOD = PLASTICITY, <t_plastic>
SOFT_DELETE
= <element_group>
.....
END_
Meaning if an individual element effective elastoplastic strain is higher than

the threshold <t_plastic> then the element is removed.
Traditionally, the effective elastoplastic strain threshold <t_plastic> for
PLASTICITY is positive. The threshold value must be set by the user. Default
settings are not available as the value strongly depends on different model
parameters (material properties).
Please note that this option can only be used for elastoplastic constitutive
material law.
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SOFT_DELETE based upon relative volume compression

If the elements in soft delete are deleted based upon the minimum relative
deformed elemental volume then the following has to be defined in soft
delete:
OPT_PARAM
.....
SOFT_DELETE_METHOD = VOLUME_CHANGE, <t_rel_vol>
SOFT_DELETE
= <element_group>
.....
END_
If an individual relative deformed elemental volume
V deform V org
V rel = ----------------------------------V org
with V org =original elemtal volume and V deform = elemental volume in

deformed configuration is lower than the threshold <t_rel_vol> then the
element is removed.
Traditionally, the relative deformed elemental volume threshold
<t_rel_vol> for VOLUME_CHANGE is negative. The threshold value must
be set by the user, default settings are not available.
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Remarks:
1. Often the elemental strains cannot be written as results for shell and
membrane elements. Thus, the only option is to use VOLUME_CHANGE for
SOFT_DELETE.
2. For examples with very large deformation soft delete seems to be more
stable using VOLUME_CHANGE instead of MAX_SHEAR_STRAIN and
MIN_PRINCIPAL_STRAIN.
3. Normally, the strain measure used for the element removal depends upon
the element type.
4. Additionally, strain measure used for the element removal can depend
upon the constitutive material modeling.
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Settings
5. Typically, finding a useful strain measure used for the element removal
requires several optimization executions.
6. Note, the strains used in the strain meaures for the elemental removal are
from the previous optimization iteration.
Thus, it is recommended to have a slow optimization iteration update of the
design variables for having consistency in the removel of the elements
which can be obtained using the following settings:
OPT_PARAM
.....
DENSITY_MOVE
= 0.10
.....
END_
Fig. 170 Shear strain and soft delete information in TOSCA.OUT
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7. The file TOSCA.OUT will for each optimization iteration contain information
for the progress regarding the SOFT_DELETE.
This information can be rather useful for choosing a correct value for the
SOFT_DELETE with respect to strain measure.
E.g. for SOFT_DELETE_METHOD = MAX_SHEAR_STRAIN the following
useful information can be found in TOSCA.OUT:
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E.g. for SOFT_DELETE_METHOD = MIN_PRINCIPAL_STRAIN the

following useful information can be found in TOSCA.OUT:
Fig. 171 Principal strain and soft delete information in TOSCA.OUT

8. Finding the correct threshold for SOFT_DELETE may require some trial
and error. The threshold value for MAX_SHEAR_STRAIN,
MIN_PRINCIPAL_STRAIN, PLASTICITY or VOLUME_CHANGE must be
set explicitly by the user. Default settings are not available as the value
strongly depends on different model parameters (material properties).
9. Using reduced speed in the design variable update (DENSITY_MOVE,
DENSITY_UPDATE) improves the accuracy of the results.
5.8.2.4 Limits for design variables and changes

In topology optimization, each relative material volume is constrained by a
lower and an upper bound as follows:
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0 < DENSITY_LOWER DENSITY_UPPER 1

By default, the lower bound is set to 0.001 and the upper bound is set to 1 in
order to avoid the global stiffness matrix to become singular. The user can
change these bounds using the commands DENSITY_LOWER and
DENSITY_UPPER, respectively. An example is
OPT_PARAM
ID_NAME
OPTIMIZE
DENSITY_LOWER
DENSITY_UPPER
=
=
=
=
opt_params
id_of_optimize
0.01
1.00
END_
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Settings
Changing the bounds is not recommended. Especially, an upper bound other

than 1 is critical. The lower bound can be increased if the default value is
likely to lead to a nearly singular stiffness matrix.
Remarks
1. DENSITY_LOWER should always be greater than zero and
DENSITY_LOWER should be lower than DENSITY_UPPER.
2. DENSITY_UPPER should always be lower or equal to one.
Furthermore, in the sensitivity based topology optimization, the maximal relative material volume change in one iteration is defined:
DENSITY_LOWER DENSITY_MOVE
+ DENSITY_MOVE DENSITY_UPPER
The reason for the change limit is that the sensitivity based optimization algorithm approximates the design responses around the actual design response
values using the sensitivities. These approximations are only valid in a small
range of design variables, thus the variation of the relative material values
should be limited.
Numerical experiments indicate that a value of 0.25 for the change limit is
usually acceptable. However, one can set the limit to, e.g., 0.4 using the
parameter DENSITY_MOVE:
OPT_PARAM
ID_NAME
OPTIMIZE
DENSITY_MOVE
= opt_params
= id_of_optimize
= 0.4
The default value of DENSITY_MOVE is 0.25. A low change limit (such as

0.1) is recommended for complicated design responses and optimization formulations. However, a lower change limit most often leads to a higher number
of optimization iterations.
5.8.2.5 Update strategy of the method of moving asymptotes

The relative material volumes of elements of the structure are updated using
the method of moving asymptotes (MMA), see Svanberg (1987). Normally,
the update method suggested in Svanberg (1987) is stable. However, if the
design responses are very sensitive, it is suggested to use a more conservative update method that requires more optimization iterations. The update
strategy is changed using the parameter DENSITY_UPDATE. The default
value of DENSITY_UPDATE is NORMAL. Setting DENSITY_UPDATE to
CONSERVATIVE leads to a conservative update of the design variables:
OPT_PARAM
ID_NAME
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OPTIMIZE
= id_of_optimize
END_
It is recommended to use the conservative update method if it is problematic

to fulfill the constraints used in the optimization formulation.
The user also has the possibility to use a more aggressive update of the
design variables in order to reduce the number of optimization iterations by
setting DENSITY_UPDATE to AGGRESSIVE:
OPT_PARAM
ID_NAME
= opt_params
OPTIMIZE
= id_of_optimize
DENSITY_UPDATE = AGGRESSIVE
END_
This may lead to unstable optimization or prevent the convergence.
5.8.2.6 Settings of the mesh filter
Fig. 172 Checkerboard effect for a bending beam
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The result of the optimization of a bending beam in Fig. 172 shows a numerical instability effect. The structure contains checkerboard-like areas with soft
(void) and hard elements. In a structure like this, many hard elements have
only the point contact to other hard elements. The result in Fig. 172 is not a
valid design because the checkerboard effect is a numerical instability. This
effect has been analyzed by BENDSE and SIGMUND (M. P. Bendse, O.
Sigmund, Topology Optimization Theory, Methods and Applications SpringerVerlag 2003) and references therein.
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Settings
This checkerboard effect depends on the mesh and the discretization. This is
obvious in Fig. 173. The mesh is refined in parts of the model.
Fig. 173 Influence of discretization on the optimization result and on the

checkerboard effect
Checkerboard structures cannot be manufactured in practice. The user also
wants to obtain a mesh-independent result from the optimization. Due to
these demands, Tosca Structure has a filter technique implemented to avoid
mesh dependence. A specification of a filter radius (FILTER_RADIUS parameter) is necessary for applying the filter. If the radius of the filter is not specified, the optimization is performed using a filter having a default radius. This
radius might be too large for coarse meshes. If the radius is too large, the
optimization result will not show a detailed structure. A small value of the
radius leads to a fine structure.
It is recommended to choose the filter radius equal to twice the mean element
edge length.
The filter radius is defined in OPT_PARAM command as follows:
ID_NAME
OPTIMIZE
= id_of_optimize
...
FILTER_RADIUS = 5.
END_
5.8.2.7 FILTER_TYPE
The filter technique for the objective function can be changed using the
parameter FILTER_TYPE in the optimization settings (OPT_PARAM command). Changing the filter technique for the objective function is mainly interesting for stiffness optimization problems.
The FILTER_TYPE can be set to STANDARD and LOW, respectively. The filter for FILTER_TYPE = LOW is a relaxation of the STANDARD filter. It is use2 - 288 User Manual
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ful for coarse meshes yielding a clearer solid-void design and a lower number
of optimization iterations.For reasonable and fine meshes FILTER_TYPE
equal to LOW would often cause checkerboard.
FILTER_TYPE equal to LOW might also be useful for stabilizing dynamic
problems like modal eigenfrequency optimization and frequency response
optimization.
Remarks:
1. Changing the filter option has no effect when the objective is to minimize
the mass.
2. Changing the filter option has no effect when manufacturing constraints are
present.
5.8.2.8 Material interpolation

Recall that the original topology optimization problem is formulated as an
integer problem (see e.g. Bendse and Sigmund (2003)),
e = 1
or
e 0
meaning that each element should be filled up with material (hard elements
with the relative material volume equal to 1) or contain no material (void elements with the relative material volume close to 0 but always positive). Thus,
the relative material volume of each element is defined as a design variable.
Numerically, the above optimization problem is an integer problem and therefore difficult to solve for a large number of design variables. Therefore, the
above optimization problem is relaxed so the relative densities can have values in between 0 and 1,
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e = ]0, 1 ]
The material interpolation schemes penalizing the Youngs modulus E for the
intermediate densities are introduced for obtaining the solution of the relaxed
problem resulting in all elements being either hard or void elements. Tosca
Structure contains two material interpolation schemes described in the following. Both material interpolation schemes contain a penalization factor p that
defines to what extent the solution is forced toward a solution having with
hard or void elements only.
The SIMP (solid isotropic material with penalization) material interpolation
scheme is defined by
E = E0
and is very popular in the literature, e.g., see Mlejnek (1992), Bendse and
Sigmund (1999) and Bendse and Sigmund (2003) and references therein.
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Settings
The Youngs modulus E 0 is the Youngs modulus when the element is filled
up with material, thus being the Youngs modulus defined by the user. The
penalty factor p should be greater than 1. Numerical experiments indicate
that p=3 is a good value.
The RAMP (rational approximation of material properties) material interpolation scheme is defined by
E = E 0 ----------------------------1 + p(1 )
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The RAMP interpolation scheme is desirable for dynamic problems because

the interpolation scheme is concave, see Hansen (2005) and Stolpe and
Svanberg (2001). For the RAMP interpolation scheme, the interpolation factor
p should be greater than 0. Numerical experiments indicate that p=3 is a
good value.
Fig. 174 shows the interpolation of the Youngs modulus for the SIMP and
RAMP material scheme, respectively. For p=1 in SIMP and p=0 in RAMP, the
material interpolation is the so-called thickness optimization problem leads to
many elements having intermediate densities. By increasing the penalization
factor p, the intermediate densities turn out to be computationally more
expensive because elements having intermediate densities require a higher
density for having the same stiffness as in the thickness optimization problem. Thus, when the penalty factor is increased, fewer elements contain have
an intermediate density. On the other side, one should not choose too large
penalty because then the likelihood for ending up in a local minimum during
the optimization is significantly higher, and, if the penalty factor is extremely
high, one will always end up in a local minimum.
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Consequently, a compromise for the penalty factor will be to choose a value

in the interval between 2 and 4 that also agrees with the numerical experiments.
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Fig. 174 The SIMP and RAMP material interpolation scheme showing how
the Young modulus is penalized for the intermediate relative densities.
By default, the optimization algorithm chooses the SIMP interpolation scheme
with p=3 if all load cases are static. However, if at least one dynamic load
case is used, the RAMP interpolation scheme with p=3 is chosen by default.
The user has the possibility to choose the interpolation scheme and the value
of the penalty factor using the commands MAT_INTERPOLATION and
MAT_PENALTY, respectively. The valid values for MAT_INTERPOLATION
parameter are SIMP and RAMP.
E.g., the SIMP material interpolation scheme and a penalty of 3.5 are used in
the following example:
OPT_PARAM
ID_NAME
= opt_params
OPTIMIZE
= id_of_optimize
MAT_INTERPOLATION = SIMP
MAT_PENALTY
= 3.5
END_
The SIMP material interpolation scheme and a penalty of 2.5 are used in the
defined in OPT_PARAM command as follows:
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Stop Condition
OPT_PARAM
ID_NAME
= opt_params
OPTIMIZE
= id_of_optimize
MAT_INTERPOLATION = RAMP
MAT_PENALTY
= 2.5
END_
5.9
Stop Condition
Stop conditions are necessary to ensure that the optimization terminates.
These stop criteria can either simply allow a certain number of loops or
depend on the convergence behaviour of the optimization.
5.9.1
Convergence Criteria
For checking if the sensitivity based topology optimization has converged two
stop criteria are implemented.
The user can specify if both stop criteria should be fulfilled or just one of the
stop criteria has to be fulfilled for the optimization algorithm to stop. Default is
that both criteria should be fulfilled before the optimization algorithm stops. To
specify that just one of the criteria has to be fulfilled set
STOP_CRITERION_LEVEL equal to SINGLE. The default value for
STOP_CRITERION_LEVEL is BOTH.
E.g. the optimization algorithm should stop when just one of the criteria is fulfilled
ID_NAME
= opt_params
OPTIMIZE
= id_of_optimize
STOP_CRITERION_LEVEL = SINGLE
END_
Convergence Criteria are defined in the SETTINGS window of Tosca ANSA

environment and the OPT_PARAM command in Tosca Structure.gui respectively.
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A second stop criterion is a measurement based upon the change in the
objective function from one optimization iteration to the next optimization iteration. This stop criterion is defined by
n n 1
---------------------------- STOP_CRITERION_OBJ
n
where the index n is representing the present optimization iteration and is n-1
is the previous iteration. When the criterion is lower than
STOP_CRITERION_OBJ the stop criterion is fulfilled. The default for
STOP_CRITERION_OBJ is 0.001. The value can be changed by the user,
e.g.
OPT_PARAM
ID_NAME
= opt_params
OPTIMIZE
= id_of_optimize
STOP_CRITERION_OBJ = 0.01
END_
This could be desirable when the number of optimization should be reduced.
5.9.1.2 Stop criterion: change in element densities

The third stop criterion is based upon the change in the densities (design variables) in each element from one optimization iteration to the next optimization
iteration and is defined by
Number of elements
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n n 1
----------------------------------------------------------------------- STOP_CRITERION_DENSITY
Number of elements
STOP_CRITERION_DENSITY the stop criterion is fulfilled. The default for
STOP_CRITERION_DENSITY is 0.005. The value can be changed by the
user, e.g.
OPT_PARAM
ID_NAME
= opt_params
OPTIMIZE
= id_of_optimize
STOP_CRITERION_DENSITY = 0.0001
END_
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Stop Condition

The two above convergence criteria are not checked before a specified number of optimization iterations have been executed. Meaning that the optimization will always be executed until STOP_CRITERION_ITER is reached. The
number is set by the number of STOP_CRITERION_ITER. If
STOP_CRITERION_ITER is changed to e.g. 2.
OPT_PARAM
ID_NAME
= opt_params
OPTIMIZE
= id_of_optimize
STOP_CRITERION_ITER = 2
END_
The default value for STOP_CRITERION_ITER is 4.
5.9.2
Global Stop Criterion (Number of iterations)

The first stop criterion is the maximum number of optimization iterations
which is default 50. When the maximum number of optimization iterations is
reached the optimization algorithm always stops independent upon the values of the two previously mentioned criteria. The allowed maximum number
of optimization iterations can be increased or decreased by the user. This is
done by modifying ITER_MAX in the STOP command
STOP
ID_NAME
ITER_MAX
= global_stop
= 55
END_
where ITER_MAX is increased to 55.
1. Please note that the global stop criterion is defined using a STOP
command whereas the convergence criteria are defined in the optimization
settings (OPT_PARAM command).
2. The global stop criterion leads to a hard stop of the optimization - independend of a complete convergence of the result (in particular with a small
number of iterations this cannot be achieved).
3. For the controller based algorithm the number of iterations required for full
convergence is set using the SPEED= ITER,<nr> parameter in the
OPT_PARAM command.
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Remark:
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5.10 References
Kabus, S. and Pedersen, C.B.W. (2012). Optimal bearing housing designing
using topology optimization. Journal of Tribology. 134(2).
Sndergaard, M.B. and Pedersen, C.B.W. (2013). Applied topology optimization of vibro-acoustic hearing instrument models. Submitted to Journal of
Sound and Vibration.
Bendse, M.P. and Sigmund, O. (2003). Topology optimization: Theory,
methods and applications. Springer-Verlag, Berlin Heidelberg
New York.
Bendse, M.P. and Sigmund, O. (1999). Material interpolations in topology
optimization, Archive of Applied Mechanics. 69:635-654.
Hansen, L.V. (2005). Topology optimization of free vibrations of fiber laser
packages. Structural and Multidisciplinary Optimization.
29(5):341-348.
Mlejnek, H.P. (1992). Some aspects of the genesis of structures. Structural Optimization. 5:64-69.
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Stolpe, M. and Svanberg, K. (2001). An alternative interpolation scheme for

minimum compliance optimization. Structural and Multidisciplinary Optimization. 22:116-124.
Pedersen, C.B.W. and Allinger, P. (2006). Industrial implementation and
applications of topology optimization and future needs. In: IUTUAM Symposium on Topological Design Optimization of Structures,
Machines and Materials: Status and Perspectives (eds.
M.P. Bendse, N. Olhoff and O. Sigmund). Springer. 147-156.
Olhoff, N. and Du, J. (2006). Topology optimization of vibrating bi-material
plate structures with respect to sound radiation. In: IUTUAM Symposium
on Topological Design Optimization of Structures, Machines and Materials: Status and Perspectives (eds. M.P. Bendse, N. Olhoff and O. Sigmund). Springer. 147-156.
Jog, C.S. (2002). Topology design of structures subjected to periodic loading.
Journal of Sound and Vibration. 253(3):687-709.
Hansen, L.V. (2005). Topology optimization of free vibrations of fiber laser
packages. Structural and Multidisciplinary Optimization.
29:341-348.
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References
Clausen, P.M. and Pedersen, C.B.W. (2006). Non-parametric large scale

structural optimization. In: ECCM 2006 III European Conference on
computational Mechanics, Lisbon, Portugal, June 5-9,
2006.
Cook, R.D., Malkus, D.S. and Plesha, M.E. (1989). Concepts and applications of finite element analysis. John Wiley & Sons Inc.
Svanberg, K. (1987). The method of moving asymptotes - A new method for
structural optimization. International Journal for Numerical
Methods in Engineering. 24:359-373.
Sigmund, O. and Jensen, J.S.(2003). Systematic design of phononic band
gap materials and structures by topology optimization. Philosophical
Transactions of the Royal Society: Mathematical, Physical
and Engineering Sciences. 361:1001-1019.
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Tcherniak, D. (2002). Topology optimization of resonating structures using

SIMP method. International Journal for Numerical Methods in
Engineering. 54:1605-1622.
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Shape Optimization
Shape Optimization
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Fig. 175 Example of nonparametric shape optimization. Pictures by courtesy of Audi AG.
6.1
General Information
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Under the possible restrictions:
Specification of design domain restrictions by FE meshes
6.1.1
Theoretical background
6.2

An optimization task always consists of the same basic elements: design
area, objective function and eventually also constraints. This chapter explains
the standard procedure for creation of an optimization task.
6.2.1

The following describes the general procedure for the definition of an optimization task. These procedures are supported by the task manager in Tosca
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The process of minimization of the deviation from a reference stress is based

on the following hypothesis by Neuber: Optimum form of a component is
achieved when the stresses running along the considered surface zone is
fully constant (stress homogenization). The targeted constant stress should
then be declared as the reference stress. The stress homogenization can
also be interpreted according to the principle of the fully stressed component
(Fully Stressed Design), i.e., the component is stressed in as many zones as
possible by the predefined value allowed.
SIMULIA
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Shape Optimization
ANSA environment (TAE) as well as the command tree in Tosca Structure.pre

screen of Tosca Structure.gui (GUI). For more information about Tosca Structure.pre see vol.2 chapter 2.
Analysis model
TAE: MODEL_LINK | FILE, select Edit, choose your model file.
GUI: Choose your model file in FEM_INPUT
Design area
2. Question: Which surface area of the FE model should be selected for
shape modifications?
Procedure: Assign node group with surface nodes to design area.
TAE: DESIGN_AREA, select Edit, choose predefined group or select new
group.
GUI: Choose or define the node group with the surface nodes of the
selected design area (volume 3: GROUP_DEF) and define the design variables (volume 3: DV_SHAPE).
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3. Question: Which area of the model should be selected for smoothing of

the FE mesh?
Procedure: Assign element group to MESH_SMOOTH area.
TAE: DESIGN_AREA, select New | MESH_SMOOTH, choose predefined
group or select new group.
GUI: Choose or define the element group defining the mesh smoothing
area (volume 3: GROUP_DEF) and define the mesh smoothing (volume 3:
MESH_SMOOTH).
4. Question: Are there nodes in the design area or in the mesh smoothing
area that are subject to certain restrictions? How can these restrictions be
described?
Procedure: Define design variable constraints for node group.
TAE: DESIGN_AREA | DV_CONSTRAINTS, select New | <type of
restriction> command, choose predefined group or select new group for
this restriction. Evtl. define link conditions using modules buttons.
GUI: Choose or define node groups with common restrictions (volume 3:
GROUP_DEF). Define the restrictions using LINK_SHAPE and
DVCON_SHAPE.
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Objective function
values be minimized or maximized or otherwise combined?
Procedure: Choose terms for optimization (design responses) and target.
TAE: OBJ_FUNC_ITEM_1, select New | <term for optimization>
command; apply Edit on OBJ_FUNC_ITEM_1 to choose whether the
objective function is to be minimized or maximized.
objective function (volume 3: OBJ_FUNC).
Constraint
6. Question: Which design response describes the constraint? Which value
should the constraint have?
Procedure: Choose term for constraint and set target value or upper/lower
boundary.
TAE: CONSTRAINT, select New | <term for constraint> command.
constraint (volume 3: CONSTRAINT).
Optimization task
Procedure: If necessary complete any additional required definitions and
prepare the optimization job.
8. Question: Should the optimization stop after a number of iterations (or

certain other conditions)?
Procedure: Define a stop condition
TAE: On GLOBAL_STOP_CONDITION, apply Edit and change number of
iterations.
GUI: STOP.
Check Run
9. Question: Would prior testing of the restriction definitions be useful?
Procedure: Apply test displacements
TAE: New | TEST_SHAPE on SHAPE_OPTMIZATION_CONTROLLER | New
| TEST_SHAPE_CHECK on CHECK_INPUTS.
GUI: TEST_SHAPE.
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Stop Condition
SIMULIA
Tosca Structure
Shape Optimization
Completion
10.Question: Has all the required data been specified?
TAE: Click twice on OUTPUT and change the jobname (or proceed with the
default jobname); Update writes the parameter file.
GUI: Save as <jobname>.par.
The essential commands required for the optimization model in shape optimization are described in the following. The order of their appearance corresponds to the order of the above listed procedures.
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Fig. 176 Block structure of shape optimization commands
6.3
Design Area
In shape optimization the form of the component is changed. The change in
form is achieved by moving the surface or a part of the component surface.
The surface area of the component that can be changed is called the design
area. The design area is defined using a node group consisting of design
nodes.
The current position of a design node in a design cycle is derived by superimposing the position of the node in the start model with an optimization displacement vector. These displacements may be restricted by design variable
constraints to ensure certain geometric properties of the component. Further,
nodes in an area surrounding the design nodes may be moved to ensure
mesh quality for the FE calculation (Mesh smooth area).
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Design Area
6.3.1
Design variables (DV_SHAPE)

Design variables for shape optimization are defined when assigning a node
group to the design area.
Remarks
1. Only surface nodes are allowed as design nodes.
2. The design nodes must define one or more continuous areas, i.e., the individual design areas must consist of at least three design nodes. Single
design nodes without neighboring design nodes are not permitted.
3. Only corner nodes (from finite elements) are supported as design nodes.
Midside nodes may be included in the design node group but the optimization displacements of the midside nodes of second order elements is interpolated from the optimization displacement of the adjacent corner nodes,
which maintains a curvature of the initial design during optimization.
Strictly speaking, design variables are the signed amounts of optimization
displacement applied to the design nodes. In unrestricted tasks, the direction
of the optimization displacement vector corresponds to the outer surface unit
normal on the node and the amount of displacement is determined by the
optimization procedure. Restrictions influence the amount and direction of the
optimization displacement vector.
Basically there are three cases that may occur: Growth means that a design
node is moved outwards (positive amount of displacement). Shrinkage
means that a design node is moved inwards (negative amount of displacement). Neutral means that a design node is moved neither outwards nor
inwards (zero displacement).
1. Note, that the optimization displacement vector contains the optimized

changes in positions of the nodes and not the displacements of the nodes
obtained from the FE analysis.
2. When unrestricted design nodes lie in component areas in which they have
only a little mechanical effect on the system as a whole, an undesirable
shrink effect may occur. Therefore, design areas should not be selected
before the mechanical component behavior is known. It is recommended to
analyze the mechanical behavior of the component in a preliminary FE
calculation before specifying the design area.
Determination of optimization displacement vectors:
The optimization displacement vector on the design node is determined by
superimposing all external element normal vectors on the boundaries of
neighboring elements. In two-dimensional models the normals are formed
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Remarks
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Shape Optimization
relative to element edges and in three-dimensional to element surfaces.

The only element edges or element surfaces that are taken into consideration are those spanning design nodes. Isolated design nodes (neighboring nodes on the surface are not design nodes) are not permitted and must
be removed from the design node group. The optimization displacement
direction is a uniform vector.
Example:
In a two-dimensional model each design node has two neighboring nodes
on the boundary of the component. If both of these neighboring nodes are
design nodes (Fig. 177 left), two normal vectors are formed, one each for
the respective element edges, and superimposed. If only one of the neighboring nodes is a design node (Fig. 177 right), there is only one normal
vector. This is identical with the normal vector of the design node.
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Fig. 177 Determination of the normal vector

If the displacement direction of a node is restricted by a design variable
constraint (see vol.2 chapter 6.3.3, Restrictions (DVCON_SHAPE)) the
direction of the optimization displacement vectors is correspondingly
adjusted.
The optimization displacement vector is derived from scaling the optimization displacement direction with the signed amount of displacement calculated by the optimization procedure.
The length of the optimization displacement vector may also be influenced
by design variable constraints (see vol.2 chapter 6.3.3, Restrictions
(DVCON_SHAPE)).
Remarks
1. The optimization displacement vector determined by the optimizer is
adjusted to the changed conditions in each design cycle (e.g. shape of the
structure, effective restrictions, mesh quality, etc.). The optimization
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Design Area
displacement vectors are therefore not constant; they are subject to certain
changes in each cycle.
2. With the VECTOR parameter in the optimization settings (OPT_PARAM
command) it is possible to control when the optimization displacement
vectors are calculated (see volume 3: OPT_PARAM).
In Tosca ANSA environment, design variables are defined in the DESIGN
AREA folder of the task manager. Edit opens the DV_SHAPE menu where the
node group of design nodes can be chosen. (For a detailed description see
vol.1 Start Manual.)
Fig. 178 Definition of design variables (DV_SHAPE) in Tosca ANSA environment

Fig. 179 Definition of design variables (DV_SHAPE) in Tosca Structure.gui

Command syntax
Design variables are defined in the parameter file using the DV_SHAPE command. Each DV_SHAPE definition has a name (ID_NAME parameter) and
references a previously defined node group (ND_GROUP parameter). The
name is required in order to subsequently activate the DV_SHAPE definition
when specifying the optimization job (see OPTIMIZE command). The design
area is specified by the node group. These two declarations are mandatory.
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In Tosca Structure.gui, design variables are defined by choosing a node

group in the DV_SHAPE mask of Tosca Structure.pre and assigning an
ID_NAME for further reference to the definition.
SIMULIA
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Shape Optimization
Other declarations cannot be made. A typical DV_SHAPE command appears

as follows:
DV_SHAPE
ID_NAME
ND_GROUP
= dv_design_nodes
= design_nodes
END_
The DV_SHAPE definition must be activated by a reference in the OPTIMIZE

command. Non-activated definitions have no influence in the optimization.
It is generally possible to limit the displacements of the design nodes with
DVCON_SHAPE definitions (see section vol.2 chapter 6.3.3). The
DVCON_SHAPE definitions must then be assigned in the OPTIMZE command.
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6.3.2
Mesh smoothing (MESH_SMOOTH)

In shape optimization the surface of a component is modified. If only the surface nodes are displaced and the inner nodes remain at their location, the
surface layer elements will be strongly distorted. As a result, the quality of the
FE calculation suffers and may no longer form a reliable basis for the optimization. To ensure realistic and high-quality results, a displacement of the surface usually necessitates a mesh displacement (mesh smoothing) in the inner
of the structure in most cases.
For shape optimization with Tosca Structure the existing inner mesh is automatically adjusted to the surface displacement after the determination of the
surface modification. No re-meshing of the model is carried out, but the displacement of the surface nodes is passed on to the inner nodes. This modified mesh is then used as the basis of the FE calculations that follow. The
parameters for mesh smoothing are specified with the MESH_SMOOTH
command.
The most important parameter is to define the area to which the mesh correction is applied. Default values for other settings are such that satisfactory
results can be achieved for most models. The most important additional
options are
FREE_SF, LEVEL_QUAL, SOLVER_CHECK/SOLVER_STOP and STRATEGY
that are described in the following chapters.
Remark
1. It is strongly recommended for the start model of the shape optimization to
have a finite element mesh of good quality. This recommendation especially applies to areas in which shape changes are expected.
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Design Area
6.3.2.1 Element group for mesh smoothing

The area to which mesh smoothing is applied to is defined by an element
group. This element group must contain all design nodes.
Fig. 180 Definition of a MESH SMOOTH area

Remarks
2. Mesh smoothing is an element-based algorithm, i.e., the MESH_SMOOTH

area is processed element by element. For FE models with relatively
numerous elements in relation to the number of degrees of freedom (tetrahedral mesh), the computing time of the optimization module can sharply
increase in comparison to the computing time of the FE analysis.
3. Only the following element shapes are allowed as MESH_SMOOTH
elements:
TRIA, QUAD, TETRA, HEXA and PENTA (with or without mid-side nodes).
If the user-defined element group contains disallowed elements, a systemdefined element group by the name of <mesh_smooth_name>_ELEM is
generated. The disallowed elements are removed in this group.
MESH_SMOOTH is only executed for the allowed elements.
4. A system-defined node group by the name of
<mesh_smooth_name>_NODE is generated. This group contains all
nodes attached to the allowed elements of the MESH_SMOOTH element
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1. The operation for mesh smoothing can require a great deal of computing
time depending on the selected options. It is therefore advisable to select
an area for the mesh smoothing that is sufficient but not too large. The size
of the area for mesh smoothing depends on the problem and must be
specified by the user.
SIMULIA
Tosca Structure
Shape Optimization
group. In this way the MESH_SMOOTH area can also be interpreted as a

node area even though the user has only defined an element group.
5. It is important to ensure that the design area is contained in the
MESH_SMOOTH area, i.e., the design node group must be a subset of the
system-defined MESH_SMOOTH node group.
6. Attention should be paid that all nodes in the MESH_SMOOTH area can be
moved by the mesh smoothing operation. For this reason, the user should
limit the MESH_SMOOTH area to the area of the structure that can actually
be changed. Structural areas that should remain unchanged should never
be allowed in a MESH_SMOOTH area!
7. In general it is possible to use a default MESH_SMOOTH area consisting
of 6 layers of elements around the design nodes. However, this method is
not recommended because the user looses control of which nodes may be
moved by MESH_SMOOTH. Thus, it is recommended to choose an
element group (in pre-processor or Tosca ANSA environment) to avoid
unwanted effects.
8. It is possible to limit the optimization displacements of the design nodes
and the displacements of the MESH_SMOOTH nodes using design variable constraints (DVCON_SHAPE definitions (see vol.2 chapter 6.3.3)).
For each mesh smooth definition, several groups are created automatically
by Tosca Structure. Some are available directly after the preprocessing of the
MESH_SMOOTH definition and are thus available for other definitions (e.g.
constraints) further on. Others are created when the definition of the optimization task is completed and read into the Tosca Structure database.
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name of the group
description
LAYER_<mesh_smooth_name>
created, if MS_LAYER is used;

contains all elements of the mesh
smooth area
<mesh_smooth_name>_ELEM
created, if the user-defined element

group contains disallowed elements;
contains all allowed elements
(TRIA, QUAD, TETRA, HEXA and
PENTA)
<mesh_smooth_name>_NODE
contains all nodes attached to the

allowed elements of the
MESH_SMOOTH element group
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Design Area
name of the group
description
<mesh_smooth_name>_SF_ELEM
contains all allowed elements of the

with at least one surface node
Table 25
Automatically generated element and node groups after preprocessing the MESH_SMOOTH command
name of the group
description
<mesh_smooth_name>_SF_NODE
contains all mesh smooth nodes at

the surface of the mesh
<mesh_smooth_name>_DV_ELEM
contains all allowed elements of the

with at least one design node
<mesh_smooth_name>_DL_NODE
contains all mesh smooth nodes

which are also design nodes or
nodes restricted with a
LINK_SHAPE
<mesh_smooth_name>_DL_ELEM
contains all elements with at least

one node out of
<mesh_smooth_name>_DL_NODE
<mesh_smooth_name>_SF
contains all mesh smooth nodes

which are automatically fixed
Automatically generated element and node groups after preprocessing the referencing OPTIMIZE command
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6.3.2.2 Fixation of free surface nodes (FREE_SF)
a)
b)
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Fig. 181 Transition nodes, with a) is FREE_SF = FIX,0 and b) is

FREE_SF = FREE
The MESH_SMOOTH area contains design nodes, surface nodes that are
not design nodes and inner nodes. In many cases it is desirable to adjust the
surface nodes (in proximity of the design nodes) in the mesh smoothing to
achieve a smooth transition between the design area and remaining area.
However, in other cases, it makes more sense to fix the surface nodes to
avoid an unwanted displacement of the nodes by the mesh smoothing. For
example, the front side of a component is the design area. The
MESH_SMOOTH area extends over the entire component. If the back side of
the component is to remain unchanged, the surface nodes on the back side
must be fixed. The FREE_SF=FIX setting enables free surface nodes to be
fixed automatically in all displacement directions during the mesh smoothing:
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Design Area
MESH_SMOOTH
...
FREE_SF = FIX, <number_of_node_layers>
END_
All surface nodes of the MESH_SMOOTH area that are neither design nodes
nor limited by restrictions (see vol.2 chapter 6.3.3) are interpreted as free surface nodes. FREE_SF=FIX,0 is set by default, i.e., the free surface nodes
cannot be moved during mesh smoothing.
The FREE_SF=FIX setting can also be modified by specifying a number of
node layers (layers field next to FREE_SF choice menu, default=0), e.g.
FREE_SF=FIX,5. This number of node layers specifies how many node layers, beginning with the design nodes along the surface, should remain free
and not be fixed. This enables the transition area in vicinity of the design area
to be kept free despite the fixed surface. Node layers consisting of mid-side
nodes are not taken into consideration, only node layers consisting of corner
nodes.
Remarks
1. All surface nodes of the MESH_SMOOTH area are interpreted as free
surface nodes if they are notdesign nodes and not restricted by a design
variable constraint. As a consequence surface nodes for which a
DVCON_SHAPE is defined will not be interptreted as free nodes.
3. Only corner nodes are fixed. Mid-side nodes are not taken into consideration.
4. In addition to the FREE_SF parameter, there is also the possibility to limit
the optimization displacements of the MESH_SMOOTH nodes using
design variable constraints (DVCON_SHAPE entries, see vol.2 chapter
6.3.3).
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2. If FREE_SF = FIX, <number of layers> these nodes are identified and fixed
using a design variable constraint (DVCON_SHAPE command, see vol.2
chapter 6.3.3). A node group with the name <mesh_smooth_name>_SF is
automatically generated for this purpose. A DVCON_SHAPE command
with the name <mesh_smooth_name>_SFIX is then automatically generated for this node group defining the fixation of the nodes. The generated
DVCON_SHAPE command is then automatically taken into account in the
optimization.
SIMULIA
Tosca Structure
Shape Optimization
6.3.2.3 Fixation of the MESH_SMOOTH area boundary
node group
<Mesh_smooth_id_name>_BOUN
with BOUNDARY = FIX
design_nodes
mesh-smooth area
Fig. 182 Boundary nodes of MESH_SMOOTH area

The boundary between MESH_SMOOTH area and the remaining model is
fixed per default as the mesh smoothing should stay restricted to the area
defined for this purpose (BOUNDARY = FIX parameter). The nodes on the
boundary are internally stored in a node group with the name
<Mesh_smooth_id_name>_BOUN.
If in some cases you may not want all "border" nodes to be fixed, you can
select the BOUNDARY = FREE option. Then you are responsible to fix the
proper nodes by yourself via DVCON_SHAPE entries.
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6.3.2.4 Automatic MESH_SMOOTH area (MS_LAYER)

The area for mesh smoothing should be as small as possible but as large as
necessary. The element group ALL_ELEMENTS should not be used for
smoothing if only a small part of the model should be optimized. The calculation time of the optimization module increases and all free surface nodes
have to be fixed explicitly by the user.
The MESH_SMOOTH parameter MS_LAYER allows the automatic definition
of a mesh smooth element group consisting of a certain number of element
layers with reference to a node group. This setting is defined by changing the
EL_GROUP drop down menu in Tosca ANSA environment to MS_LAYER
and then choosing your node group and the number of layers. Tosca Structure.gui it is chosen by switching the radio button for the mesh smooth area to
ND_GROUP, LAYER in and choosing group and number correspondingly.
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Design Area
Example
Starting at the design node group, a mesh smooth domain should be generated with 5 element layers:
MESH_SMOOTH
ID_NAME
MS_LAYER
FREE_SF
= new_mesh_smooth
= design_nodes, 5
= FIX, 3
END
Fig. 183 Definition of a mesh smooth area using layers in Tosca ANSA
environment (left) and Tosca Structure.gui (right)
The algorithms for mesh smoothing are iterative, i.e., the mesh smoothing is
performed in several successive steps. The decisive factor for the convergence of the smoothed mesh is the number of steps in combination with the
increments. The iterative process can be influenced using the convergence
parameter, LEVEL_CONV. The default setting is LEVEL_CONV=LOW, i.e.,
only a few iterations with large increments are performed. This is the most
efficient setting. The convergence behavior can be improved with the settings
LEVEL_CONV=MEDIUM and LEVEL_CONV=HIGH. These settings result in
increasingly more iterations with smaller increments to be performed which,
however, can result in a substantial increase in the computing time required.
The goal should always be to work with the lowest possible convergence
parameter to avoid unnecessarily long computing times!
MESH_SMOOTH
...
LEVEL_CONV
END_
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6.3.2.5 Convergence of the smoothed mesh (LEVEL_CONV)
SIMULIA
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Shape Optimization
Remarks
1. It is recommended to adjust the setting of the LEVEL_QUAL parameter
instead of increasing the convergence level.
2. The LOW convergence level is sufficient to create a good mesh. If a higher
convergence level (MEDIUM, HIGH) is desired, be prepared for a substantial increase in computing time.
6.3.2.6 Enforcing restrictions (LEVEL_DVCON)

The mesh smoothing algorithm consists of several sub-algorithms that are
executed consecutively. The displacement of the MESH_SMOOTH nodes
can be restricted by DVCON_SHAPE entries (declared with OPTIMIZE). The
LEVEL_DVCON setting can be used to control the enforcement of the
DVCON_SHAPE entries in the individual sub-algorithms for the mesh
smoothing. LEVEL_DVCON=LOW is set by default, i.e., the DVCON_SHAPE
entries for mesh smoothing are forced. This is the most efficient setting. The
settings LEVEL_DVCON=MEDIUM and LEVEL_DVCON=HIGH causes the
DVCON_SHAPE entries to be forced more often. The goal is to work with the
lowest parameter value possible to avoid unnecessarily long computing
times!
MESH_SMOOTH
...
LEVEL_DVCON
END_
= LOW
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6.3.2.7 Quality control and improvement (LEVEL_QUAL)

Mesh smoothing attempts to improve the quality of the mesh despite the
mesh distortion that results from the optimization displacement of the design
nodes. The mesh quality can be controlled usingthe LEVEL_QUAL parameter. The value LEVEL_QUAL=LOW is set by default, i.e., improvement of the
mesh quality is attempted during the mesh smoothing. This is the most efficient setting. Generally, an increase to LEVEL_QUAL=MEDIUM or
LEVEL_QUAL=HIGH leads to further improvement of the mesh quality but at
the cost of increased computing time. The sub-algorithm can be deactivated
by setting LEVEL_QUAL=NOT.
MESH_SMOOTH
...
LEVEL_QUAL
END_
= LOW
Remarks
1. It is not recommended to deactivate the quality level
(LEVEL_QUAL=NOT).
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Design Area
2. The LOW level is sufficient for many applications. A higher level (MEDIUM,
HIGH) should only be selected if the results are unsatisfactory or the
quality of the mesh needs to be improved.
3. The more TETRA elements there are in a mesh, the higher the quality level
needed. The additional computing time should be endured in any case
because it is usually possible to achieve greater changes to the shape.
4. Further quality improvement may be achieved by reducing the amount of
optimization displacement (see vol.2 chapter 6.8.1). This option should be
tried if satisfying results have not been achieved despite having used the
HIGH level setting.
Quality parameters
The quality values of the sub-algorithm mentioned are determined for each
element and base on the angle quality and, for tetrahedral elements, the
quality of the aspect ratio. The quality value lies between 1 (best element
quality) and 0 (poorest element quality). The poorest quality value of an angle
or aspect ratio is always decisive for the element. The user can specify the
interval limit (*_LOW_*, *_HIGH_*) outside of which the elements are rated
as poor by the quality algorithm. The poorer an element is rated, the greater
the consideration it will be given in improving the element quality.
MESH_SMOOTH
...
QUAD_LOW_ANGLE
= <value>
QUAD_HIGH_ANGLE = <value>
TRIA_LOW_ANGLE
= <value>
TRIA_HIGH_ANGLE = <value>
TETRA_LOW_ASPECT = <value>
TETRA_HIGH_ASPECT = value>
The way the quality values are determined can be outlined as follows:
QUAD planes (QUAD elements, lateral planes of HEXA and PENTA elements):
- Optimum angle is 90-> quality=1.
- Angle smaller or equal to QUAD_LOW_ANGLE -> quality=0.
- Angle greater or equal to QUAD_HIGH_ANGLE -> quality=0.
TRIA surfaces (TRIA elements, lateral surfaces of TETRA and PENTA elements):
- Optimum angle is 60 -> quality=1.
- Angle smaller or equal to TRIA_LOW_ANGLE -> quality=0.
- Angle greater or equal to TRIA_HIGH_ANGLE -> quality=0.
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SIMULIA
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Shape Optimization
TETRA elements:
- Optimum aspect ratio is 1.33 -> quality=1.
- Aspect ratio smaller or equal to TETRA_LOW_ASPECT -> quality=0.
- Aspect ratio greater or equal to TETRA_HIGH_ASPECT -> quality=0.
Remarks
1. With LEVEL_QUAL=NOT no element quality is calculated and the interval
limits are not required.
2. The default values are practical and usually do not need to be changed.
Changing the interval limits usually only leads to a slight change in the
mesh quality.
3. The value for QUAD_LOW_ANGLE must lie between 0 and 89. The
value for QUAD_HIGH_ANGLE must lie between 91 and 180. The value
for TRIA_LOW_ANGLE must lie between 0 and 59. The value for
TRIA_HIGH_ANGLE must lie between 61 and 180. The value for
TETRA_LOW_ASPECT must lie between 0.00177 and 1.30. The value for
TETRA_HIGH_ASPECT must lie between 1.36 and 999.
4. Determination of the local quality in the MESH_SMOOTH is decoupled
from the global quality determination that is activated for the entire model
with the READ_ELEM_QUALITY parameter of the OPTIONS command.
Output of the global quality values can be made through the Patran interface or the parameter LIST, ELEM, QUAL (see volume 3: LIST). The local
quality values of MESH_SMOOTH cannot be accessed by the user.
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Poor quality elements

A list of the elements that are rated as poor quality by MESH_SMOOTH with
an internal quality value of zero can be made as an output. To do so, set the
QUAL_LIST=YES parameter. The default setting is QUAL_LIST=NO, no list
of poor quality elements is printed out.
MESH_SMOOTH
...
QUAL_LIST
= NO
END_
Remark
5. The list of poor quality elements can only be printed for
LEVEL_QUAL=LOW, MEDIUM or HIGH. No element qualities are calculated with LEVEL_QUAL=NOT and poor elements cannot be identified.
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Design Area
6.3.2.8 Quality criteria of the solver (SOLVER_CHECK)

In shape optimization there is a danger that the desired optimum cannot be
achieved with the specified mesh which is continually adjusted to changing
conditions. This means that the mesh is a component that should be
restricted in the optimization job. Usually, the quality of the mesh decreases
with an increase in the number of design cycles.
The program for the finite element analysis may abort as a result. Some quality criteria for elements are checked in the finite element analysis program. If
the solver identifies elements that are too poor in quality, the finite elements
analysis is aborted. This has the disadvantage that no analysis results for the
subsequent design cycle are then available in Tosca Structure and therefore,
the optimization must be aborted (error message due to lack of results data
instead of error message due to poor mesh quality, for more see vol.2 chapter
13.6.1, FE model of the next iteration is not calculated).
Using the option SOLVER_CHECK=YES (default is NO) the user has the
possibility, to check some finite element solver quality criteria in the Tosca
Structure optimization module before the actual finite elements analysis. The
quality criteria Q4TAPER, Q4SKEW, T3SKEW and TETRAAR are checked.
The poorest values and the corresponding elements are logged to the output
file. The default values in Tosca Structure can be changed by the user using
the options Q4TAPER, Q4SKEW, T3SKEW and TETRAAR. The option
SOLVER_STOP=YES (default is NO) causes a regular program stop in the
Tosca Structure optimization module when one of the quality criteria is violated. This means that the subsequent finite elements analysis, which would
be canceled without results data, is no longer carried out. This setting has the
advantage that an optimization stop is easier to understand for the user who
is saved from having to check the finite element solver results files for the
source of the error.
...
SOLVER_CHECK
Q4TAPER
Q4SKEW
T3SKEW
TETRAAR
SOLVER_STOP
=
=
=
=
=
=
YES
<value>
<value>
<value>
<value>
YES
END_
Remarks
1. The allowed value limit for the element quality should be set identically in
Tosca Structure and the finite element solver.
2. The option SOLVER_STOP=YES is only active when
SOLVER_CHECK=YES is also set. This means that the regular program
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Tosca Structure
Shape Optimization
stop due to poor mesh quality can only be carried out if the mesh quality is
checked.
3. The optimization in Tosca Structure stops when the SOLVER_STOP condition is fulfilled or stops when reaching the global condition STOP,
ITER_MAX (STOP) which set the maximum number of allowed iterations
(design cycles).
6.3.2.9 Correction of distorted elements (CORRECT_ELEMENTS)

In some cases the program for the finite element analysis aborts due to bad
element quality (inverted element or aspect ratio too big) some time during
the optimization and thus prevents Tosca Structure from performing the optimization task. Very often only a few elements cause this trouble and the
desired optimum is only slightly affected when modifiying the concerned elements in order to gain a better mesh quality.
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Fig. 184 Correction of distorted elements: a) original element, b) optimized

element with bad aspect ratio (d), c) corrected element (good
aspect ratio)
For tetrahedral and hexahedral elements this can be activated with the
CORRECT_ELEMENTS = YES option (default, use NO to disable). For
hexahedral elements and tetrahedral elements with bad element quality, it is
tried to correct the element CE_CORRECTION_LOOPS times by multiplying
the optimization displacements with CE_CORRECTION_FACTOR (default is
0.5). If the element is still in a poor state it depends on CE_FAIL_ACTION
what is done next: If CE_FAIL_ACTION = RESET is set (default), the optimization displacement is set to zero. If CE_FAIL_ACTION is set to CONTINUE
the element is left as it is (with the risk that the solver will abort).
MESH_SMOOTH
...
TETRAAR
= <value>
CORRECT_ELEMENTS=YES | NO
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Design Area
CE_CORRECTION_LOOPS=<int value>
CE_CORRECTION_FACTOR=<value> (0.5)
CE_FAIL_ACTION = RESET | CONTINUE
END_
Remarks
1. The element quality for tetrahedral elements with four nodes is determined
by calculating the aspect ratio. Use the TETRAAR setting to influence the
quality detection.
2. The element quality for quadratic tetrahedral elements and for hexahedral
elements is determined by calculating the Jacobian. If it is negativ the
element needs to get corrected.
3. To make sure that the solver will not fail due to bad element quality, the
TETRAAR quality criteria should be set a little bit lesser than in the solver.
4. This option is only working with tetrahedral, hexahedral and pyramid
elements (with or without midnotes).
5. The modified elements are saved to a group with name
CORRECTED_ELEMENTS_<iteration>.
6. When used during TEST_SHAPE with more than one increment only the
group of the last increment step is saved.
The mesh smooth strategy is defined by the parameter STRATEGY. By default,

STRATEGY = CONSTRAINED_LAPLACIAN, and the default mesh smoothing
method is used. If, instead, STRATEGY = LOCAL_GRADIENT is chosen, the
optimization-based mesh smoothing algorithm is used. In each iteration, it
identifies the elements with the worst element quality and improves them by
displacing the nodes. For relatively small models (less than 1000 nodes in the
mesh smooth area), the method usually results in meshes with elements having the optimal shape; the measure of the optimality is roughly the ratio of the
element volume (area for shell elements) to the corresponding power of its
diameter. For larger models, the iterations tend to stop before the optimal
mesh quality is reached since otherwise the calculation time becomes too
large. In this case, the changes might only affect the elements with the worst
element quality. The nodes on the surface are displaced as well, though their
displacements are chosen to be parallel to the surface. It guarantees that the
overall geometry remains mostly unchanged by the algorithm.
Note that LEVEL_CONV and LEVEL_DVCON parameters are not used if STRATEGY = LOCAL_GRADIENT is specified.
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6.3.2.10 Mesh smooth strategy (STRATEGY)
SIMULIA
Tosca Structure
Shape Optimization

In Tosca ANSA environment, mesh smooth areas are defined below the item
DESIGN_AREA in Task Manager. In MESH_SMOOTH dialog the element group
for the mesh smooth area is chosen and further settings are defined. It is
opened by New | MESH_SMOOTH command on DESIGN_AREA item (if
MESH_SMOOTH item did not exist before) or Edit command on an already
existing MESH_SMOOTH item.
.
Fig. 185 Definition of a mesh smooth area (MESH_SMOOTH) in Tosca

ANSA environment
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In Tosca Structure.gui, mesh smooth areas are defined in the

MESH_SMOOTH command of Tosca Structure.pre screen where the element
group for the mesh smooth area can be chosen and further settings be
defined.
Fig. 186 Definition of a mesh smooth area (MESH_SMOOTH) in Tosca

Structure.gui
Command syntax
Each MESH_SMOOTH definition has a name (ID_NAME parameter) and references a previously defined element group (EL_GROUP parameter). The
name is required in order to subsequently activate the MESH_SMOOTH definition when specifying the optimization job (see OPTIMIZE command). The
area for the mesh smoothing is specified by the element group. These two
User Manual 2 - 319
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Design Area
declarations are mandatory. A typical MESH_SMOOTH command appears as

follows:
MESH_SMOOTH
ID_NAME
EL_GROUP
...
= mesh_smooth_name
= elem_group_name
END_
All other declarations are optional and are used for additional specifications in
the MESH_SMOOTH definition by the user.
Remarks
1. The recommended procedure is to define MESH_SMOOTH area immediately after defining the design area (see DV_SHAPE command) since the
two areas are assigned to one another.
2. The MESH_SMOOTH definition must be activated by reference in the
OPTIMIZE command. Non-activated definitions have no influence in the
optimization. The reference in the OPTIMIZE command assigns the design
area (see DV_SHAPE command) and the area for mesh smoothing (see
MESH_SMOOTH command) to one another.
3. It is recommended to define MESH_SMOOTH before the DVCON_SHAPE
entries (see vol.2 chapter 6.3.3) or a volume constraint (see vol.2 chapter
6.5.1). This enables the system-defined MESH_SMOOTH node group to
then be used for the DVCON_SHAPE definitions or the user/systemdefined MESH_SMOOTH element group to be used for the definition of the
volume constraint.
Restrictions (DVCON_SHAPE)
For shape optimization, restrictions are defined as boundary conditions that
limit the potential area of the node displacement. A design variable constraint
is a restriction that directly affects the individual design variables, i.e., the individual design nodes. Since the nodes in the mesh smoothing area (see volume 3: MESH_SMOOTH) can be interpreted as second order design nodes,
there is also the possibility to apply the restrictions (to a limited degree) to the
nodes of the mesh smoothing area. Compared to geometrical optimization
based on a few parameters, Tosca Structure.shape allows every design node
to be displaced independently from other design nodes.
To meet functional and manufacturing requirements, it is usually necessary to
limit the solution area and therefore the independence of the design nodes.
Unrestricted shape optimization can produce trivial results. For example, if
the shape of a shaft shoulder under axial tensile stress is optimized without
restricting the design nodes, a smooth beam will arise that will not be able to
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6.3.3
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Tosca Structure
Shape Optimization
fulfill the original function. To achieve the best results the rule: As much flexibility as possible, as few restrictions as necessary! should be followed. The
possible restrictions are the specification of an allowed displacement area by
limiting the directional amount of optimization displacement and the specification of variation and frozen areas. It is also possible to influence the allowed
displacement direction by limiting the displacement to specific coordinate
directions. In addition, the optimization displacement of a node can be made
dependent on the optimization displacement of another node. The definition
of the design variable constraints for shape optimization is done with the
DVCON_SHAPE command.
The following restrictions are available for shape optimization:
Restriction of the amount of displacement (see vol.2 chapter 6.3.3.2)
Maximum and minimum member size (see vol.2 chapter 6.3.3.3)
Displacement check against solids (see vol.2 chapter 6.3.3.4)
Displacement check against elements of an element group (see vol.2
chapter 6.3.3.5)
Restriction of the displacement direction (see vol.2 chapter 6.3.3.6)
Restricting the displacement to a slide surface (see vol.2 chapter 6.3.3.7)
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Assignment of a coupling condition (see vol.2 chapter 6.3.3.8)
Fig. 187 Design variable constraints available in Tosca ANSA environment

(left) and Tosca Structure.gui
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Design Area
Remarks
1. Some of the design variable constraints for shape optimization can be
interpreted as side constraints or bounds (design variable boundaries) in
the same way these terms are used in standard optimization nomenclature.
2. Some of the design variable constraints for shape optimization relate not
only to the design variable itself but also to the corresponding optimization
displacement vectors (or the design coordinates). The term design variable constraint in this case should be interpreted in a more general sense.
3. In contrast to the DVCON_SHAPE parameter, which has a direct effect on
the individual design variables, the CONSTRAINT parameter defines a
constraint for the optimization job that affects the functional relationships of
several design variables (e.g. volume constraint).
4. The activated DVCON_SHAPE entries are executed in the order in which
they are referenced in the OPTIMIZE command or defined in Tosca ANSA
environment. The individual DVCON_SHAPE entries are checked independent of one another, i.e., a DVCON_SHAPE entry always overrides the
preceding DVCON_SHAPE entry. If mutually independent restrictions are
declared all restrictions are observed. If mutually dependent restrictions
are declared the user must select an order of execution that is logical and
specific for the problem.
This section only contained a general overview of the command forms without going into detail about the exact syntax and operations of the individual
restrictions. In the following sections the individual restrictions are described
in more detail.
6.3.3.1 Node group for design variable constraints

The area to which restrictions are applied to is defined by a node group. This
node group must contain only design nodes or nodes in the mesh smooth
area.
Remarks
1. The restrictions are checked only for the corner nodes of the node group
(ND_GROUP parameter). If mid-side nodes are contained in the node group
they are subsequently placed in between the neighboring corner nodes.
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5. The restricted nodes are checked at the beginning and the execution stops
if the defined constraint is not fulfilled (CHECK_SLIDE, CHECK_LINK).
This behavior can be switched off with the parameter
FEASIBLE_START=NO. But for example if the surface described node
group is not stampable and this check is switched off the restriction
enforces the stampable surface.
SIMULIA
Tosca Structure
Shape Optimization
Therefore, for mid-side nodes, it is not possible to guarantee adherence to

the restrictions; a small amount of deviation may occur.
2. It is important to ensure that the only node groups referenced in the
DVCON_SHAPE definitions are those whose nodes are contained in the
MESH_SMOOTH area.
6.3.3.2 Restricting the amount of displacement

It is possible to specify a maximum allowed absolute optimization displacement for each node in relation to the starting geometry. This involves differentiating between growth (node is moved outwards) and shrinkage (node is
moved inwards). This function can be used, for example, in the optimization
of mold parts that require a specific minimum and maximum wall thickness to
allow the component to be cast. The parameters
CHECK_GROW
CHECK_SHRINK
= <MAX_GROW_VALUE>
= <MAX_SHRINK_VALUE>
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specify a maximum amount of displacement <max_grow_value> allowed in

the growth direction and a maximum amount of displacement
<max_shrink_value> allowed in the shrink direction. Both values must be
positive and can be set in the GROW/SHRINK_CONTROL menu of Tosca
ANSA environment or the Displacement fields in Tosca Structure.gui. Fig.
188 provides a graphic illustration of the allowed displacement area.
Fig. 188 Specification of an upper and lower displacement limit relative to

the start contour
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Design Area
Remark
1. The CHECK_GROW and CHECK_SHRINK restrictions can only be
defined for surface nodes since only surface nodes exhibit a growth or
shrinkage direction. If inner nodes are contained in the node group
(ND_GROUP parameter), the DVCON_SHAPE definition will be rejected.
6.3.3.3 Minimum or maximum member size
Fig. 189 Minimum member size with radius = 3.0 (thickness = 6.0 for TAE)
A typical parameter set for the member size restriction is of the following
form:
DVCON_SHAPE
ID_NAME
ND_GROUP
CHECK_MAX_MEM
CHECK_MIN_MEM
CHECK_NDGR
TOLERANCE
DVCON_SHAPE
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=> ...
=> <MEMBER_SIZE_NODES>
=> <MEMBER_SIZE_RADIUS>
=> <MEMBER_SIZE_RADIUS>
=> <MEMBER_SIZE_CHECK_GROUP>
=> <TOLERANCE_FOR_INTERSECTION_TESTS>
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For the definition of minimum member size a radius is specified, such that
normal to the surface of the model a minimum thickness of 2*radius must be
achieved. If optimization displacements break this restriction they will be
readapted according to the selected master criterion. If the structure is
smaller in certain regions from the very first, only growth is permitted in these
areas unless the areas fit the condition. CHECK_MAX_MEM works analogously. In Tosca ANSA environment, the settings are edited in
MEMBERSIZE_CONTROL dialog.
SIMULIA
Tosca Structure
Shape Optimization
Technically the implementation is based on the surface of the finite elements

of the design nodes. The member size is calculated as the distance between
a node and the intersection point in negative normal direction to an element
surface. If no element surface is intersected the member size is ignored for
this node.
The ND_GROUP parameter specifies the node group that is modified by the
algorithm. This group should be a subset of the meshsmooth area. The distance of the nodes in this group is tested against the node group specified by
CHECK_NDGR. This is an optional parameter and set by default to
<MEMBER_SIZE_NODES>. This option is useful if the member size shall only
be tested against certain regions like in Fig. 190.
The TOLERANCE parameter is important for intersection tests: If the intersection
test
for
one
node
misses
the
border
of
the
<MEMBER_SIZE_CHECK_GROUP> slightly, the element faces can be
extended by the TOLERANCE value (in absolute units) so that the intersection
test succeeds and the desired member size for this node is not ignored. However a too large TOLERANCE value implies the risk of getting incorrect distances. This parameter is optional and the default value is 0.1 * max element
length.
ND_GROUP
CHECK_NDGR
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Fig. 190 Example for ND_GROUP and CHECK_NDGR

Remark:
1. If you want to ensure the minimum (maximum) member size restriction for
a certain region which is not necessarily part of the mesh smooth area,
choose all surface nodes of this region as CHECK_NDGR. Areas which
alreadfy fulfil your restriction and are not influenced by the optimization can
be left out.
2. The minimum member size restriction tends to be non-conservative. This
means that the resulting member size is possibly smaller than the desired
one. A workaround is to give a higher desired minimum meber size value.
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Design Area
3. For the same reason, the maximum member size tends to be conservative.
4. If your starting model does not fulfill your desired thickness, the member
size restriction is unable to fit the model to these values.
6.3.3.4 Displacement check against solids (CHECK_SOLID)

It is possible to define geometric primitives (solids) as a restriction of the node
displacements. Geometric primitives are defined using the SOLID parameter.
The SOLID command allows the definition of circles, circle segments, ring
segments and rectangles in two-dimensional models and cylinders, cylinder
segments, tubes, cubes and cube segments in three-dimensional models.
There is a differentiation between a variation solid and a restriction solid
(variation area or restriction area, see vol.2 chapter 3.9, Solids (Geometric
Primitives)).
The parameter:
CHECK_SOLID
= solid_name
specifies a solid whose borders may not be penetrated. Fig. 191 provides a
graphic illustration. The solid must be defined using the SOLID menu (New |
SOLID command on a CHECK_SOLID item found below DV_CONSTRAINTS)
in Tosca ANSA environment or with the SOLID command in Tosca Structure.gui before being referenced.
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Fig. 191 Displacement check against a solid
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Fig. 192 CHECK_SOLID definition using Tosca ANSA environment (left)

and Tosca Structure.gui
Remarks
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1. The CHECK_SOLID restrictions can be performed for surface nodes as

well as for inner nodes. To limit the exterior form of a component, it only
makes sense to restrict surface nodes. However, the node displacements
in the MESH_SMOOTH area should be limited.
2. Up to six different CHECK_SOLID parameters can be defined in every
DVCON_SHAPE command. They are executed in the order of their declaration within the DVCON_SHAPE command. In Tosca ANSA environment this
corresponds to the order of the solid entries in the task manager.
3. If the solid is a variation solid, all nodes of the node group in the start model
(see ND_GROUP parameter) must be located inside the variation solid. If
nodes are located outside the variation solid, the DVCON_SHAPE definition will be rejected. If the solid is a restriction solid, all nodes of the node
group in the start model (see ND_GROUP parameter) must be located
outside the restriction solid. If nodes are located inside the restriction solid,
the DVCON_SHAPE definition will be rejected.
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Design Area
6.3.3.5 Penetration check (CHECK_ELGR, PENETRATION_CHECK)

Element surfaces and lines as well as solid elements can be defined as limiting surfaces, lines or solids in order to check node displacements against any
contour. This option offers more flexibility than the check for the absolute
amount of displacement or the check against geometric primitives. The limiting surfaces are formed by beam structures in 2D models and by shell structures or solid structures in 3D models. The limiting surfaces are generated in
the FE preprocessor and loaded via the interface (MODEL_LINK Folder or
FEM_INPUT command, ADD_FILE parameter) in the optimization preprocessor. The parameter
CHECK_ELGR
= elgr_name
can be defined in the CHECK_GROUP field of the PENETRATION_CHECK menu
in Tosca ANSA environment or in the Element Group field of Tosca Structure.gui. It specifies an element group whose elements may not be penetrated (contact condition) by the nodes of the node group specified by the
ND_GROUP parameter for shell or beam elements. For solid elements, all
nodes inside the solids specified by the CHECK_ELGR parameter are frozen
and for all nodes outside the penetration into the solid is avoided. Fig. 193
provides a graphic illustration.
Activation of the element check represents a collision control. If a node
attempts to penetrate an element, the node displacement is scaled back so
the effected node remains on the side of the element where it is intended.
The element group must be defined with GROUP_DEF or in the analysis file
before it can be referenced with CHECK_ELGR.
Remarks
Fig. 193 Displacement check against solid and beam elements
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1. CHECK_ELGR restrictions can be performed for surface nodes as well as

for inner nodes. To limit the exterior form of a component, it only makes
sense to restrict surface nodes. However, the node displacements in the
MESH_SMOOTH area should be limited.
SIMULIA
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Shape Optimization
2. Up to six CHECK_ELGR parameters can be defined in every

DVCON_SHAPE command. They are executed in the order of their declaration within the DVCON_SHAPE command. In Tosca ANSA environment for
each group a new PENETRATION_CHECK entry has to be created.
3. To simplify the definition of the contact check it is useful to divide the
limiting surfaces by assigning various element property numbers (or materials). This greatly simplifies the selection and assembly of groups in the
optimization preprocessor (when using manual selection).
4. The nodes (ND_GROUP parameter) and the elements (CHECK_ELEM
parameter) should have a definite minimum distance to ensure that a node
must remain on the right element side and the initial model is feasible.
5. For determining penetration by beam elements (without lateral dimension),
a hypothetical tolerance area amounting to 1% of the beam length
surrounds each beam element. A beam element is considered penetrated
when a node is moved into the tolerance area. A node displacement
moving alongside the tolerance area is not considered a penetration.
6. If the elements being used in the check are loaded with the ADD_FILE
parameter of FEM_INPUT command, attention should be paid that node or
element IDs are not used twice since Tosca Structure cannot process duplicated IDs.
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6.3.3.6 Restricting displacement directions (CHECK_BC, CHECK_DOF)

In Tosca Structure.shape the displacement direction of the design nodes
(optimization displacement vector) is normally determined as the surface normal (see vol.2 chapter 6.8.1). The inner nodes are subsequently recalculated
in relation to the displacement of the design nodes determined by the
selected mesh smoothing algorithm. However, to meet functional and manufacturing requirements it is often necessary to deviate from the automatically
determined displacement direction for design nodes as well as for mesh
smoothing nodes. In doing so, every translational degree of freedom can be
fixed for any node in a freely defined coordinate system. In this way, a node
can be restricted to move on one plane only (fixed to one value) or to move
within a displacement vector (fixed to two values). The restriction of all three
translational degrees of movement is equivalent to a constraint of the node in
the shape optimization.
The displacement boundary condition must be unique.In contrast to FE
boundary conditions for several load cases, the total of all the supports for all
load cases are considered as supports in the optimization. A prescribed node
displacement as an optimization boundary condition is also not permitted.
Tosca Structure.shape offers the user two possibilities for restricting the displacement directions of nodes.
User Manual 2 - 329
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Design Area
Loading the Node Fixations via the Interface from the FE Program
The full or partial fixation of nodes is the most common and most important
type of restriction; it is practically used in every optimization model. The most
efficient method for defining the displacement restrictions in the FE preprocessor is as an extra load case in the analysis model and then load it via the
FE interface in the optimization preprocessor. The interface must first be activated with the OPTIONS, BC = ... parameter. In this way all node fixations for
the optimization model can be defined in advance in the FE preprocessor.
The fixation is always based on the FE displacement coordinate system of
the node. The parameter
CHECK_BC
= YES
activates the node fixations of the node group (ND_GROUP parameter) that
are loaded in the FE model. Fixations that reference nodes not contained in
the node groups are not activated. To prevent loaded fixations from being
activated enter:
CHECK_BC
= NO
Direct definition of the displacement restriction

If it is necessary to restrict other displacement directions in addition or at a
later stage, this can be accomplished with the CHECK_DOF parameter in the
menu DOF_Control (Tosca ANSA environment) or the field DOF (Tosca
Structure.gui). This restriction is applied to a node group (defined in the FE
File, using group definition or graphically in Tosca ANSA environment). The
coordinate system must also be defined or loaded. With the parameter
CHECK_DOF
= <cs_name>, FIX/FREE, FIX/FREE, FIX/FREE
all the displacements of all nodes in the node group selected with ND_GROUP
are fixed (FIX) or free (FREE) relative to the specified coordinate directions of
the coordinate system <cs_name>. Either FREE or FIX is allowed for each
coordinate direction.
1. The restrictions CHECK_BC or CHECK_DOF can be applied to both: surface

nodes and inner nodes.
2. The essential difference between CHECK_BC and CHECK_DOF is:
CHECK_BC is read in through the FE interface whereas CHECK_DOF is
defined in the optimization preprocessor. With CHECK_BC each node
generally has its own fixation in its own displacement coordinate system,
whereas with CHECK_DOF all nodes of the node group are all fixed in the
same coordinate system.
6.3.3.7 Restricting displacement to a slide surface

Element surfaces can be defined as slide surfaces in order to force the
design nodes onto this contour (CHECK_SLIDE). This option offers more
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Remarks
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Tosca Structure
Shape Optimization
flexibility than restricting the direction of displacement. The limiting surfaces

are formed by shell structures. Those surfaces can be generated automatically with a link shape command.
Fig. 194 Master nodes generate the slide surface

A master node group is required describing sufficiently the contour of the surface. The following command defines a surface of revolution with rotation axis
Z in the global coordinate system:
ID_NAME
MASTER
CLIENT
CLIENT_DIR
TOL
CS
=
=
=
=
=
=
surface
NDGR, slide_master_ndgr
SURF_TURN
0, 0, 1
0.1, 0.1, 0.1
CS_0
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LINK_SHAPE
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Design Area
END
Fig. 195 Generated slide surface

This slide surface is connected to a node group via a DVCON_SHAPE command:
DVCON_SHAPE
= slide_restriction
= surface
= restricted_nodes
END_
Alternatively the limiting surfaces are generated in the FE preprocessor and

loaded via the interface (FEM_INPUT command, ADD_FILE parameter) in
the optimization preprocessor. With a LINK_SHAPE command
LINK_SHAPE
ID_NAME
MASTER
CLIENT
TOL
CS
END_
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=
=
=
=
=
surface
NDGR, slide_ndgr
FREE_FORM
0.1, 0.1, 0.1
CS_0
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ID_NAME
CHECK_SLIDE
ND_GROUP
SIMULIA
Tosca Structure
Shape Optimization
Here, the node group "slide_ndgr" is used to generate the surface on which
the design nodes will be restricted. The CLIENT = FREE_FORM allows for
freeform surfaces.
Remarks
1. CHECK_SLIDE restrictions can be performed for surface nodes as well as
for inner nodes. To limit the exterior form of a component, it only makes
sense to restrict surface nodes. The restriction of inner nodes can be
undertaken. However, the node displacements in the MESH_SMOOTH
area should be limited.
2. To simplify the definition of the contact check it is useful to divide the
limiting surfaces by assigning various element property numbers (or materials). This greatly simplifies the selection and assembly of groups in the
optimization preprocessor.
parameter of FEM_INPUT command, attention should be paid that node or
element IDs are not used twice since Tosca Structure cannot process duplicated IDs.
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6.3.3.8 Assigning link/coupling conditions (CHECK_LINK)

A parameter-free optimization is performed for shape optimization in Tosca
Structure, i.e., each of the design nodes can be moved independent of the
other design nodes. However, in some cases certain restrictions are specified
that make it necessary to link or couple design nodes.The design nodes are
then no longer allowed to move freely; there is an interdependent relationship
between the individual design nodes. This relationship is defined by a link
condition.
The following are examples of the type of restrictions that might necessitate
the activation of link conditions: All design nodes in the start model are
located on a cylinder and should also be located on a cylinder (with an altered
radius) in the optimized model. Another example: due to a specified punch
direction, the design nodes must lie along the punch direction. Yet another
example: an originally symmetrical component should still be symmetrical following the optimization despite asymmetric stress. The parameter
CHECK_LINK
= link_shape_name
activates a link condition for the nodes of the node group (ND_GROUP parameter). This link condition must be defined with the LINK_SHAPE parameter
and referenced with its unique name (link_shape_name). The possibilities for
defining link conditions are numerous and varied. All of the definition options
are described in vol.2 chapter 6.3.4. Since it is not necessary to know the link
conditions for the basic definition of a shape optimization job, inexperienced
User Manual 2 - 333
SIMULIA
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Design Area
readers should skip this chapter at this time. This section can be read when
the need arises.
Remarks
1. An individual link condition can be assigned several times, i.e., an individual link condition can be activated in several DVCON_SHAPE entries for
several node groups.
2. Some manufacturing restrictions require the definition of numerous node
groups and restrictions. To make this easier, you can automatically
generate node groups using the GROUP_AUTO_DEF command and automatically assign link conditions as restrictions using the
DVCON_AUTO_SHAPE command.
3. A detailed description of the LINK_SHAPE command is available in vol.2
chapter 6.3.4.
4. In Tosca ANSA environment coupling conditions can be defined using the
modules buttons LINK_SHAPE and DVCON_SHAPE.

In Tosca ANSA environment, design variable constraints are defined below
the item DV_CONSTRAINTS of the task manager. The dialog where a node
group to be restricted is chosen and further settings are defined is opened by
New | <constraint type> command applied on DV_CONSTRAINTS item
(if a new design variable constraint is to be created) or by Edit command on
an already existing item that corresponds to the design variable constraint.
In Tosca Structure.gui, design variable constraints are defined in the

DVCON_SHAPE mask of Tosca Structure.pre where the node group for the
restrictions can be chosen and further settings be defined.
6.3.3.11 Command syntax

Each DVCON_SHAPE definition has a name (ID_NAME parameter) and references a previously defined node group (ND_GROUP parameter). The name
is required to subsequently activate the DVCON_SHAPE definition when specifying the optimization job (see OPTIMIZE command). The node group specifies the node area where the restriction is in effect.
The following parameters define the individual restrictions for shape optimization:
CHECK_GROW, CHECK_SHRINK: Restriction of the amount of displacement (see vol.2 chapter 6.3.3.2)
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6.3.3.10 Definition in Tosca Structure.gui
SIMULIA
Tosca Structure
Shape Optimization
CHECK_MAX_MEM, CHECK_MIN_MEM: Definition of a maximum and

minimum member size (see vol.2 chapter 6.3.3.3)
CHECK_SOLID: Check the displacements against geometric primitive solids (see vol.2 chapter 6.3.3.4)
CHECK_ELGR: Check the displacements against elements of an element
group (see vol.2 chapter 6.3.3.5)
CHECK_BC, CHECK_DOF: Restriction of the displacement direction
(see vol.2 chapter 6.3.3.6)
CHECK_SLIDE: Restricting the displacement to a slide surface
CHECK_LINK: Assignment of a coupling condition
A DVCON_SHAPE command using all of the individual restrictions appears as
follows:
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DVCON_SHAPE
ID_NAME
=name_of_dvcon_shape
ND_GROUP
=name_of_node_group
CHECK_GROW
=<max_grow_value>
CHECK_SHRINK =<max_shrink_value>
CHECK_MAX_MEM =<radius>
CHECK_MIN_MEM =<radius>
CHECK_SOLID
=name_of_solid
CHECK_ELGR
=name_of_element_group
CHECK_BC
=cs_name,[FREE|FIX],[FREE|FIX],[FREE|FIX]
CHECK_DOF
=[YES|NO]
CHECK_SLIDE
=name_of_link_shape
CHECK_LINK
=name_of_link_shape
FEASIBLE_START =[YES|NO]
END_
Remarks
1. It is possible to define several individual CHECK_* restrictions within a
DVCON_SHAPE command. The order of the execution of the individual
restrictions within a DVCON_SHAPE command appears as follows:
CHECK_GROW/ CHECK_SHRINK, CHECK_MAX_MEM,
CHECK_MIN_MEM, CHECK_SOLID, CHECK_ELGR, CHECK_BC,
CHECK_DOF, CHECK_SLIDE, CHECK_LINK. The individual restrictions
are checked independent of one another, i.e., an individual restriction
always overrides the preceding restriction.
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Design Area
2. It is possible to define several design variable constraints using the

DVCON_SHAPE command. Each DVCON_SHAPE definition must have its
own unique name.
3. The DVCON_SHAPE definitions must be activated by a reference in the
OPTIMIZE command. Non-activated definitions have no influence upon the
variable constraints, the design area (see DV_SHAPE command) and the
area for mesh smoothing (see MESH_SMOOTH command) to one
another. Therefore, it is important to ensure that the only node groups
referenced in the DVCON_SHAPE definitions are those whose nodes are
contained in the MESH_SMOOTH area.
4. The recommended procedure is to define the assigned restrictions immediately after defining the design area (see DV_SHAPE command) and the
mesh smoothing area (see MESH_SMOOTH parameter). The systemdefined MESH_SMOOTH node group can then be reused to define the
restrictions.
Link and coupling conditions (LINK_SHAPE)

Shape optimization involves determining the displacement of each design
node in order to homogenize the stress on the surface based on the optimization criteria. The displacement of the neighboring nodes is not coupled, i.e.,
each of the design nodes can move independent from the other design
nodes. For example, during optimization free-form surfaces may develop
from flat surfaces. By coupling the design nodes the optimization can maintain the regularity of planes.
In order to take into account functional and manufacturing restrictions in
shape optimization, certain link conditions can be set with the command
LINK_SHAPE.
Link conditions are defined using Modules Buttons toolbar of Tosca ANSA
environment (click the button LINK_SHAPE on LINK_CONDITIONS panel,
then click New) or using the LINK_SHAPE command in Tosca Struc-
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6.3.4
SIMULIA
Tosca Structure
Shape Optimization
ture.gui.Using Tosca ANSA environment, link definitions are visualized graphically in the model view.
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Fig. 196 LINK_SHAPE definition in Tosca ANSA environment

Each link condition has a name (ID_NAME parameter). A criterion for determining the master node (MASTER parameter) is defined as well as a rule for
the displacement of the client nodes (CLIENT parameter). A typical
LINK_SHAPE command appears as follows:
LINK_SHAPE
ID_NAME
MASTER
CLIENT
...
= name_of_link_shape
= ...
= ...
END_
Depending on the selected CLIENT parameter, other parameters are also

required. In some circumstances a coordinate system (CS parameter) or tolerances (TOL parameter) must be specified. These parameters of a
LINK_SHAPE command may appear as follows:
User Manual 2 - 337
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Design Area
LINK_SHAPE
...
CS
TOL
= name_of_coord_system
= <tol_1>, <tol_2>, <tol_3>
END_
In the following subsections the MASTER and CLIENT parameters are

described in detail. The CS and TOL parameters are also described when
applicable.
design nodes
design nodes (coupled)
without node coupling
master node
including node coupling
Fig. 197 Synchronous coupling of design nodes

Remarks
2. The definition of coupling conditions can require a great deal of time and
effort. In order to be able to estimate the best possible potential of an optimization, one optimizationshould be performed with as few restrictions as
possible and only a few coupling conditions at the beginning of a project.
3. Coupling conditions restrict the range of solutions for the system and
reduce the optimization potential.
6.3.4.1 Determining the master node (MASTER)

The MASTER parameter is used in each definition of a link condition to specify how to determine the master node. This node prescribes the displacement
of the nodes affected by the link condition. It can be set explicitly by the user:
MASTER = NODE, NODE_NR
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1. Link conditions basically only define a coupling rule without referencing a

specific node group. The coupling condition is assigned to a node group
after activation with CHECK_LINK in the DVCON_SHAPE command. In
Tosca ANSA environment, the link definition can be chosen after typing a
"?" in the CHECK_LINK field (click DVCON_SHAPE in RESTRICTIONS panel
of Modules Buttons toolbar, then click New so that the window with the
design variable constraint settings appears). In Tosca Structure.gui the link
condition is assigned in the drop down menu of the DVCON_SHAPE
command.
SIMULIA
Tosca Structure
Shape Optimization
This causes the master displacement to be determined from the same node
during the entire optimization.
Furthermore the master node may be determined from a master node group.
This allows the user to define a components edge to be the master edge for
optimization. The algorithm will determine the master node automatically from
the master node group. In this case the master node group must contain
exactly one node of each link group.
MASTER = NDGR, <NODEGROUP>
Another way is to have the system automatically determine the master node
according to two different criteria:
MASTER = MAX
or
MASTER = MIN
In this case, the master node is re-determined in every cycle. When the master node is automatically determined, the critical factor is identifying which
node displacement (determined by the stress) for the coupling group is relevant. Principally, there exist four different cases of how the largest and smallest node displacements relate to the reference value within the node group:
Case 1
The stress everywhere is greater than the reference value, i.e., a positive
displacement is determined for all design nodes of the coupling group. All
design nodes will grow out of the component.
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Case 2
The stress everywhere is less than the reference value, i.e., for all design
nodes of the coupling group a negative displacement is determined. All
design nodes will shrink inwards.
Case 3
There are nodes with greater and less stress than the reference value and
the absolute shrinkage is greater than the absolute growth (abs(max_neg)
> abs(max_pos)).
Case 4
There are nodes with greater and less stress than the reference value and
the absolute shrinkage is less than the absolute growth (abs(max_neg) <
abs(max_pos)).
Case 1
Case 2
Case 3
Case 4
ALL_GROWTH
ALL_SHRINK
MORE_SHRINK
MORE_GROWT
H
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max_growth
min_growth
OBJ_FUNC
max_growth
max_growth
OBJ_FUNC
min_shrink
OBJ_FUNC
max_shrink
max_shrink
OBJ_FUNC
max_shrink
lab1 =
Selected Master Displacement Value
MAX
max_growth
min_shrink
max_growth
max_growth
MIN
min_growth
max_shrink
max_shrink
max_shrink
The two criteria MAX and MIN, respectively, select different master nodes
corresponding to the selected displacement values:
MAX
The MAX-Criterion is the conservative option. Here, the maximum growth
(as in the cases 1, 3, 4) or the smallest shrinkage (as in case 2) is always
used to select the master node. This is the standard criterion for shape
optimization.
MIN
The MIN-Criterion moves the component surface inward as far as possible.
This criterion has to be used when linking conditions are required while
optimizing contact surfaces.
Remark
2. Older parameters CRIT_1 and CRIT_2 correspond to MAX and MIN

respectively. With Tosca Structure 8.1.0 these older definitions are still
supported.
6.3.4.2 Displacement of the client nodes (CLIENT)

The CLIENTparameter is used in each definition of a link condition to set a
rule for determining the displacement of the client nodes based on the displacement of the master node. The client nodes are moved relative to the
master node. The following rules can be selected:
Plane symmetry (PLANE_SYM, see chapter 6.3.4.3 Plane symmetry
(PLANE_SYM))
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1. CHECK_LINK in the DVCON_SHAPE command assigns the link condition to

a node group. For MASTER=NODE, node_nr, the explicitly declared node
must not necessarily be contained in the node group. For MASTER=MAX
or MASTER= MIN, the master node is always determined from the nodes
of the node group.
SIMULIA
Tosca Structure
Shape Optimization
Plane symmetry for non-symmetric meshes (SURF_PLANE_SYM, see

chapter 6.3.4.4 Plane symmetry for non-symmetric meshes
(SURF_PLANE_SYM))
Cyclic symmetry for non-symmetric meshes
(SURF_CYCLIC_ROTATIONAL_SYM, see 6.3.4.5chapter 6.3.4.5 Cyclic
symmetry for non-symmetric meshes (SURF_CYCLIC_SYM) )
Cyclic-plane symmetry combination (SURF_CYCLIC_PLANE_SYM, see
chapter 6.3.4.6 Cyclic-plane symmetry combination
(SURF_CYCLIC_PLANE_SYM))
Point symmetry (POINT_SYM, see vol.2 chapter 6: Point symmetry
(POINT_SYM))
Rotational symmetry (ROTATION_SYM, see chapter 6.3.4.8 Rotational
symmetry (ROTATION_SYM))
Coupling of displacement coordinates (VECTOR, see chapter 6.3.4.9 Coupling displacement coordinates (VECTOR))
Coupling of the displacement direction (DIRECTION, see chapter 6.3.4.10
Coupling displacement direction (DIRECTION))
Coupling of the amount of displacement (LENGTH, see chapter 6.3.4.11
Coupling amount of displacement (LENGTH))
Coupling of coordinates in the FE displacement coordinate system
(DISP_CS, see chapter 6.3.4.12 Coupling coordinates in the FE displacement coordinate system (DISP_CS))
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Coupling as stampable surface (SURF_STAMP, see chapter 6.3.4.13

Stampable surface (SURF_STAMP))
Coupling as turnable surface (SURF_TURN, see chapter 6.3.4.14 Turnable surface (SURF_TURN))
Coupling as drillable surface (SURF_DRILL, see chapter 6.3.4.15 Drillable
surface (SURF_DRILL))
Coupling as demoldable surface (SURF_DEMOLD, see chapter 6.3.4.16
Demoldable surface (SURF_DEMOLD))
Defining a free form slide surface (FREE_FORM, see chapter 6.3.3.7
Restricting displacement to a slide surface)
The individual rules for determining the client displacements are described in
detail in the following chapters..
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Design Area
6.3.4.3 Plane symmetry (PLANE_SYM)

To be able to couple displacements symmetric to a plane, the position and the
orientation of the plane must be exactly specified. It is also necessary to
specify tolerances in order to identify symmetric nodes. The following four
parameters are necessary for the definition of the link condition:
CLIENT
CLIENT_DIR
CS
TOL
=
=
=
=
PLANE_SYM
<X_1>, <X_2>, <X_3>
name_of_coord_system
<TOL_1>, <TOL_2>, <TOL_3>
The origin of the coordinate system referenced by CS defines a point on the

plane. The direction specified by the CLIENT_DIR parameter defines the normal of the plane. The symmetry of the nodes (assigned by ND_GROUP in the
DVCON_SHAPE command) is checked against the symmetry plane. Symmetric nodes are assembled into a symmetry group (normally two symmetric
nodes per symmetry group). Then the master node of the symmetry group is
determined and the displacements of the client nodes are calculated in such
a way that they move symmetrically to the plane of the master node (see Fig.
198).
The tolerances are required in order to identify symmetric nodes.Symmetric
nodes share equal coordinates in the plane and inversely equal coordinates
normal to the plane (and added tolerances). The three tolerance values tol_*
are assigned to the three coordinate directions of the coordinate system referenced by CS.
Remarks
1. The coordinate system referenced by CS must be a Cartesian coordinate
system.
Fig. 198 Symmetric coupling relative to a plane
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2. Only the MASTER=MAX or MASTER=MIN criteria are allowed for determination of the master node.
SIMULIA
Tosca Structure
Shape Optimization
6.3.4.4 Plane symmetry for non-symmetric meshes (SURF_PLANE_SYM)

To be able to couple displacements symmetrically to a plane on not necessarily symmetrically meshed geometries, the position and the orientation of the
plane must be specified. The following four parameters are necessary for the
definition of the link condition:
CLIENT
CLIENT_DIR
CS
TOL
=
=
=
=
SURF_PLANE_SYM
<X_1>, <X_2>, <X_3>
tolerance_value

symmetry plane. The direction specified by the CLIENT_DIR parameter
defines the normal of the plane. The tolerance value specified by TOL is used
as absolute tolerance in intersection tests and can be used to influence the
behaviour on the border of the selected node group.
The symmetry of the nodes (assigned by ND_GROUP in the
DVCON_SHAPE command) is checked against the symmetry plane. For
each node a reference displacement is calculated for its symmetric "counterpart". This counterpart is obtained by reflecting the node at the symmetry
plane, i.e. by intersecting a line through the node in plane normal direction
with the surface defined by all selected nodes. The reference displacement is
obtained by interpolation of the optimization displacements of the adjacent
nodes.
The tolerance is required to find reference displacements at the border of the
selected node group, where it will happen that nodes do not have an opposite face (with respect to the plane definition) and thus no intersection points
in plane normal directions can be found.
Optional, a strategy to determine node position influence on the result can be
chosen:
= MAX | MIN
The symmetry is built up by using the maximum (default) or the minimum of

the displacement of the selected node (d1 in Fig. 199) and the interpolated
displacement of its plane symmetric counter part (reference displacement d2
in Fig. 199).
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MASTER
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Design Area
node,
reflected
by
symmetry
plane
displaced
model
surface
y
displaced
node
d1
d2
plane of
symmetry
original
position of
node
Fig. 199 Symmetric coupling relative to a plane

Remarks
system.
This link condition couples nodes in a not necessary symmetric mesh that
reoccur in a cyclic manner around a rotational axis.
To be able to build up the coupling, a symmetry axis and an angle must be
specified. The following six parameters are necessary for the definition of the
link condition:
CLIENT
CLIENT_DIR
CS
TOL
ANGLE
CYCLIC_SYM_START
=
=
=
=
=
=
SURF_CYCLIC_SYM
<X_1>, <X_2>, <X_3>
tolerance_value
angle_in_degree
<X_1>, <X_2>, <X_3>
The CLIENT_DIR parameter defines the rotational axis and is specified in

coordinates of the coordinate system CS. Like for the SURF_PLANE_SYM
link condition (chapter 6.3.4.4 Plane symmetry for non-symmetric meshes
(SURF_PLANE_SYM)) the TOL parameter is used in intersection tests as
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6.3.4.5 Cyclic symmetry for non-symmetric meshes (SURF_CYCLIC_SYM)
SIMULIA
Tosca Structure
Shape Optimization
absolute tolerance. The ANGLE divides the area around the axis
(CLIENT_DIR) in pieces of equal size that shall be made symmetric. Thus,
the angle must be a divisor of 360. The CYCLIC_SYM_START point defines
the starting point for the partitioning (see Fig. 200). Its coordinates are given
with reference to the global cartesian coordinate system. It must not lie on the
rotational axis.
Again, like for the SURF_PLANE_SYM link condition (chapter 6.3.4.4 Plane
symmetry for non-symmetric meshes (SURF_PLANE_SYM)) a master strategy might be selected:
MASTER
MAX | MIN}
Again, the strategy determines if the maximum or the minimum displacement

of the linked nodes should be used to return a symmetric result. The link is
determined in a similiar way as for plane symmetry: for each node, reference
points on the surface with respect to the rotational cyclic symmetry and their
interpolated displacements are calculated. The master criterion then influences which optimization displacement will be applied.
axis
CYCLIC_SYM_START
Fig. 200 Cyclic coupling relative to a rotational axis
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Remarks
system.
3. The coordinates of parameter CYCLIC_SYM_START are given with reference to the global cartesian coordinate system.
6.3.4.6 Cyclic-plane symmetry combination (SURF_CYCLIC_PLANE_SYM)

This link condition is a combination of cyclic rotational and planar symmetry.
(chapter
6.3.4.4
Plane
symmetry
for
non-symmetric
meshes
(SURF_PLANE_SYM) and chapter 6.3.4.5 Cyclic symmetry for non-symmet-
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Design Area
ric meshes (SURF_CYCLIC_SYM)). First, the cyclic symmetry is enforced

and afterwards the surface is modified to ensure plane symmetry in each segment. The plane for each segment cuts the segment into two halves. The following parameters are necessary for the definition of the link condition:
CLIENT
CLIENT_DIR
CS
TOL
ANGLE
CYCLIC_SYM_START
=
=
=
=
=
=
SURF_CYCLIC_PLANE_SYM
<X_1>, <X_2>, <X_3>
tolerance_value
angle in degree
<X_1>, <X_2>, <X_3>
In comparison to the SURF_CYCLIC_SYM case, the CYCLIC_SYM_START

point is really important here. As it defines the starting point of the partitioning
process, this point directly influences the areas that shall be made plane symmetric. Its coordinates are given with reference to the global cartesian coordinate system.
axis
planes of
symmetry
CYCLIC_SYM_START
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Fig. 201 Combination of cyclic and plane symmetry
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a)
b)
c)
Fig. 202 Differences of symmetries:

a) plane symmetry (SURF_PLANE_SYM),
b) cyclic symmetry (SURF_CYCLIC_SYM),
c) combination of plane and cyclic symmetry
(SURF_CYCLIC_PLANE_SYM)
6.3.4.7 Point symmetry (POINT_SYM)

To be able to couple displacements symmetric to a point, the position of the
point must be exactly specified. It is also necessary to specify tolerances in
order to identify nodes that lie symmetric to one another relative to the point.
The following three parameters are necessary for the definition of the link
condition:
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CLIENT
CS
TOL
= POINT_SYM
= <TOL_1>, <TOL_2>, <TOL_3>
The origin of the coordinate system referenced by CS defines the symmetry

point. The symmetry of the nodes (assigned by ND_GROUP in the
DVCON_SHAPE command) is checked against the symmetry point. Symmetric
nodes are assembled into a symmetry group (normally two symmetric nodes
per symmetry group). Then the master node of the symmetry group is determined and the displacements of the client nodes are calculated in such a way
that they move symmetric to the point of the master node (see Fig. 203).
The tolerances are required in order to identify symmetric nodes. Point symmetric nodes share inversely equal coordinates (and added tolerances). The
three tolerance values tol_* are assigned to the three coordinate directions of
the coordinate system referenced by CS.
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Design Area
Remarks
1. The coordinate system referenced by CS must be a cartesian coordinate
system.
Fig. 203 Symmetric coupling relative to a point
6.3.4.8 Rotational symmetry (ROTATION_SYM)

To couple displacements rotational symmetric about an axis, the position and
the orientation of the axis must be exactly specified. It is also necessary to
specify tolerances in order to identify nodes lying rotational symmetric relative
to the axis. The mesh of the coupled node group should be rotational symmetric. These parameters are specified as follows:
=
=
=
=
ROTATION_SYM
<X_1>,<X_2>,<X_3>
<TOL_1>, <TOL_2>, <TOL_3>

axis. The direction specified by the CLIENT_DIR parameter defines the axis
direction. The symmetry of the nodes assigned by ND_GROUP in the
DVCON_SHAPE command is checked against the symmetry axis. Symmetric
nodes are assembled into a symmetry group (a simplification of the
GROUP_AUTO_DEF command, where these symmetry groups can be build
according to cylindrical coordinate systems, in combination with
LINK_SHAPE, CLIENT=VECTOR and DVCON_AUTO_SHAPE). Then the
master node of the symmetry group is determined and the displacements of
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CLIENT
CLIENT_DIR
CS
TOL
SIMULIA
Tosca Structure
Shape Optimization
the client nodes are calculated in such a way that they move rotational symmetric to the axis (see Fig. 204).
Fig. 204 Symmetry groups for rotational symmetric coupling

Additionally an angle can be defined to divide the search area into discrete
sections.
ANGLE
= <real>
For a detailed description of discrete and continuous node selection see vol.2
chapter 3.6.5, Automatic node group definition (GROUP_AUTO_DEF).
6.3.4.9 Coupling displacement coordinates (VECTOR)
CLIENT
CS
= VECTOR
The procedure involves calculating the difference between the current coordinates and start coordinates of the master node in relation to the coordinate
systems referenced by CS.Then the start coordinates of the client nodes are
calculated in relation to the coordinate system, the difference of the master
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The following two parameters are entered for coupling displacement coordinates:
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Design Area
node is applied and the current coordinates of the client nodes are determined (see Fig. 205).
Fig. 205 Coupling of displacement coordinates (relative to a Cartesian

coordinate system).
It is also possible to couple only single displacement coordinates by adding
options to the standard form of the CLIENT=VECTOR parameter:
CLIENT
CS
= VECTOR, ON/OFF, ON/OFF, ON/OFF

Each of the three coordinates can be set to either ON or OFF. Only those displacement coordinates set to ON are coupled. Displacement coordinates set
to OFF are not taken into consideration for the coupling. The default setting is
VECTOR=ON, ON, ON.
Remarks
1. The coordinate system referenced by CS can be a Cartesian coordinate
system or a cylindrical or spherical coordinate system.
3. If the coordinate system is cylindrical or spherical, the displacement

vectors of the master node and client nodes with respect to the global
Cartesian coordinate system can generally differ. Corresponding coordinates are determined in the relevant coordinate system. For example, if a
group of moving nodes allocated in a circle have the same radial coordinates in relation to a cylindrical coordinate system and are coupled with
respect to this coordinate system, the nodes of the final design will always
lie on the same circle.
6.3.4.10 Coupling displacement direction (DIRECTION)

The following two parameters are entered for coupling the displacement
direction:
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2. If the coordinate system is Cartesian, all nodes have the same displacement vector (given the name CLIENT=VECTOR), i.e., all nodes are moved
translational like a rigid body. All nodes have the same displacement
direction and the same amount of displacement.
SIMULIA
Tosca Structure
Shape Optimization
CLIENT
CS
= DIRECTION
The procedure is the same as that for CLIENT=VECTOR, but with the difference that the retained displacement vector is rescaled to the original displacement amount of the client nodes (see Fig. 206).
Fig. 206 Coupling of the displacement direction (with reference to a Cartesian coordinate system)
Remark
1. See note for CLIENT=VECTOR (see vol.2 chapter 6: Remarks).
6.3.4.11 Coupling amount of displacement (LENGTH)

The following parameter is entered for coupling the amount of displacement:
CLIENT
= LENGTH
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The procedure is as follows: The amount of displacement of the master node

is calculated and the displacement direction of the master node is determined
(growth or shrinkage). The displacements of the client nodes are scaled in
such a way that the displacement amount of the master node is retained (see
Fig. 207).
Fig. 207 Coupling of the amount of displacements
User Manual 2 - 351
SIMULIA
Tosca Structure
Design Area
6.3.4.12 Coupling coordinates in the FE displacement coordinate system

(DISP_CS)
The following parameter is entered for coupling the coordinates in the FE displacement coordinate system:
CLIENT
= DISP_CS
The procedure is as follows: The optimization displacements (coordinates) of

the master node with reference to the FE displacement coordinate system
are transferred directly into the FE displacement coordinate system of the client nodes. It is also possible to couple only single displacement coordinates
by adding parameters to the standard form of the CLIENT=DISP_CS parameter
CLIENT
= DISP_CS, ON/OFF, ON/OFF, ON/OFF
Each of the three coordinates can be set to either ON or OFF. Only those displacement coordinates set to ON are coupled. Displacement coordinates set
to OFF are not taken into consideration for the coupling. The default setting is
DISP_CS=ON, ON, ON.
Remarks
1. The FE displacement coordinate system of the coupled nodes must be of
the same type, i.e. either Cartesian, cylindrical or spherical.
2. Each node can have its own FE displacement coordinate system. Alternatively, if all nodes have the same FE displacement coordinate system, an
identical link condition with CLIENT=VECTOR can be defined.
6.3.4.13 Stampable surface (SURF_STAMP)
CLIENT
CLIENT_DIR
CS
= SURF_STAMP
= <x_1>,<x_2>,<x_3>
The master nodes are found using the standard master criterion. The stamping surface is defined using the given stamping direction and the cutting edge
automatically generated by Tosca Structure. All nodes of the node group are
linked to this surface.
An additional demolding direction can be included:
DEMOLD_DIR
= <x_1>,<x_2>,<x_3>
The demolding direction has to be orthogonal to the client direction. Therefore Tosca Structure projects the demold vector onto a plane normal to the client direction.
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Maintaining a stampable surface during optimization involves defining a

stamping direction. The stamping domain is defined using a node group. The
direction defined by the CLIENT_DIR parameter specifies the stamping
direction.The link condition is defined using the following parameters:
SIMULIA
Tosca Structure
Shape Optimization
Remarks
1. This link condition allows the definition of stamping restrictions to arbitrary
meshes. No special meshing conditions have to be taken into consideration.
2. It is possible to define stamping restrictions for initial components which are
not stampable in the beginning of the optimization procedure. However,
this is not recommended because the conditions for stamping are met in
the first design cycle. This may lead to large node displacements and a
distorted finite element mesh.
6.3.4.14 Turnable surface (SURF_TURN)

Maintaining a turnable surface during optimization involves defining a rotation
axis. The domain that assures a turnable surface is defined using a node
group, i.e. all nodes of the specified surface node group are checked for rotation symmetry in the given rotation axis. The link condition is defined using
the following parameters:
CLIENT
CLIENT_DIR
CS
= SURF_TURN
= <X_1>,<X_2>,<X_3>
The direction defined by the CLIENT_DIR and the origin of the coordinate
system specify the exact position and direction of the rotation axis.
The master nodes are found using the standard master criteria. The turning
surface is defined using the given rotation axis and the cutting edge automatically generated by Tosca Structure. All nodes of the node group are linked to
this surface.
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Remarks
1. This link condition allows the definition of turning restrictions to arbitrary
meshes. No special meshing conditions have to be taken into consideration.
2. The referenced coordinate system must lie exactly on the rotation axis as
the algorithm always orientates the surface towards the coordinate system.
If non-symmetrical effects occur during optimization, the correct position of
the coordinate system has to be checked.
3. It is possible to define turning restrictions for initial components that are not
turnable in the beginning of the optimization procedure. However, this is
not recommended because the conditions for turning are met in the first
design cycle. This may lead to large node displacements and a distorted
finite element mesh.
User Manual 2 - 353
SIMULIA
Tosca Structure
Design Area
6.3.4.15 Drillable surface (SURF_DRILL)

The drill restriction is a combination of the turning and the demolding restriction. Maintaining a drillable surface during optimization involves defining the
drill axis and the drill feed. The drilling domain is defined using a node group,
i.e. all nodes of the specified surface node group are checked for drilling in
the given drill direction. The link condition is defined using the following
parameter:
CLIENT
CLIENT_DIR
CS
ANGLE
=
=
=
=
SURF_DRILL
<X_1>,<X_2>,<X_3>
<real> (0 < angle < 45)
The direction defined by the CLIENT_DIR and the origin of the coordinate
system specify the exact position and direction of the drill axis, the angle
specifies a minimum surface angle.
The shape of the drilling surface can be specified with an additional undercut
tolerance. The term drilling surface in this case should be interpreted in a
more general sense.
UNDERCUT_TOL
= <real> (>0)
drill
direction
Fig. 208 Drilling surface with undercut tolerance

Remark
1. See note for CLIENT=SURF_TURN (see vol.2 chapter 6: Remarks).
6.3.4.16 Demoldable surface (SURF_DEMOLD)

Defining a demolding or forging restriction involves specifying the manufacturing direction. The area to restrict is defined using a node group of surface
nodes. Demolding in the specified direction or forging against this direction is
maintained during optimization and undercuts are avoided. The link condition
for the demold restriction is defined as follows:
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undercut
tolerance
SIMULIA
Tosca Structure
Shape Optimization
CLIENT
DEMOLD_DIR
CS
CHECK_GROUP
TOL
=
=
=
=
=
SURF_DEMOLD
<X_1>,<X_2>,<X_3>
name_of_node_group
<TOL_1>, <TOL_2>, <TOL_3>
The direction defined by the DEMOLD_DIR specifies the demolding direction

respectively the negative forging direction. All nodes in the node group are
checked for undercuts and for demolding against the specified
CHECK_GROUP. This group of surface nodes should qualify the cast sufficiently. In the simplest case the group of all surface nodes can be chosen. In
Fig. 209 node group 1 describes the demolding area. If the check group contains only node group 1 the undercut is not detected because the check
group describes no restricting surface. Only node group 1 and 2 together
qualify a surface to detect undercuts reliably.
Fig. 209 Demolding check group

In addition, an angle for the surface inclination may be specified using the
ANGLE parameter.
ANGLE
= <real>
The undercut tolerance specifies the maximum valid undercut (default = 0):
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UNDERCUT_TOL
= <real>
Remarks
1. It is possible to define demolding restrictions for initial components which
are not demoldable at the beginning of the optimization procedure.
However, this is not recommended as the conditions for demolding are met
in the first design cycle. This may lead to large node displacements and a
distorted finite element mesh.
2. No single master nodes need to be determined for demolding restrictions.
The master criterion in this case is used to determine a priority rule
between nodes in the undercut and overlapping nodes.
3. All SURF_xxx link commands have a parameter called: SURF_PARAM =
<master_areas>, <net_points> which are used to create a spline that
User Manual 2 - 355
SIMULIA
Tosca Structure
Design Area
it may help setting SURF_PARAM. Important is that <master_areas> must

be larger than 4 and at least double the size of <net_points>. Good values
are e.g. SURF_PARAM = 12, 4.
4. Another reason for the above error message is that there is not enough
nodes in the design area to create the "surface" for the SURF_xxx condition.
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defines the "surface" in the SURF_xxx LINK_SHAPE commands. The

values <master_areas>, <net_points> are integer values and automatically
determined by Tosca Structure. In the event of an error like:
SIMULIA
Tosca Structure
Shape Optimization
5. Default tolerances for all SURF_xxx LINK_SHAPE commands are TOL =

0.01, 0.01, 0.01. If you have a mesh where these values are either very
large or very small consider setting them to about 0.25 * element edge
length in design area.
6.3.4.17 Command examples

This section contains examples of link conditions.
Link condition with fixed master node
All nodes of the previously defined node group node_rigid should have the
same displacement with respect to the global Cartesian coordinate system as
the design node with the number 46. Node 46 need not be a part of the node
group node_rigid. The link condition should have the name link_rigid. The
link condition is then used in the restriction with the name dvcon_rigid.
LINK_SHAPE
ID_NAME
MASTER
CLIENT
CS
=
=
=
=
link_rigid
NODE, 46
VECTOR
CS_0
END_
DVCON_SHAPE
ID_NAME
ND_GROUP
CHECK_LINK
= dvcon_rigid
= node_rigid
= link_rigid
END_
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Coupling condition with automatic determination of the master node

All nodes of the node group ndgr_left should have the same displacement
as the node from ndgr_left that has the greatest outward displacement. In
the same way, all nodes of the node group ndgr_right should have the same
displacement as the node from ndgr_right that has the greatest outward displacement. This requires a link condition and two restrictions.
LINK_SHAPE
ID_NAME
MASTER
CLIENT
CS
=
=
=
=
link_left_or_right
MAX
VECTOR
CS_0
END_
User Manual 2 - 357
SIMULIA
Tosca Structure
Objective Function
DVCON_SHAPE
ID_NAME
ND_GROUP
CHECK_LINK
= dvcon_left
= ndgr_left
= link_left_or_right
END
DVCON_SHAPE
ID_NAME
ND_GROUP
CHECK_LINK
= dvcon_right
= ndgr_right
END_
In each design cycle the system identifies which nodes in each of the node
groups, ndgr_left and ndgr_right, has the greatest positive displacement (in
the growth direction). Usually, these are the nodes with the largest stress difference between the effective value and the targeted value. These displacements are then applied to all nodes of the node groups ndgr_left and
ndgr_right, respectively. The following command can be used instead of the
two individual DVCON_SHAPE commands:
DVCON_AUTO_SHAPE
ID_NAME
= dvcon_*
ND_GROUP_FAMILY = ndgr_*
CHECK_LINK
END_
6.4
Objective Function
minimized.
6.4.1
Overview
the FE analysis combined into design responses (DRESP).
Tosca Structure.shape works with a CONTROLLER-based algorithm which
homogenizes the stresses with respect to a reference value (see also chapter
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The naming left and right is determined automatically from the complete
name of the node groups and added to the root name of the automatically
generated DVCON_SHAPE entries. However, this requires that only these
two node groups begin with the name ndgr_ otherwise other node groups
will be taken into consideration.
SIMULIA
Tosca Structure
Shape Optimization
6.1.1 Theoretical background). For simple optimizations this reference value

can be ignored - Tosca Structure.shape will automatically generate a reference value which will be adequate for most cases.
6.4.2
Reference stress
You may want to define a reference value yourself. In this case you need to
understand how Tosca Structure.shape works. The CONTROLLER-based
algorithm is driven by following redesign rule:
Design nodes with stress above the reference value are moved outwards
(growth).
Design nodes with stress below the reference value are moved inwards
(shrinkage).
This produces components with homogenized stress in the design area.
So, if you choose a high reference value most design nodes will shrink in
order to achieve this value. A low reference value will have the opposite
effect. With some practice, a good choice of reference value can be estimated giving the designer an optimal control over the shape optimization.
You may also choose the reference value to variable e.g. dependent on a
design response. This has a special use by design of relief notches where the
reference value is chosen outside the design nodes area. This causes the
design nodes to shrink until they have the same stress value as the reference
value. This trick can only be done if the design area is relatively close to the
area where the reference value is. Otherwise, you will not get the stress
dampening effect of a relief notch.
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Remarks:
1. A reference value is NOT the same as a CONSTRAINT! For most real
structures, the maximum stress of a converged shape optimization will be
some percent larger than the given or the automatically calculated reference stress.
2. Some structures and/or loading situations are not well suited for the
CONTROLLER-based algorithm. You must have the correlation between
growth in design nodes also minimizes the stresses.
- One example is a cantilever beam with a prescribed displacement at its
free end. Due to the high stresses at the supports, the beam will become
thicker. Because of the prescribed displacement the stresses will be
higher in the next iteration. The homogenization works but the stresses
will increase because the beam stiffness increases as well.
User Manual 2 - 359
SIMULIA
Tosca Structure
Objective Function
- Another example is shape design in contact area: In this case we know

that the design rule must be the opposite the normal design rule because
growth will cause even greater contact stresses. This can be turned
around by using the optimization setting SCALE and set it to a negative
value. Now, the shape optimization will shrink by high contact stresses
and thus homogenize these to achieve an homogeneous contact.
6.4.3
Objective function terms

Tosca Structure.shape allows optimization on different stress hypotheses,
strain formulations and damage results (see also chapter 4.4 Design
Responses). The most used equivalent stress is von Mises (SIG_MISES).
Description
SIG_1
SIG_2
SIG_3
Maximum principal stress

2nd. principal stress
Minimum principal stress
SIG_11
SIG_22
SIG_33
SIG_12
SIG_23
SIG_13
Components of stress tensor
SIG_ABS_123
Maximum of the absolute value of the

principal stresses
SIG_ABS_3
Absolute value of the minimum principal stress
* The marked design responses are only supported by the Abaqus and
ANSYS interface, see vol.2 chapter 11.1, Abaqus and vol.2 chapter 11.2,
ANSYS.
** Note that ABQ_ND_PEEQ is the scalar value that Abaqus calculates as
PEEQ, which is NOT the same as STRAIN_PLASTIC. ABQ_ND_PEEQ is
only available in Abaqus.
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Stress hypotheses
SIMULIA
Tosca Structure
Shape Optimization
SIG_MISES
SIG_TRESCA
SIG_BELTRAMI
SIG_GALILEI
SIG_KUHN
SIG_MARIOTTE
SIG_SANDEL
SIG_SAUTER
SIG_DRUCKER_PRAGER
SIG_CONTACT_PRESSURE *
von Mises stress hypothesis

Tresca stress hypothesis
Beltrami stress hypothesis
Galilei stress hypothesis
Kuhn stress hypothesis
Mariotte stress hypothesis
Sandel stress hypothesis
Sauter stress hypothesis
Drucker-Prager stress hypothesis
Contact stress pressure
SIG_CONTACT_SHEAR *
SIG_CONTACT_SHEAR_X *
SIG_CONTACT_SHEAR_Y *
SIG_CONTACT_TOTAL *
Total shear contact stress

Shear X Contact stress
Shear Y Contact stress
Total Contact stress
Strain formulations
STRAIN_ELASTIC*
STRAIN_PLASTIC*
STRAIN_TOTAL *
STRAIN_ENERGY
STRAIN_ENERGY_DENS
Solver specific results
ABQ_ND_PEEQ **
Damage results
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DAMAGE
DAMAGE_LC
Description
Elastic Strain
Plastic Strain
Total Strain (elastic + plastic)
Strain energy
Strain energy density
Description
Abaqus PEEQ nodal value
Description
Damage value from durability analysis
Damage value from durability analysis
with loadcase information (mustuse
ONF 601)
* The marked design responses are only supported by the Abaqus and
ANSYS interface, see vol.2 chapter 11.1, Abaqus and vol.2 chapter 11.2,
ANSYS.
** Note that ABQ_ND_PEEQ is the scalar value that Abaqus calculates as
PEEQ, which is NOT the same as STRAIN_PLASTIC. ABQ_ND_PEEQ is
only available in Abaqus.
Remark:
ref
1. For controller based shape optimization the reference value ( i , see

chapter 4.1.1 Mathematical formulation) has a special meaning. The reference value is the value around which Tosca Structure homogenizes the
ref
stress around. Thus, a value i
= 0 usually does not make sense and
User Manual 2 - 361
SIMULIA
Tosca Structure
Constraints
ref
Tosca Structure calculates a default reference value if REFERENCE ( i )

is unset. The reference calculated can be seen in TOSCA.OUT
----------------------------------------------------------------f OBJ_FUNC_TERM
Value
Weight
Reference
|
----------------------------------------------------------------DRESP_MAX_MISES
92.5353
1.00000
87.4261
-----------------------------------------------------------------
2. Also, for controller based shape optimization the user must either set all
REFERENCE-values or none at all (automatic reference value calculation).
6.5
Constraints
The only allowed constraints for controller based shape optimization are volume and weight constraints.
6.5.1
Volume constraint
In order to select volume as the design response, the volume must be
requested with TYPE=VOLUME. The individual element volumes of the element group (EL_GROUP parameter) are then added together by the summation parameter (GROUP_OPER=SUM parameter) to achieve the total
volume. The volume is a variable independent of the load cases. The design
response is labeled with a unique name (ID_NAME parameter) so it can be
referenced as a constraint. A typical definition of a design response appears
as follows:
DRESP
=
=
=
=
=
=
dresp_volume
SYSTEM
all_elements
VOLUME
SUM
EVER
END_
Once the volume of an element area has been defined as the design
response, the design response must be defined as a constraint using the
CONSTRAINT parameter. The value of the equality constraint (EQ_VALUE
parameter) is also declared. In addition, the parameter EQ_VALUE is declared
as absolute value (MAGNITUDE=ABS) or relative value (MAGNITUDE=REL)
in relation to the initial volume. The constraint is labeled with a unique name
(ID_NAME parameter) so it can be referenced in an optimization job (see
OPTIMIZE command). A typical definition of a constraint appears as follows:
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ID_NAME
DEF_TYPE
EL_GROUP
TYPE
GROUP_OPER
UPDATE
SIMULIA
Tosca Structure
Shape Optimization
CONSTRAINT
ID_NAME
DRESP
MAGNITUDE
EQ_VALUE
=
=
=
=
volume_constraint
dresp_volume
REL
1
END_
Example:
The total volume of a element group in the start model is 2000. For the optimized model a total volume of 1800 is requested for the element group. Using
absolute values, MAGNITUDE=ABS, EQ_VALUE=1800 must be declared.
Using relative values, MAGNITUDE=REL, EQ_VALUE=0.9 must be
declared.
Remarks
1. The CONSTRAINT definition must be activated by a reference in the OPTIMIZE command.
2. It is highly recommended to choose a volume constraint near the orignal
volume, say +/- 5% depending on the mesh quality and size of design area.
3. Tosca Structure.shape will enforce the volume constraint in first design
cycle. This may destroy the mesh, esspecially if the volume constraint is far
away from the initial volume. If you want to turn off this mechanism and let
Tosca Structure.shape iterate for more iteration to achieve volume
constraint use OPTIONS. This setting is not recommended as it will
simply cause more design cycles before the mesh is corrupted.
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OPTIONS
SHAPE_FORCE_VOLUME = OFF
END_
4. Maintaining the volume constraint involves an iterative process, i.e. several

steps are performed within each design cycle to approximate the volume
constraint. Each step in the volume iteration involves executing a complete
MESH_SMOOTH algorithm. In order to keep the computing time within
limits, it is strongly recommended to select the MESH_SMOOTH area as
small as possible and to keep the various levels of the MESH_SMOOTH
definition (particularly LEVEL_CONV, LEVEL_DVCON and LEVEL_QUAL)
as low as possible! A complex mesh smoothing can result in a significant
increase in computing time!
5. It is also recommended to define a volume constraint when using the
objective function maximization of the lowest natural frequency. The user
can control the volume increase or decrease by activating this constraint.
User Manual 2 - 363
SIMULIA
Tosca Structure
Typical Optimization Tasks for Static Analysis
Consequently, it may be possible to achieve a further increase in the

frequency.
6.5.2
Weight constraint
Weight constraints are defined in exactly the same way as volume constraints
(see chapter 6.5.1 Volume constraint). Using this design response a physical
target weight can be set explicitly. This is in particular useful when different
materials are present in the model. The corresponding design response is
defined as follows:
DRESP
ID_NAME
DEF_TYPE
EL_GROUP
TYPE
GROUP_OPER
UPDATE
=
=
=
=
=
=
dresp_volume
SYSTEM
all_elements
WEIGHT
SUM
EVER
END_
Once the volume of an element area has been defined, the design response
must be referenced in the CONSTRAINT definition.
6.6

The section describes the typical optimization tasks for linear or non-linear
static analysis.
Minimization of maximum equivalent stress

Probably the most used shape optimization type is a minimization of the maximal von Mises stresses. This task is automated in Tosca Structure so that the
user must not care about any reference values.
If the default settings cause the geometry to change unwanted in size a volume constraint can be utilized. See also chapter 6.6.2 Notch optimization with
fixed reference value.
Example: Define a minimum of maximum von Mises stress with a volume
constraint.
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6.6.1
SIMULIA
Tosca Structure
Shape Optimization

1. Apply New | EQUIVALENT_STRESS command on OBJ_FUNC item
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2. Apply Edit on OBJ_FUNC item. Set TARGET = MINMAX.
User Manual 2 - 365
SIMULIA
Tosca Structure
Commands
DRESP
ID_NAME
DEF_TYPE
TYPE
ND_GROUP
LC_SET
LC_SET
GROUP_OPER
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=
=
=
=
=
=
=
DRESP_VON_MISES
SYSTEM
SIG_MISES
design_nodes
ALL,1,All
ALL,2,All
Max
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Tosca Structure
Shape Optimization
END_
OBJ_FUNC
ID_NAME
TARGET
DRESP
= MY_OBJ_FUNC
= MINMAX
= DRESP_VON_MISES, ,
END_
6.6.2
Notch optimization with fixed reference value

For full control over the Tosca Structure.shape controller the user may prescribe a fixed reference value. This can be used to force the homogenization
to around a certain value. Again, it must be stressed that this is not a stress
constraint! It is simply a way to gain more influence over the shape controller.
In the shown example Fig. 210 the effect is clearly seen:

A low reference value enforces more growth
A high reference value enforces more shrinkage
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Fig. 210 The hole plate example with a reference value of 70 N/mm and
120 N/mm
User Manual 2 - 367
SIMULIA
Tosca Structure

Apply New | EQUIVALENT_STRESS command on OBJ_FUNC item.
Command
OBJ_FUNC
ID_NAME
TARGET
DRESP
END_
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= MY_OBJ_FUNC
= MINMAX
= DRESP_VON_MISES, , 120.
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Tosca Structure
Shape Optimization
6.6.3
Notch relief with variable reference value

Increasing the stress in one notch can decrease the stress in another near by
notch (Neubers law of load stress decay). This is typically called a relief
notch. This is a very useful tool if you experience too large stresses in an area
that you are not allowed to change, but you are allowed to change nearby
geometry (the "nearby" is important - the stress decay does not work over
great distances but only locally).
To understand this type of optimization a simple example is the best explanation:
Fig. 211 Design area and reference nodes for determining the reference
stress
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In Fig. 211 is a simple notch shown with a relief notch. The primary notch is
not allowed to be changed only the relief notch. The result is shown in Fig.
212 where the stresses at the reference nodes are drastically minimized
through the optimized relief notch.
Fig. 212 Optimization result using variable reference value
User Manual 2 - 369
SIMULIA
Tosca Structure
Tosca Structure.gui
1. Define a VARIABLE for the reference stress of the reference nodes.
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2. Use this VARIABLE in as reference value in the objective function,

OBJ_FUNC.
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Tosca Structure
Shape Optimization
Commands
VARIABLE
ID_NAME
DEF_TYPE
TYPE
ND_GROUP
LC_SET
LC_SET
GROUP_OPER
=
=
=
=
=
=
=
REF_NODE_STRESS
SYSTEM
SIG_MISES
refence_nodes
ALL,1,All
ALL,2,All
Max
=
=
=
=
=
=
=
DRESP_VON_MISES
SYSTEM
SIG_MISES
design_nodes
ALL,1,All
ALL,2,All
Max
END_
DRESP
ID_NAME
DEF_TYPE
TYPE
ND_GROUP
LC_SET
LC_SET
GROUP_OPER
END_
OBJ_FUNC
ID_NAME
TARGET
DRESP
= MY_OBJ_FUNC
= MINMAX
= DRESP_VON_MISES, , REF_NODE_STRESS
END_
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6.7
Advanced Tosca Structure.shape

Optimizations
Tosca Structure.shape is used for the optimization of already detailed
designs. Thus, a detailed and realistic analysis model is required for reliable
optimization results. Tosca Structure allows optimization in combination of
non-linear or contact analysis to avoid error prone model simplifications. This
chapter describes these advanced features used for shape optimization.
6.7.1
Highly nonlinear shape optimization

For highly non-linear calculations is the stress measure not always a good
indicator e.g. a structure under plastic deformations will (for ideal plastic)
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Advanced Tosca Structure.shape Optimizations
have a large constant stress over the plastic area. For this reason most analysts use a strain measure to inspect these areas.
Tosca Structure.shape optimization supports different strain measures for this
purpose, currently only supported by Abaqus, see vol.2 chapter 11.1,
Abaqus, and ANSYS, see chapter 11.2 ANSYS.
Example:
Choose TOTAL_STRAIN_ENERGY as design response measure:
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Shape Optimization
Tosca Structure.gui
Command
DRESP
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ID_NAME
DEF_TYPE
TYPE
ND_GROUP
LC_SET
GROUP_OPER
=
=
=
=
=
=
MY_DRESP
SYSTEM
STRAIN_TOTAL
design_nodes
ALL,1,All
Max
END_
6.7.2
Minimization of contact pressure

Another special usage of Tosca Structure.shape controller algorithm is the
optimization of contact zones. Here it is important to understand that the normal shape optimization must be reversed because growth in a contact zones
will result in a higher contact pressure and shrinkage in a lower. This is done
by changing the setting SCALE in OPT_PARAM to a negative value, usually a
small negative value e.g. -0.001.
The Tosca Structure.shape optimization of contact zones only works within
the contact zone where small changes in the contact surface usually has a
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Advanced Tosca Structure.shape Optimizations
big influence on the contact pressure. This is the reason for a small SCALE
value.
The CONTACT_PRESSURE design responses are currently only supported by
Abaqus, see vol.2 chapter 11.1, Abaqus.
1. Choose TYPE = SIG_CONTACT_PRESSURE
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2. Change the SCALE parameter in the dialog opened by New | SETTINGS

command applied on SHAPE_OPTIMIZATION_CONTROLLER item.
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Shape Optimization
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Tosca Structure.gui
Commands
DRESP
ID_NAME
DEF_TYPE
TYPE
ND_GROUP
LC_SET
GROUP_OPER
=
=
=
=
=
=
MY_DRESP
SYSTEM
SIG_CONTACT_PRESSURE
DESIGN_NODES
ALL,1,All
Max
END_
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Settings
OPT_PARAM
ID_NAME
OPTIMIZE
SCALE
= MY_PARAMETERS
= MY_OPTIMIZATION_TASK
= -0.001
END_
6.8
Settings
Fig. 213 Optimization settings (OPT_PARAM) in Tosca ANSA environment

Each OPT_PARAM command has a unique name (ID_NAME parameter) and
references a previously defined optimization job (OPTIMIZE command). The
specified parameters only relate to the given optimization task. A typical
OPT_PARAM command appears as follows:
OPT_PARAM
ID_NAME
OPTIMIZE
...
END_
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= param_for_shape_optimization
= shape_optimization
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Shape optimization in Tosca Structure operates with a controller-based

method. The controller has been given numerous default settings that deliver
satisfying results for a variety of optimization models. Usually, these default
settings do not need to be changed by the user. However, using a specific
configuration of the controller for a given optimization task can lead to a modified controller response and consequently the optimization procedure can be
improved. The user can set several optimization parameters using the
OPT_PARAM command and thereby influence the controller response. In
Tosca ANSA environment, the settings are available in the task manager
(New | SETTINGS command on SHAPE_OPTIMIZATION_CONTROLLER
item) or using the OPT_PARAM button in the modules buttons. In Tosca
Structure.gui, the settings are defined in OPT_PARAM command.
SIMULIA
Tosca Structure
Shape Optimization
Six parameters can be set by the user for shape optimization:

Scaling of the allowed amount of displacement
Treatment of the midside nodes during the optimization
Curvature based modification of the optimization movement vector
Filtering of the optimization displacements
Updating of the normal vectors (optimization displacement vector)
Control of the increments according to the allowed displacements
Remark
1. The OPT_PARAM command is also used in topology optimization (volume
3: OPT_PARAM). However, the optimization parameters that can be set
depend on the type of optimization. The only parameters that can be set
here are those allowed for shape optimization.
6.8.1
Scale of displacement (SCALE)

The controller provides an automatic increment control of the optimization
displacements. An initial increment is first determined based on the mesh of
the FE start model. The size of the increment is then automatically adjusted in
every design cycle. Usually, the user does not need to modify the increment
control manually. The user can increase or decrease the increment using a
scaling factor (SCALE parameter):
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...
SCALE
...
= <REAL_VALUE>
The default setting is SCALE=1.0, i.e. the optimization displacements are

applied in increments determined by the controller. If the selected scaling factor has a value greater than one, the increment size determined by the controller will increase correspondingly, i.e. the optimization is accelerated. On
the other hand, if the selected scaling factor has a value less than one, the
increment size determined by the controller will decrease accordingly, i.e. the
optimization is slowed down.
Example: With SCALE=2.0 the increment size as determined by the controller is doubled. With SCALE=0.8 the increment size of the controller is
reduced to 80% of the initial increment size.
The scaling factor can be split in a factor for growth and a factor for shrinkage:
...
SCALE
...
= <GROW_VALUE>, <SHRINK_VALUE>
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Settings
Remarks
1. It is highly recommended to perform the first optimization run with the
default increment size (SCALE=1.0). From evaluating the obtained results,
it can be decided if the optimization should be accelerated or slowed down.
2. Increasing the increment size can be useful when several optimization
steps in the same direction are performed in the beginning of the optimization and hardly any change in the increment size is observed. Especially,
for tight FE meshes with small element edge lengths, the increment size is
relatively small which leads to numerous design cycles with relatively small
changes in the model in each design cycle. If the selected increment size is
too large, the possibility that the optimum will be bypassed exists and the
optimization will not converge. In addition, the mesh quality decreases with
increasing increment size. In extreme cases individual elements may
collapse.
3. Decreasing the increment size is recommended when the start model is
close to optimum at the start. A decrease of the increment size can also be
helpful when numerous restrictions with link conditions (DVCON_SHAPE
with CHECK_ LINK) are contained in the optimization task. A decrease of
the increment size can also be of advantage when the mesh quality is poor.
6.8.2
Treatment of the midside nodes (MID_NODES)

Only corner nodes (from finite elements) are supported as design nodes. Midside nodes may be included in the design node group but the optimization
displacements of the midside nodes of second order elements is interpolated
from the optimization displacement of the adjacent corner nodes. The interpolation method can be chosen with the MID_NODES parameter:
...
MID_NODES
...
= [ LINEAR | INTERPOLATE ]
With the default option LINEAR the midside node positions are linearly interpolated from the optimized position of the connected corner nodes. With the
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4. With a license for the module Tosca Structure.nonlinear a negative scale

factor can be executed. In this case, the calculated nodal displacements
are multiplied with the scale factor and the direction of the displacement
changed. The controller strategy can be inverted (i.e. high stress =
shrinkage, low stress = growth). This functionality allows the optimization of
contact surfaces as an example (see chapter 6.7.2 Minimization of contact
pressure).
SIMULIA
Tosca Structure
Shape Optimization
polated from the optimization displacement of the connected corner nodes. If

in the initial position the midside node is on the line between the corner nodes
there will be no difference between the two methods. But if the edge of the
element is bent only with INTERPOLATE the bending can be prevented.
6.8.3
Curvature based modification of optimization

displacements
The nodal optimization movement vector is modified in areas of high curvature to prevent a collapse of the mesh for large volume changes
(CURV_SMOOTH). A bigger radius causes a bigger curvature based modification of the optimization movement vector. (Default=5.0 * element edge
lengths; OFF=0.0)
= 5.0
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...
CURV_SMOOTH
...
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Settings
6.8.4
Filter function for the optimization displacements (FILTER)

To smooth local peaks of the nodal reference stresses, the item FILTER can
be specified to activate a filter function:
...
FILTER
...
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= <RADIUS>, <SIGMA>, <EXPONENT>
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Fig. 214 Curvature based modification of the optimization movement vector
SIMULIA
Tosca Structure
Shape Optimization
The filter is given by:

N
i = 1 i Bij
j = ---------------------------N
i = 1 Bij
B ij = ( r j d ji )
r j = r max e
0 ,5 ( max )
max = max ( n j n R )
is the filter value for node j. The main filter function (B) decreases with the
distance (d) between node i and j. The maximal radius ( rmax ) defines the maximum distance for the nodes i to influence the filter value. The curvature
dependency ( r j ) defines a weight function to reduce the radius at higher local
surface curvature ( max ) approximated by the vector product of the node normal ( n j ) to the neighboring nodes ( n k ).
SIGMA ( ) and EXPONENT (p) are optional with the default values (0.2 and
1., respectively). The smaller the SIGMA, the larger is the influence of the
surface curvature. To avoid this effect, use a large SIGMA value (e.g.,
10000).
The exponent value defines the weight function which controls the influence
depending on the distance from the node.
To smooth local peaks of the nodal reference stresses, use the DRESP
OPER=FILTER which gives the user the possibility to define filters that correspond to single design responses. Example:
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DRESP
ID_NAME
DEF_TYPE
VAR_OPER
VAR_A
RADIUS
EXPONENT
SIGMA
=
=
=
=
=
=
=
DRESP_MISES_FILTERED
OPER
FILTER
DRESP_MAX_MISES
30.0
1.0
1.0
END_
The parameters RADIUS, EXPONENT and SIGMA have the same meaning
as in the filtering of nodal displacements.
Remark
Large values of RADIUS may increase CPU-time.
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Settings
6.8.5
Updating the optimization displacement vectors (VECTOR)

As explained in section vol.2 chapter 6.3.1 an optimization displacement vector is determined by the optimization algorithm for every design node. This
vector graphically corresponds to the outer surface unit normal at the node
and indicates the optimization displacement direction. Restrictions influencing
the direction (DVCON_SHAPE with CHECK_DOF and CHECK_BC) are included
in the calculation of the optimization displacement vectors. The VECTOR
parameter enables the user to specify the design cycle in which to determine
the optimization displacement vectors:
...
VECTOR
...
= [ EVER | FIRST ]
Fig. 215 Fixed and updated optimization displacement vectors
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The default setting is VECTOR=EVER. The optimization displacement vectors are re-determined in every design cycle by the optimization algorithm
and consequently adjusted to changed conditions (for example shape of the
structure, effective restrictions, mesh quality, etc.). With the setting VECTOR=FIRST, the optimization displacement vectors are calculated only once
in the first design cycle and then kept constant in all other cycles. The optimization displacement vectors are not adjusted to changes in conditions during
the remaining part of the optimization. Fig. 215 provides an illustration of the
two settings. Generally, VECTOR=EVER provides better results since the
mesh smoothing algorithm is less restricted and a better mesh can be
achieved. However, in certain cases the setting VECTOR=FIRST can be of
advantage.
SIMULIA
Tosca Structure
Shape Optimization
6.8.6
Control of the amount of optimization displacement (DISP)

Based on the current FE mesh, an allowed amount of displacement is determined for every design node. This displacement variable limits the amount of
the optimization displacement, i.e. optimization displacements that are
greater than the allowed displacements are scaled back automatically to the
allowed value node by node. This is intended for avoiding the collapse of a
neighboring element when having a large optimization displacement of one
node.
The controller provides automatic increment control of the optimization displacements. The increment size is dependent on the allowed displacements
of the design nodes. A decrease of the allowed displacements (a decrease in
the quality of the FE mesh) automatically leads to a decrease in the increment size of the controller. The increment size of the controller is automatically adjusted in every design cycle.
The DISP parameter enables the user to specify which allowed displacement
is to be used in the increment control:
...
DISP
...
= [ MINIMUM | AVERAGE ]
DISP=AVERAGE is the mean value of the allowed amount of displacement

for the design nodes used in the increment control; DISP=MINIMUM (default)
is the smallest value used. The setting DISP=AVERAGE delivers a larger
increment size and consequently a faster approximation to the optimum.
However, this opens for the possibility that nodes for which only small displacements are allowed move too little causing undesirable corners in the
design area.
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6.9
Check run (TEST_SHAPE)

After the definition of the optimization task, all definitions should be checkedfor completeness and correctness. This can be done using a TEST_SHAPE
run which performs a "virtual optimization" with fictitious displacements.
6.9.1
General
Before beginning an optimization, it is advisable to check the output file
(TOSCA.OUT) of the optimization preprocessors for any possible warnings or
errors. If the optimization preprocessing (for more detailed information see
vol.2 chapter 12) has been performed without error, the user has the option of
carrying out a test run for the shape optimization without a prior FE analysis.
This is done by applying pseudo optimization displacements. This option
enables the user to quickly and easily check if the mesh smoothing (see vol.2
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chapter 6.3.2) and the restrictions (see vol.2 chapter 6.3.3) are fully defined
and will deliver the desired results. The above procedure is especially recommended for link conditions (see vol.2 chapter 6.3.4). The following are typical
questions that such a test run can answer:
Is the design area, i.e., the design nodes, selected correctly?
Is the MESH_SMOOTH area too small or too large?
Is the selected transition area between the design area and the border of
the MESH_SMOOTH area in order?
Will all of the restrictions be fulfilled (displacement directions, amount of
displacement, contact against solids or elements, link conditions)?
Will any nodes be moved by MESH_SMOOTH although they should not be
modified, so that additional restriction of these nodes is needed?
The results of the test run are sent to user-defined files that can be subsequently loaded into a suitable postprocessor for evaluation. This allows the
test results to be easily displayed and checked. If the results of the test run
are not satisfying, the optimization model may need to be modified. The effort
required to perform a test run in the optimization preprocessor is much less
than the effort required for a complete optimization. Unwanted side effects
can make a costly and time-consuming optimization useless although the
side effects might have been recognized without much effort in a test run.
Test run (CHECK_INPUTS) in Tosca ANSA environment

In Tosca ANSA environment the test run is available in the CHECK_INPUTS
item of Task Manager. First apply New | TEST_SHAPE_CHECK command
on CHECK_INPUTS item, then apply New | TEST_SHAPE command on
TEST_SHAPE_CHECK item. The test is performed when Update command is
applied on the created TEST_SHAPE item. The results are opened in Tosca
Structure.view using the item VTF_VISUALIZATION that is also created
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6.9.2
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Tosca Structure
Shape Optimization
below TEST_SHAPE_CHECK. For a detailed description please refer to vol.1

chapter , Start Manual.
Fig. 216 CHECK_INPUTS: Definition of a test run for shape optimization
6.9.3
Test run in Tosca Structure.gui

In Tosca Structure.gui your test displacements will be defined using the
TEST_SHAPE command mask. To start the test run, start Tosca Structure with
Type test1. Create your visualization sequence using Tosca Structure.report. For a detailed description please refer to vol.1 chapter 2.3.6.1.
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Fig. 217 Start of a test run for shape optimization in Tosca Structure.gui
6.9.4
Command syntax
The test run in the shape optimization is controlled by the TEST_SHAPE
command. A test run is always based on a previously defined optimization job
that is referenced in the OPTIMIZE command. The format information for the
postprocessing is specified with the FORMAT parameter. The name of the file
into which the postprocessing data is written is specified with the FILE_NAME
parameter. The test displacement in a specified direction (DIRECTION) is
applied in a specified number of increments (INCREMENT parameter) until
reaching a maximum displacement (DISPLACEMENT parameter). A typical
TEST_SHAPE command appears as follows:
TEST_SHAPE
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OPTIMIZE
FORMAT
DIRECTION
DISPLACEMENT
INCREMENT
= <name_of_optimize>
= ONF FILE_NAME=<name_of_output_file>
= [ GROW | SHRINK | RANDOM ]
= <value_of_max_displacement>
= <number_of_increments>
END_
Remarks
1. If all the information entered by the user is correct, the TEST_SHAPE
command is executed immediately after it is entered. The command does
not have its own name with which it can be referenced and all command
data are only temporarily active during the execution of the command.
2. The referencing of a previously defined optimization task (OPTIMIZE
command) is mandatory. The test displacements are applied to the design
nodes of the optimization job.
3. Specification of a file name (FILE_NAME parameter) is optional. By default
the file name TEST_SHAPE is used. An increment number is always
attached to the file names (for example, 000, 001, 002 etc.) to enable identification of the results from the various increments. Caution: The automatic
creation of the vtfx report requires the use of the default file name
"TEST_SHAPE".
5. Because uniform displacements are applied with DIRECTION=GROW or

SHRINK, it may occur that LINK_SHAPE conditions will be insufficiently
tested due to the fact that LINK_SHAPE conditions (conditional on the
uniform displacements) may be fulfilled a priori. If the optimization job
contains LINK_SHAPE conditions, it is recommended to apply non-uniform
displacements using DIRECTION=RANDOM. This will allow the correct
operation of the LINK_SHAPE conditions to be tested.
6. Specification of the maximum amount of displacement (DISPLACEMENT
parameter) is optional. If no maximum amount of displacement is specified
by the user, then a maximum amount of displacement dependent upon the
measurements of the FE mesh will be automatically determined.
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4. Specification of a displacement direction (DIRECTION parameter) is

optional. The default setting is GROW. Three possibilities can be selected
in specifying the displacement direction: uniform growth of all design nodes
in the optimization group outwards (DIRECTION=GROW), uniform
shrinkage of all design nodes in the optimization group inwards (DIRECTION=SHRINK) or non-uniform randomly controlled displacement of the
design nodes in the optimization group (DIRECTION=RANDOM).
SIMULIA
Tosca Structure
Shape Optimization
7. Specification of a number of increments (INCREMENT parameter) is

optional. The default value is INCREMENT=1. If the user specifies 5 increments, for example, 6 results files are generated, whereby the first result
file with the file extension 000 represents the initial state.
8. If DIRECTION=RANDOM is selected, it is possible that the design node
with the maximum displacement will have a smaller amount of displacement than is specified in the DISPLACEMENT parameter. Here, the
maximum specified displacement only represents an upper limit that does
not need to be achieved due to the randomly controlled distribution of the
displacements.
Example:
The optimization task named shape_optimization should be subjected to a
test run. The file names are to have the name test_grow. In the growth direction five displacement increments should be applied with a maximum displacement of 1.5 length units, i.e. the displacements are applied in
increments of 0.0, 0.3, 0.6, 0.9, 1.2 and 1.5.
TEST_SHAPE
OPTIMIZE
FILE_NAME
DIRECTION
DISPLACEMENT
INCREMENT
=
=
=
=
=
shape_optimization
test_grow
GROW
1.5
5
END_
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6.10 Morphing
With TOSCA Structure.morph it is possible to apply changes to certain areas,
so called morph areas, by moving the nodes of these morph areas. This can
be used, e.g., to automatically generate several model variants and submit
analysis runs for these models. Further it allows to study the simultaneous
influence of changes in the morph areas on certain design responses defining
the quality of the design. These design responses are normally used to formulate optimization targets and constraints. Based on these quality criteria an
optimum start design for a subsequent local shape optimization can be
derived.
Please note: morphing is a new feature within Tosca Structure implemented
to access more optimization potential. At this point not all practical requirements may be considered yet. We appreciate your feedback to continuously
improve our user interfaces and workflow.
User Manual 2 - 387
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Morphing
6.10.1 General
Performing a local shape optimization sometimes does not exploit the complete potential for design improvement. In particular for complex models,
when e.g. thermomechanical fatigue is involved, global interactions can be
observed. A change in the model geometry, in particular a large wall thickness modification in "less critical" areas, will influence the stiffness and transient temperature distribution in critical areas, but will have no significant
influence on the less critical areas.
Shape optimization results can thus be improved through start with a design
where these global effects are already considered..
Using TOSCA Structure.morph several design variants can be created automatically. With these variants global interactions and influences can be
assessed and evaluated prior to a local shape optimization. Thereby a specific design of experiments is performed which modifies the predefined morph
areas according to an user defined experiment plan.
Morphing is offered as add-on to shape optimization, where "morphed models" are created based on the experiment plan. In each step of the morphing
process (each experiment) a constant displacement is applied independently
to the nodes of each morph area. The modified (morphed) model is analysed
and the requested design responses (i.e. all values required for the optimization task) are evaluated.
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Fig. 218 Interaction between morphing areas and critical areas
SIMULIA
Tosca Structure
Shape Optimization
The base of the parameter file is a shape optimization task where all nodes in
any MORPH_AREA must be part of the design area. MESH_SMOOTH and
DVCON_SHAPE commands defined in OPTIMIZE are referenced by
MORPH-command and thus used. Objective function and eventually constraint define relevant values for postprocessing and evaluation of the quality
of the design. These values will be available e.g. as fringe plots on the several morphing variants.
6.10.1.1 Morphing areas
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A morphing area (MORPH_AREA) is a node group which will be modified

independently of other morphing areas during the morphing process. All
nodes in one morphing area obtain the same morphing displacement in one
morphing step.
This may lead to unwanted sharp edges in your structure. Thus, transition
zones can be introduced for each morphing area. The transition zone is
formed by the nodes of the morphing area which are connected to the border
of the morph area by no more edges than specified with the
TRANSITION_ZONE command. These nodes will not be displaced by the
same constant morphing displacement applied to the rest of the morphing
area but will be moved back to an intermediate position to assure a smooth
transition between, e.g., two adjacent morphing areas or a morphing area
and its surrounding area. .
Fig. 219 Morphing area, morphing displacement and transition zone
Remarks
1. For one optimization several independent (non-intersecting) morphing
areas can be defined.
2. All nodes in any MORPH_AREA must be part of the design area.
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Morphing
3. Each area will be assigned a morphing type. Currently, only NORMAL is

supported, where all nodes in the morphing area are moved ("morphed") in
node-normal direction.
4. All definitions made for the design variables (design variable constraints
and mesh smooth definitions) also apply to morphing areas. Consequently,
these definitions are also considered during morphing. Thus, e.g.,
symmetry definitions may enforce symmetry for symmetric morphing areas
even if unsymmetric morphing displacements are applied. Also, mesh
smoothing ensures high mesh quality for the morphed models and thus
reliable analysis results for evaluation of the model quality.
5. Mesh smoothing in general may not allow for smooth transitions between
single morphing areas as all morphing areas are part of one big design
area. This can only be ensured if each morphing area is surrounded by
some (at least 3-5) layers of nodes which do not belong to morphing areas.
If the model contains adjacent morphing areas, use the parameter
TRANSITION_ZONE of the MORPH_AREA command instead for smooth
results.
The size of the transition zone should be in reasonable relation to the size
of the morphing area and the morphing displacement (e.g. 10% of the
morphing area diameter or twice as large as the morphing displacement).
Fig. 220 Transition zone with 0, 2 and 4 layers
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6. If a morph area with TRANSITION_ZONE>0 is situated close to an edge of

the geometry with an angle larger than 60 degree no transition zone is
choosen for this edge.
SIMULIA
Tosca Structure
Shape Optimization

For each morphing area add a MORPH_AREA block via right-click on MORPHING folder (added to your optimization task within the Task Manager with
right clicking on Tosca Structure Task -> New -> MORPHING).
For each MORPH_AREA different properties can be defined. Define a name
for your MORPH_AREA, here MORPH_AREA_1, then select GROUP_DEF,
under ND_GROUP. In GROUP_DEF, enter a ? and select or define a
node_group describing the area to morph. Under TYPE, select the direction
of the morphing displacements vectors. So far only NORMAL is supported
Under TRANSITION_ZONE the number of nodes as transition zone can be
entered.
Fig. 222 Morph area properties

Definition in Tosca Structure.gui.
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Define the morphing area in the command MORPH_AREA by selecting the

corresponding node group (predefined at the command GROUP_DEF) and
entering the number of transition zones.
Fig. 223 MORPH_AREA definition in Tosca Structure.gui

Command
MORPH_AREA
ID_NAME
= <MORPH_AREA_name>
[string]
ND_GROUP
= <MORPH_AREA_nd_goup> [string]
TYPE
= NORMAL
TRANSITION_ZONE =
<number_of_transition_nodes>
User Manual 2 - 391
SIMULIA
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Morphing
[integer]
END_
6.10.1.2 Morphing displacement

For each step of the morphing process a constant displacement is applied
independently to the nodes of each morph area.
.
Fig. 224 Morphing displacement

The displacements are defined in an external morphing parameter file
<morph_csv_file_name>.csv referenced in the MORPH command. The
external file offers easier access from external process automation programs
(like ISight or OPTIMUS) and reusabiltiy:
Morphing parameter file
0, <MORPH_DEF_NAME_1>, <MORPH_DEF_NAME_2>,<MORPH_..._3>,
!
2, < MORPH_DISP _1>, < MORPH_DISP _2>, < MORPH_DISP _3>,

5,
The first line in the morphing parameter file contains the morphing areas
involved in the morphing process (referenced MORPH_AREA commands).
The order of appearance does not matter, but the commands must have been
defined in the parameter file prior to the MORPH command.
Each further line describes an experiment. Each morph_disp in a line tells
how much the corresponding MORPH_AREA area should be moved.
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Shape Optimization
<morph_disp>=0.0 means no movement. Negative and positive values are

accepted.
Example test_morph.csv:
0,
!
1,
2,
3,
4,
5,
6,
Morph2, Morph3, Morph4, Morph1

1.0, 0.0, 0.0, 0.0
0.0, 1.0, 0.0, 0.0
0.0, 0.0, 1.0, 0.0
0.0, 0.0, 0.0, 1.0
1.0, 1.0, 1.0, 1.0
-1.0, -1.0, -1.0, -1.0
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This file describes six morphing steps for four morphing areas Morph2,
Morph3, Morph4, Morph1. The first four lines move the nodes of each
MORPH_AREA by 1.0 each, starting with Morph2. Line 5 moves the nodes of
all areas together by 1.0 outwards, and line 6 moves all nodes inwards.
.
Fig. 225 Six morphing steps with 4 different morphing areas
6.10.1.3 Morphing task

Using the MORPH command, the single morphing areas (MORPH_AREA) ,
the morphing parameter file and the optimization task are combined:
MORPH
ID_NAME
OPTIMIZE
MORPH_AREA
MORPH_AREA
MORPH_AREA
=
=
=
=
=
<morph_name>
[string]
<optimization_name> [string]
<MORPH_AREA_name_1>
[string]
<MORPH_AREA_name_2>
[string]
User Manual 2 - 393
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Morphing
MORPH_PARAM_FILE = <morph_csv_file_name> [string]

NUMBER_OF_PARALLEL_JOBS = <number>
SMOOTHING
= YES|NO [string]
END_
The parameter NUMBER_OF_PARALLEL_JOBS defines optionally a number of

jobs which can be run in parallel. If omitted or =1, a sequential run will be performed (default).
SMOOTHING is another optional parameter that switches off the surface mesh
smoothing for the nodes in the morph areas. By default surface smoothing is
omitted to gain the exact displacement as specified in the csv-file. However
some manufacturing constraint might not work as expected in this case.
Fig. 227 Morph command: MORPH_PARAM_FILE and selection of morph

areas
Define the morphing task in the command MORPH by selecting the corresponding optimization task. Morph areas can be entered by clicking the but-
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Add a new MORPH command via right-click on MORPHING folder and adding New -> MORPH.
Link your MORPHING with a valid shape optimization task: click in OPTIMIZE and select via typing ? your previously defined shape optimization,
here OPTIMIZE_1_SHAPE_OPTIMIZATION_CONTROLLER.
Select your MORPH_PARAM_FILE csv file describing your morphing task
and the combinations of morphing displacements to be executed. Then select
the morphing areas.
PARALLEL_JOBS and SMOOTHING can be defined optionally.
SIMULIA
Tosca Structure
Shape Optimization
ton Add and activating the corrsponding areas. Enter a morph parameter file
and the number of processors..
Fig. 228 MORPH definition in Tosca Structure.gui
6.10.2 Morphing in Tosca ANSA environment

areas on/off.
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Fig. 230 Morph command: PARALLEL_JOBS and SMOOTHING
User Manual 2 - 395
SIMULIA
Tosca Structure
Morphing
After these settings you can run the morph task. Add a RUN_MORPH command via right-click on MORPHING folder.
Fig. 232 Run your defined morph task
6.10.3 Morphing in Tosca Structure.gui
Fig. 233 Start of a morphing run for shape optimization in Tosca Structure.gui
6.10.4 Command Syntax

Command example:
Please note: a complete shape optimization task is required!
FEM_INPUT
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In Tosca Structure.gui your morphing will be defined using the MORPH command mask. To start the morphing run, start Tosca Structure with your parameter file including the morphing commands. Create your visualization
sequence using Tosca Structure.report. For an example please refer to vol.4
chapter 7, Morphing.
SIMULIA
Tosca Structure
Shape Optimization
ID_NAME
FILE
= OPTIMIZATION_MODEL
= model.ext
END_
DV_SHAPE
ID_NAME
ND_GROUP
areas)
= design_variables
= design_nodes (must contain all MORPH_DEF
END_
MORPH_AREA
ID_NAME
ND_GROUP
TYPE
= Morph1
= LEFT_NODES
= NORMAL
END_
MORPH_AREA
ID_NAME
ND_GROUP
TYPE
= Morph2
= UPPER_ROUND
= NORMAL
END_
MORPH_AREA
ID_NAME
ND_GROUP
TYPE
= Morph3
= LOWER_ROUND
= NORMAL
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END_
MORPH_AREA
ID_NAME
ND_GROUP
TYPE
= Morph4
= LOWER
= NORMAL
END_
DRESP
ID_NAME
DEF_TYPE
= DRESP_MAX_MISES
= SYSTEM
User Manual 2 - 397
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Morphing
TYPE
UPDATE
ND_GROUP
GROUP_OPER
= SIG_MISES
= EVER
= design_nodes
= MAX
END_
OBJ_FUNC
ID_NAME
DRESP
TARGET
= minimize_max_mises
= DRESP_MAX_MISES
= MIN
END_
OPTIMIZE
ID_NAME
DV
OBJ_FUNC
STRATEGY
=
=
=
=
shape_optimization
design_variables
minimize_max_mises
SHAPE_CONTROLLER
END_
STOP
ID_NAME
ITER_MAX
= global_stop
= 5
END_
ID_NAME = tosca_morph
OPTIMIZE = shape_optimization
MORPH_DEF = Morph1
MORPH_DEF = Morph2
MORPH_DEF = Morph3
MORPH_DEF = Morph4
MORPH_PARAM_FILE = test_morph.csv
NUM_PROCS = 1
SMOOTHING = NO
END_
Postprocessing shows fringe plots of the typical results shown for the associated optimization task (in shape optimization; controller input for the objective
function, as well as optimization displacement) and a table of the requested
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MORPH
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Tosca Structure
Shape Optimization
design responses (values of objective, evtl. Constraint) for each morphing

step. For an example see vol.4 chapter 7, Morphing.
Remark:
Pleate note: In general Tosca Structure does not keep all input decks and all
solver output files for each design variant. If these should be saved for all
design cycles, please change the settings in your configuration file (e.g.
tosca_ctrl.cfg) or using the CONFIG parameter in your parameter file:
CONFIG
set_copy_solver_info_list("ever", "SAVE.${inp_ext}",
"${__FE_FILE__}");
add_move_per_iter_list("ever", "SAVE.${res_ext}",
"${__FE_MODEL__}.fil");
add_move_per_iter_list("ever", "SAVE.${res_ext}",
"${__FE_MODEL__}.odb");
add_move_per_iter_list("ever", "SAVE.msg",
"${__FE_MODEL__}.msg");
add_move_per_iter_list("ever", "SAVE.dat",
"${__FE_MODEL__}.dat");
add_move_per_iter_list("ever", "SAVE.sta",
"${__FE_MODEL__}.sta");
END_
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6.10.6 Evaluation
The morphing process can be used for a global indirect optimization to get an
improved start model for a subsequent local shape optimization. To this end,
the results of the different morphing steps are evaluated. Design responses
characterizing the objective and constraint are monitored and the best model
is considered. Eventually some more experiments with combined morphing
steps are required to get the best improvement in objective and constraint
values. The best morphing model can then be optimized by Tosca Structure.shape.
6.11 Stop Condition

Generally, it is helpful to formulate a stop condition to check the fulfillment of
the optimization task and end the optimization when the minimum (or maximum) has been reached.
User Manual 2 - 399
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Stop Condition
6.11.1 Global Stop Condition

reached the optimization algorithm always stops independent of other criteria.
The allowed maximum number of optimization iterations can be increased or
decreased by the user. This is done by modifying ITER_MAX in the STOP
command
STOP
ID_NAME
ITER_MAX
= global_stop
= 5
END_
where ITER_MAX is decreased to 5.

A global stop condition should be set for each optimization task to limit the
number of design cycles. The optimization algorithm does not have its own
stop condition; a stop condition must always be defined by the user.
Since a partially optimized model can be used as a starting model for a subsequent optimization, it makes sense to calculate first a few design cycles
and then to use information from the optimization result to calculate more
design cycles with adjusted settings.
Remarks:
1. For shape optimization tasks it is sufficient to limit the number of iterations
to 5 or 10. In this case it is important to define the stop condition by yourself. Using TAE, the stop condition is predefined already (default=5).
6.11.2 Local Stop Condition

The possibilities for local stop conditions might include the following:
If an objective function without a constraint should be minimized (maximized), the value of the objective function of the current design cycle
should be smaller (greater) than the value of the objective function for the
design in the previous optimization cycle. If this is not the case, the optimization can be ended.
Only relatively small changes in the value of the objective function are to be
expected when approaching the optimum. If the relative change in the
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2. The global stop criterion leads to a hard stop of the optimization - independend of a complete convergence of the result. For shape optimization tasks
this is no drawback as the optimization task can be continued for some
more steps using the input file of the last iteration as start file.
SIMULIA
Tosca Structure
Shape Optimization
objective function falls below a tolerance limit in one design cycle, the optimization can be considered as completed.
If the norm of the optimization displacements is smaller than a certain tolerance value within one design cycle, the modifications of the model will only
be small and the optimization is stopped. This condition has the advantage
that it is suitable for optimization jobs with and without constraints. The
condition can be equally used without any changes for a variety of objective functions (stress or frequency).
Stop conditions can be formulated and combined by linking the VARIABLE
definitions with LOGICAL variables. However, experiments have shown that it
is usually not worthwhile to define complicated stop conditions for shape optimization. It is often sufficient to limit the maximum number of allowable
design cycles as a global stop condition.
Also, a compact form of a stop condition is available which enables to compare the actual value of a variable with a value from the first or previous step
(parameters MOD_TYPE for the definition of the variable, MOD_OPER for the
comparison operator and MOD_REF for the reference value definition).
Remark:
command whereas convergence criteria are defined in the optimization
Per default, a global stop condition limiting the number of design cycles to 5 is
defined (visible in the task manager tree). If necessary, the number of design
cycles
can
be
changed
(Edit
command
applied
on
GLOBAL_STOP_CONDITION_1 item).
Several local stop conditions can be entered in the task manager (New |
STOP_CONDITION
command
applied
on
SHAPE_OPTIMIZATION_CONTROLLER item). In the pop up window the
parameters described above or in detail in vol.3 Commands Manual can be
defined. As this compact form of stop conditions is usually sufficient for opti-
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6.11.3 Stop Condition in Tosca ANSA environment
User Manual 2 - 401
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Stop Condition
mization tasks, more complicated stop conditions including logical variables

are not supported by Tosca ANSA environment.
Fig. 234 Local stop condition for shape optimization in Tosca ANSA environment
6.11.4 Stop Condition in Tosca Structure.gui
Fig. 235 Local stop condition for shape optimization in Tosca Structure.gui
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In Tosca Structure.gui, the definition of stop conditions is available in the commands menu. For details about the several parameters refer tovol.3 Commands Manual. More complicated stop conditions like in vol.2 chapter 6:
Example 3: can be defined using variables, combining them to logical expressions and referring them in the stop condition.
SIMULIA
Tosca Structure
Shape Optimization
6.11.5 Examples
Example 1:
The number of design cycles should be limited to 5 as a global stop condition:
STOP
ID_NAME
ITER_MAX
OPTIMIZE
= stop_condition
= 5
END_
Example 2:
The stop condition is fulfilled, if the maximum equivalence stress in the node
group ALL_NODES is less than 1% of the maximum equivalence stress of the
first iteration.
STOP
ID_NAME
MOD_NDGR
MOD_TYPE
MOD_OPER
MOD_REF
OPTIMIZE
=
=
=
=
=
=
stop_command
all_nodes
MAX, CTRL_INP_SHAPE
LE
0.01, MULT, FIRST
run
END_
Example 3:
If the sum of the optimization displacements of the design node group in a
given design cycle is smaller than 1% of the sum of the optimization displacements in the initial design cycle, the optimization should be stopped:
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VARIABLE
ID_NAME
DEF_TYPE
TYPE
ND_GROUP
GROUP_OPER
UPDATE
=
=
=
=
=
=
sum_disp
SYSTEM
SHAPE_MOVE
design_nodes
SUM
EVER
=
=
=
=
=
=
sum_disp_first
SYSTEM
SHAPE_MOVE
design_nodes
SUM
FIRST
END_
VARIABLE
ID_NAME
DEF_TYPE
TYPE
ND_GROUP
GROUP_OPER
UPDATE
User Manual 2 - 403
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References
END_
VARIABLE
ID_NAME
DEF_TYPE
VALUE
= one_percent
= FIX
= 0.01
END_
VARIABLE
ID_NAME
DEF_TYPE
VAR_OPER
VAR_A
VAR_B
=
=
=
=
=
sum_disp_first_001
OPER
MULT
one_percent
sum_disp_first
=
=
=
=
=
logical_for_stop
SYSTEM
LT
sum_disp
sum_disp_first_001
END_
LOGICAL
ID_NAME
DEF_TYPE
OPER
VAR_A
VAR_B
END_
STOP
ID_NAME
LOGI_NAME
OPTIMIZE
= stop_optimization
= logical_for_stop
END_
Meske, R., Sauter, J., and Schnack, E. (2005). Nonparametric gradient-less

shape optimization for real-world applications. Structural and Multidisciplinary Optimization. 30:201218, 2005. 10.1007/s00158-0050518-0.
Sauter, J. (1992). Applied mathematics and mechanics. ZAMM - Journal
of Applied Mathematics and Mechanics / Zeitschrift fr
Angewandte Mathematik und Mechanik. 72(6):T566T614.
Schnack, E. (1979). An optimization procedure for stress concentrations by
the finite element technique. International Journal for Numerical
Methods in Engineering. 14:115124.
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6.12 References
SIMULIA
Tosca Structure
Bead Optimization
Bead Optimization
mass to the structure. The beads can easily be added in the stamping process which makes beads a low weight and cost neutral alternative to
enhance a sheet-metal structures.
7.1
General Information
a)
b)
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Fig. 236 Simple plate in bending with loading and supports (a) and an
optimalbead (b). The maximal displacement of (a) is 6.6 mm and
(b) is 0.25 mm
In Fig. 236 is a simple flat plate in bending shown. It is evident that the solution in Fig. 236 (b) has a much greater stiffness than the original flat plate in
Fig. 236 (a).
made:
Bead height
Bead width
Fig. 237 Bead height and bead width
The bead height (see Fig. 237) has the most significant effect on the stiffness
of the plate structure. Usually, the greater the bead height the greater the stiff-
User Manual 2 - 405
SIMULIA
Tosca Structure
ness. But, the bead height is usually controlled by manufacturing capabilities

i.e how deep can you draw a bead with your available tools.
the stiffness of the sheet structure. The Tosca Structure.bead default values usually suffice, but if an optimal solution is sought you must try more
bead widths.
Fig. 238 Bead layouts for simple geometries with a uniform pressure load.
7.2

Tosca Structure.bead is a module that automatically determines the optimum
bead location and orientation for arbitrary shell structures. For this task Tosca
Structure provides two algorithms:
Sensitivity based bead optimization (BEAD_SENSITIVITY)
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For more complex loads or dynamic problems i.e. eigenvalue or frequency

response, the optimal bead layout is not intuitive anymore (see also Fig. 238).
SIMULIA
Tosca Structure
Bead Optimization
7.2.1
Controller based bead optimization

The controller based bead optimization (BEAD_CONTROLLER) is based
upon a special bending hypothesis developed at IPEK at Karlsruhe University. It determines the orientation of the maximum bending stress or Differential Stress Tensor (DST) for each point in the design domain. Special filters
are used to generate the beads along the bending trajectories.
Fig. 239 Distribution of bending stress and scalar fields for bead direction
This method has the following advantages:
Solver-independent and sensitivity-independent
mesh-independent
clear results
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restrictions on the bead form can be included

Remark
1. It should be emphasized that bead optimization does NOT always give
better mechanical behavior. The design problem must be suited for bead
optimization, that is:
- Design area should be mainly in bending or a bending mode. The bead
algorithm will then increase the moment of inertia which leads to a
greater stiffness or eigenfrequency.
- Design area should NOT be in a membrane stress state (see also vol.2
chapter 7.8.1.5, Penalty conditions (BEAD_MIN_STRESS and
BEAD_MAX_MEMBRANE)). A bead may in this case make the structure
softer.
User Manual 2 - 407
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Tosca Structure
7.2.2
Sensitivity based bead optimization

Sensitivity based bead optimization (BEAD_SENSITIVITY) makes it possible
to define very complex optimization tasks. It has been shown in industrial size
examples that the method is very powerful and attractive, especially for
dynamic problems.
The typical problems which can be solved by this algorithm are:
Maximize stiffness (linear static)
Minimize displacement for critical nodes (linear static)
Maximize first eigenvalue (modal)
Maximize a certain eigenvalue (using mode tracking)
Move eigenvalues away from certain frequency
(band gap optimization with modal analysis)
Remarks
1. The sensitivity based algorithm has no bead filter implemented. This
means that the results are not necessarily a distinct bead pattern like the
results from the controller algorithm.
2. Design nodes must be connected to elements which are supported by
Tosca Structure. See Table 27.
Differences between bead optimization algorithms

The user may choose between two bead optimization algorithms in Tosca
Structure.bead. The algorithms have different ways to find the solution and
their differences will be discussed in this chapter.
In the attempt to avoid confusion the following chapters will be marked with
either "BEAD_CONTROLLER" or "BEAD_SENSITIVITY" if it is only valid for
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7.2.3
SIMULIA
Tosca Structure
Bead Optimization
the one algorithm. If the chapter is not marked (like this chapter or e.g. vol.2
chapter 7.3, Design Area) the content applies to both algorithms
a)
b)
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Fig. 240 Bead pattern of maximization of first eigenfrequency using controller (a) vs. sensitivity (b) based algorithm
User Manual 2 - 409
SIMULIA
Tosca Structure
a)
Fig. 241 Iteration history for controller (a) and sensitivity (b) based optimization from Fig. 240.
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b)
SIMULIA
Tosca Structure
Bead Optimization
In Fig. 240 and Fig. 241 is the same optimization task, maximizing first eigenvalue, done by the sensitivity based optimization algorithm and controller
based algorithm. Some of the main differences between the two algorithms
are listed here:
1. Bead pattern. The controller based algorithm creates nice bead structures
because of its bead-filter. Such bead generation is not implemented in the
sensitivity based solution, why the results do not show a distinct bead
pattern (see Fig. 240).
2. Number of optimization iterations. The controller based algorithm
always uses 3 optimization iterations. Whereas for the sensitivity based
optimization algorithm usually needs 20 or more iterations to converge (see
Fig. 241).
3. Analysis types. The controller based supports all analysis types which
produces a stress tensor as output, although it is recommended to only use
the algorithm for static analysis.
The sensitivity based algorithm supports the responses of:
- linear static
- linear eigenfrequency
- frequency response
Note the better results by sensitivity based optimization for dynamic problems, e.g. Fig. 241.
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4. Objective and constraint types. The sensitivity based algorithm can have
one objective function and several constraints where the constraints are all
inequality constraints. The objective and the constraints can be based
upon the compliance, displacements, eigenfrequencies or frequency
dependent displacements. Whereas the controller based algorithm has the
compliance as objective and the BEAD_HEIGHT as an equality constraint.
5. Supported element types. The sensitivity based algorithm supports only
the elements given in Table 27. The controller algorithm supports all plate
and shell elements.
6. BEAD_HEIGHT. For sensitivity based algorithm all DRESP which can be
used in the object function (OBJ_FUNC) can also be used in the
CONSTRAINT definitions. The maximal nodal displacement is in this
context not considered a design response but instead a design variable
constraint (DVCON_BEAD). DRESP of the type BEAD_HEIGHT is not
allowed in sensitivity based algorithm (see volume 3: DRESP).
To get a similar optimization displacement in sensitivity based algorithm in
a benchmark example against the controller algorithm use:
DVCON_BEAD
User Manual 2 - 411
SIMULIA
Tosca Structure
ID_NAME
ND_GROUP
CHECK_GROW
CHECK_SHRINK
=
=
=
=
name_of_dvcon_bead
design_nodes
<BEAD_HEIGHT>
0.0
END_
where the <BEAD_HEIGHT> is equal to the bead height defined by the controller input deck. Also note that the sensitivity based algorithm can move the
nodes in positive and in negative direction, thus the optimization parameter
SCALE has no effect by sensitivity based algorithm.
As already stated the following chapters will differ with respect to the two
bead optimization algorithms. To make it easier to distinguish which chapter
concerns what method we introduce two key words:
BEAD_CONTROLLER
BEAD_SENSITIVITY
These two words reappear in the OPTIMIZE commands item STRATEGY.
Fig. 243 In Tosca Structure.gui the strategy is chosen in the OPTIMIZE

command
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Fig. 242 Select the appropriate Tosca Structure Task in Tosca ANSA environment to choose between BEAD_CONTROLLER or
BEAD_SENSITIVITY strategies.
SIMULIA
Tosca Structure
Bead Optimization
7.2.4

The following describes the general procedure for the definition of an optimization task. These procedures are supported by the task manager in Tosca
ANSA environment (TAE) as well as the command tree in Tosca Structure.pre
(GUI) (see vol.1 chapter 1, Getting Started with Tosca ANSA environment,
vol.1 chapter 2, Getting Started with Tosca Structure.gui, vol.2 chapter 2,
Working with Tosca Structure). The analysis model must be completely
defined in advance.
Analysis Model
TAE: MODEL_LINK | FILE | [EDIT], choose your model file.
GUI: Choose your model file in FEM_INPUT
Design Area
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2. Question: Which surface area of the FE model should be selected

regarding bead optimization?
Procedure: Assign node group with surface nodes to design area.
TAE: DESIGN_AREA | [EDIT], choose predefined group or select new
group.
GUI: Choose or define the node group with the surface nodes of the
selected design area (GROUP_DEF) and define the design variables
(DV_BEAD).
3. Question: Are there nodes in the design area that are subject to certain
restrictions? How can these restrictions be described?
Procedure: Define design variable constraints for node group. For sensitivity based bead optimization nodes must be constrained in maximum
positive and negative displacement.
TAE: DESIGN_AREA | DV_CONSTRAINTS | [NEW] | <type of
restriction>, choose predefined group or select new group for this
restriction. If required, define link conditions using modules buttons.
GUI: Choose or define node groups with common restrictions
(GROUP_DEF). Define the restrictions using DVCON_BEAD.
TAE: DESIGN_AREA | DV_CONSTRAINTS | [NEW] |
[SYMMETRY_CONTROL].
GUI: Create a LINK_BEAD condition and reference it in a restriction
User Manual 2 - 413
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Tosca Structure
command (DVCON_BEAD). LINK_BEAD is not supported by sensitivity

based bead optimization.
Objective Function
values be minimized or maximized or otherwise combined?
Procedure: Choose terms for optimization (design responses) and target.
TAE: OBJ_FUNC_ITEM_1 | [NEW] | <term for optimization>,
OBJ_FUNC_ITEM_1 | [EDIT] for choice of target (min, max).
GUI: Define the design response (DRESP) and assign it to the objective
function (OBJ_FUNC).
Constraint
6. Question: Which design response describes the constraint? Which value
should the constraint have?
Procedure: Choose term for constraint and set target value or upper/lower
boundary.
TAE: CONSTRAINT | [NEW] | <term for constraint>.
GUI: Define the design response (DRESP) and assign it to the constraint
(CONSTRAINT).
Optimization Task
8. Question: Are you using controller or sensitivity based optimization

strategy?
Procedure: Choose corresponding strategy.
TAE: Chosen in the beginning with your task
(BEAD_OPTIMIZATION_CONTROLLER or
BEAD_OPTIMIZATION_SENSITIVITY).
GUI: Set the correct value to either BEAD_CONTROLLER or
BEAD_SENSITIVITY in OPTIMIZE subcommand STRATEGY.
Stop Condition
9. Question: Should the optimization stop after a number of iterations (or
certain other conditions)?
Procedure: Define a stop condition
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Procedure: If necessary complete any additional required definitions and
prepare the optimization job.
SIMULIA
Tosca Structure
Bead Optimization
TAE: GLOBAL_STOP_CONDITION | [EDIT] and change number of iterations.

GUI: STOP.
Check Run
10.Question: Would prior testing of the restriction definitions be useful?
Procedure: Apply test displacements
TAE: BEAD_OPTMIZATION... | [NEW] | TEST_BEAD or
CHECK_INPUTS | [NEW] | TEST_BEAD_CHECK.
GUI: TEST_BEAD.
Completion
11.Question: Has all the required data been specified?
TAE: Click twice on OUTPUT and change the jobname.
GUI: Save as <jobname>.par.
Fig. 244 Block structure of bead optimization commands
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The essential commands required for the optimization model in bead optimization are described in the following.
User Manual 2 - 415
SIMULIA
Tosca Structure
Design Area
7.3
Design Area
7.3.1
Design variables (DV_BEAD)

In bead optimization shell models may be modified by moving the nodes perpendicular to the shells. Only nodes which are members of a shell element
may be used as design nodes. Nodes for solid elements cannot be design
nodes.
The design variables for bead optimization are defined using the DV_BEAD
command (design variable bead).
Fig. 245 Selecting the design node group in Tosca Structure.gui
Fig. 246 Defining DESIGN_AREA in Tosca ANSA environment. The

selected group must consist of nodes.
Remark
1. For BEAD_CONTROLLER the nodes are only moved in the positive direction
of the shells determined by the element definition in the FE analysis. For
BEAD_SENSITIVITY the nodes may move in both the positive (GROW) as
well as the negative (SHRINK) normal direction. See Fig. 247
2. If you want to have nodal movement in negative normal direction and using
BEAD_CONTROLLER invert the optimization displacement direction by
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SIMULIA
Tosca Structure
Bead Optimization
defining a negative SCALE factor in the OPT_PARAM command. This has

no effect for BEAD_SENSITIVITY.
Fig. 247 Optimization displacement direction for bead optimization

3. BEAD_SENSITIVITY is restricted to using only certain shell elements.
Please consult Table 27.
Valid element types for sensitivity
based bead optimization
Abaqus
element
type
ANSYS element type
Shell elements
SHELL_TRIANG_3
S3
S3R
STRI3
SHELL_QUAD_4
S4
S4R
SHELL143
SHELL181
SHELL41
SHELL43
SHELL63
SHELL_QUAD_8
S8R
SHELL93
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SHELL_TRIANG_6
User Manual 2 - 417
SIMULIA
Tosca Structure
Design Area
Valid element types

attached to the design
nodes for sensitivity
based bead
optimization
MSC
Nastran
element
type
Marc
element
type
PERMAS
element
type
Shell elements
SHELL_TRIANG_3
CTRIA3
CTRIAR
SHELL_TRIANG_6
CTRIA6
CTRIAX6
SHELL_QUAD_4
SHELL_QUAD_8
Table 27
7.3.2
138
TRIA3
TRIA3K
CQUAD4
CQUADR
CSHEAR
18
139
140
QUAD4
CQUAD8
30
72
Valid elements connected to design nodes for sensitivity

based bead optimization.
Restrictions (DVCON_BEAD)
Restrictions in bead optimization can either be defined as boundary conditions that limit the node displacement or as a LINK-condition. The latter is
only allowed for controller based bead optimization. A design variable constraint is a restriction that directly affects the individual design variables or the
individual design nodes.
Possible restrictions are: the specification of an allowable displacement area
by limiting the signed absolute displacement and the specification of variation
and frozen areas. It is also possible to influence the allowable displacement
direction by limiting the displacement to specific coordinate directions. At last
it is possible to link the design variables and thereby force them to be optimized in a symmetric way (only controller).
The definition of the design variable constraints for bead optimization is done
using the DVCON_BEAD command.
Remarks
1. Possible restrictions for bead optimization are very similar to the restrictions of shape optimization (see vol.2 chapter 6.3.3, Restrictions
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7.3.2.1 General
SIMULIA
Tosca Structure
Bead Optimization
(DVCON_SHAPE)). The definition of the CHECK parameters is often identical.

2. Some of the design variable constraints for bead optimization relate not
only to the design variable itself but also to the corresponding optimization
displacement vectors or the design coordinates. The term design variable
constraint in this case should be interpreted in a more general way.
Restrictions for bead optimization
The following individual restrictions can be defined for bead optimization:
CHECK_GROW: Restriction of the absolute displacement in shell normal
direction (see vol.2 chapter 7.3.2.2) *
CHECK_SHRINK: Restriction of the absolute displacement opposite the
shell normal direction (see vol.2 chapter 7.3.2.2) *
CHECK_SOLID: Check the displacements against geometric primitive solids (see vol.2 chapter 7.3.2.3)
CHECK_ELGR: Check the displacements against elements of an element
group (see vol.2 chapter 7.3.2.4)
CHECK_BC, CHECK_DOF: Restriction of the displacement direction
CHECK_LINK: Assignment of a coupling condition
(only BEAD_CONTROLLER)(see vol.2 chapter 7.3.2.6)
A DVCON_BEAD command using all of the individual restrictions appears as
follows:
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DVCON_BEAD
ID_NAME
ND_GROUP
CHECK_SOLID
CHECK_ELGR
CHECK_GROW
CHECK_SHRINK
CHECK_BC
CHECK_DOF
CHECK_LINK
=
=
=
=
=
=
=
=
=
name_of_dvcon_bead
name_of_node_group
name_of_solid
name_of_element_group
<max_grow_value>
<max_SHRINK_value>
cs_name, FREE/FIX, FREE/FIX, FREE/FIX
YES/NO
<link_name>
END_
Remarks
1. Using CHECK_GROW and CHECK_SHRINK is the easiest way to constrain
design nodes for sensitivity based optimization. See also chapter 7.3.2.2
Restricting the absolute displacement.
User Manual 2 - 419
SIMULIA
Tosca Structure
Design Area
2. CHECK_SHRINK has no effect on controller algorithm while it only "grows".

3. CHECK_LINK has no effect on sensitivity based algorithm.
4. The restrictions are checked only for the corner nodes of the node group
(ND_GROUP parameter). If midside nodes are contained in the node group
they are subsequently placed in between the neighboring corner nodes.
Therefore, its not possible for mid-side nodes to guarantee adherence to
the restrictions; a small amount of deviation may occur.
5. It is possible to define several individual CHECK_* restrictions within a
DVCON_BEAD command. The order of the execution of the individual
restrictions within a DVCON_BEAD command appears as follows:
CHECK_GROW, CHECK_SOLID, CHECK_ELGR, CHECK_BC,
CHECK_DOF, CHECK_LINK. The individual restrictions are checked independently of each other, i.e. an individual restriction always overrides the
previous restriction.
6. The activated DVCON_BEAD entries are executed in the order in which they
are referenced in the OPTIMIZE command. The individual DVCON_BEAD
entries are checked independently of each other, i.e. a DVCON_BEAD entry
always overrides the previous DVCON_BEAD entry. If mutually independent
restrictions are declared all restrictions are observed. If mutually dependent restrictions are declared the user must select an order of execution
that is logical and specific to the problem.
8. The DVCON_BEAD definitions must be activated by a reference in the

OPTIMIZE command. Non-activated definitions have no influence on the
variable constraints and the design area (see DV_BEAD command) to
each other. The recommended procedure is to define the assigned restrictions immediately after defining the design area.
7.3.2.2 Restricting the absolute displacement

It is possible to specify a maximum allowable absolute displacement for each
node in relation to the starting geometry. The parameters
CHECK_GROW
= <MAX_GROW_VALUE>
CHECK_SHRINK
= <MAX_SHRINK_VALUE>
specifies a maximum absolute displacement <max_grow_value> allowed in

the growth direction and <max_shrink_value> in the opposite direction.
The values must be positive.
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7. It is possible to define several design variable constraints using the

DVCON_BEAD command. Each DVCON_BEAD definition must have its own
unique name.
SIMULIA
Tosca Structure
Bead Optimization
In controller based bead optimization the maximum displacement amount of

the design nodes is restricted in the constraint of the optimization task (see
DRESP type "BEAD_HEIGHT" and volume 3: CONSTRAINT). The definition
of an additional restriction by the DVCON_BEAD command allows for the definition of additional restrictions on specified design nodes.
For sensitivity based algorithm the DVCON_BEAD are the only restriction on
the design nodes optimization displacement and must therefore be defined.
If any node in the design area is not restricted Tosca Structure will stop with
an error.
The easiest way to constrain all design nodes is to this is to use:
DVCON_BEAD
ID_NAME
ND_GROUP
CHECK_GROW
CHECK_SHRINK
=
=
=
=
MY_DVCON_BEAD
DESIGN_NODES
10.0
0.0
END_
The command above is equivalent to define the following BEAD_HEIGHT constraint in the controller based algorithm.
CONSTRAINT
ID_NAME
DRESP
EQ_VALUE
MAGNITUDE
=
=
=
=
MY_BEAD_HEIGHT_CONSTRAINT
BEAD_HEIGHT_DRESP
10.0
ABS
END_
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Realization in Tosca ANSA environment

To create a design variable constraint in Tosca ANSA environment select
Tosca
Structure
Task
|
PRE-PROCESSING
|
BEAD_OPTIMIZATION_<type> | DESIGN_AREA | DV_CONSTRAINTS |
[New].
User Manual 2 - 421
SIMULIA
Tosca Structure
Design Area
Here is the example just described constraint all design nodes to a maximum
growth of 10.0 and no shrink using GROW/SHRINK_CONTROL.
7.3.2.3 Displacement check against solids (CHECK_SOLID)

It is possible to define geometric primitives (solids) as a restriction of the node
displacements. Geometric primitives are defined using the SOLID parameter.
The SOLID parameter allows for the definition of circles, circle segments, ring
segments and rectangles in two-dimensional models and cylinders, cylinder
segments, tubes, cubes, cube segments in three-dimensional models. There
is a differentiation here between a variation solid and a restriction solid (vari-
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Realization in Tosca Structure.gui

Example just described constraining all design nodes to a maximum growth
of 10.0 and no shrink using DVCON_BEAD.
SIMULIA
Tosca Structure
Bead Optimization
ation area or restriction area, see vol.2 chapter 3.9, Solids (Geometric
Primitives)).
The parameter:
CHECK_SOLID
= solid_name
specifies a solid whose borders may not be penetrated. The solid must be
defined with a SOLID command before being referenced.
Remarks
1. Up to six different CHECK_SOLID parameters can be defined in every
DVCON_BEAD command. They are executed in the order of their declaration within the DVCON_BEAD command.
2. If the solid is a variation solid, all nodes of the node group in the start model
(see ND_GROUP parameter) must be located inside the variation solid. If
nodes are located outside the variation solid, the DVCON_BEAD definition
will be rejected. If the solid is a restriction solid, all nodes of the node group
in the start model must be located outside the restriction solid. If nodes are
located inside the restriction solid, the DVCON_BEAD definition will be
rejected.
7.3.2.4 Displacement check against elements (CHECK_ELGR)

Element surfaces/lines can be defined as limiting surfaces/lines in order to
check node displacements against any contour. This option offers more flexibility than the check for the absolute displacement or the check against geometric primitives. The limiting surfaces are formed by beam, shell or solid
structures. The limiting surfaces are generated in the FE preprocessor and
loaded via the interface (FEM_INPUT) in the optimization preprocessor. The
parameter
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CHECK_ELGR
= elgr_name
specifies an element group whose elements may not be penetrated (contact

condition) by the nodes of the node group (ND_GROUP parameter). Activation
of the element check represents a collision control. If a node attempts to penetrate an element, the node displacement is scaled back so that the affected
node remains on the side of the element where it is intended to be. For example, the element group must be defined with GROUP_DEF before it can be referenced with CHECK_ELGR.
Remarks
1. Up to six CHECK_ELGR parameters can be defined in every DVCON_BEAD
command. They are executed in the order of their declaration within the
DVCON_BEAD command.
User Manual 2 - 423
SIMULIA
Tosca Structure
Design Area
2. To simplify the definition of the contact check if it is useful to divide the

limiting surfaces by assigning various element property numbers (or materials). This simplifies the selection and assembly of groups in the optimization preprocessor.
3. All nodes of the selected node group are checked against all elements of
the element group, elgr_name. To keep the number of control conditions
within limits, only those nodes and elements that have the potential for
penetration should be checked against one another. The groups should be
correspondingly defined.
4. The nodes (ND_GROUP parameter) and the elements (CHECK_ELEM
parameter) should have a definite minimum distance in the initial model in
order to verify on which side of the element a node must remain.
parameter (FEM_INPUT), care should be taken that node or element IDs
are not used twice as Tosca Structure cannot process duplicated IDs.
7.3.2.5 Restricting the direction of displacement

In Tosca Structure.bead the displacement direction of the design nodes (optimization displacement vector) is normally determined as the surface normal
(see vol.2 chapter 7.8.1.2). A restriction of the displacement direction in bead
optimization may be necessary due to two reasons:
2. Some areas in the design domain should not be modified during optimization, e.g. the boundary of the design domain. These areas may be
restricted using the CHECK_DOF or CHECK_BC parameters.
The displacement boundary condition must be unique. In contrast to FE
boundary conditions of several load cases, the total of all supports for all load
cases are considered as supports in the optimization. A prescribed node displacement as an optimization boundary condition is also not permitted.
Loading Node Fixations via the Interface from the FE Program
The full or partial fixation of nodes is the most common and most important
type of restriction; it is practically used in every optimization model. The most
efficient method for defining the displacement restrictions in the FE preprocessing as an extra load case in the transition model and then to load it via
the FE interface in the optimization preprocessor. In order to do this, the interface must first be activated with OPTIONS, READ_BC=.... In this way all
node fixations for the optimization model can be defined in advance in the FE
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1. Standardly, the displacement direction in bead optimization is determined

in the initial model and is not modified during optimization (OPT_PARAM,
VECTOR = FIRST). In order to define own displacement directions the
original displacement directions may be restricted.
SIMULIA
Tosca Structure
Bead Optimization
preprocessor. The fixation is always based on the FE displacement coordinate system of the node. The special features of the FE interfaces are
described in vol.2 chapter 11. The parameter
CHECK_BC
= ALL
activates the node fixations of the node group (ND_GROUP parameter) which
are loaded through the FE interface. Fixations that reference nodes not contained in the node groups are not activated. To prevent loaded fixations from
being activated enter:
CHECK_BC
= NO
Definition of the Displacement Direction by Command

The CHECK_DOF parameter can be used to restrict other displacement
directions if necessary as an addition or at a later stage. When entering node
fixations by command and in contrast to load the node fixations via the FE
interface, it is necessary to first compile all nodes that should be assigned a
certain attribute to a node group. The coordinate system must also be defined
or loaded. With the parameter
CHECK_DOF
= cs_name,[FIX|FREE],[FIX|FREE],[FIX|FREE]
all the displacements of all nodes in the node group selected with ND_GROUP
are fixed (FIX) or free (FREE) relative to the specified coordinate directions of
the coordinate system, cs_name. Either FREE or FIX is allowed for each
coordinate direction.
Remark
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1. The main difference between CHECK_BC and CHECK_DOF is:

CHECK_BC is read in through the FE interface whereas CHECK_DOF is
defined in the optimization preprocessor. Generally, with CHECK_BC each
node has its own fixation in its own displacement coordinate system,
whereas all nodes of the node group are all fixed in the same coordinate
system with CHECK_DOF.
7.3.2.6 Symmetry conditions (CHECK_LINK)

BEAD_CONTROLLER
Symmetry conditions can also be applied in Tosca Structure.bead. A LINKcondition is needed to create a symmetry condition. The types of symmetry
supported by Tosca Structure.bead is point, plane and rotational symmetry
LINK_BEAD
ID_NAME
TYPE
CS
= <link_name>
= POINT_SYM
PLANE_SYM, AXIS_*
ROTATIONAL_SYM, AXIS_*
= <cs_name>
User Manual 2 - 425
SIMULIA
Tosca Structure
Design Area
END_
The origin of the coordinate system referenced by the <cs_name> (vol.2

chapter 3.8) is the symmetry point or a point on the symmetry plane, where
AXIS_* is the normal to this plane. For rotational symmetry the origin of the
coordinate system is a point on the symmetry axis, where AXIS_* gives the
direction.
symmetry
Loads
Loads
Fig. 248 An asymmetric load case without (left) and with (right) symmetry
condition.
Remarks
1. AXIS_* can be AXIS_1, AXIS_2 or AXIS_3 of the chosen coordinate
system.
3. The name of the link is referenced in a DVCON_BEAD command using

CHECK_LINK=<link_name>.
7.3.2.7 Example LINK_BEAD

Creating a plane symmetry condition about the global coordinate system in
the Y-axis for controller based bead optimization.
Command syntax
LINK_BEAD
ID_NAME
CS
TYPE
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= MY_LINK_BEAD
= CS_0
= PLANE_SYM, AXIS_2
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2. Only cartesian coordinate systems can be used for symmetry conditions.
SIMULIA
Tosca Structure
Bead Optimization
END_
DVCON_BEAD
ID_NAME
CHECK_BC
ND_GROUP
CHECK_LINK
=
=
=
=
MY_DVCON_BEAD_SYM
NO
DESIGN_NODES
MY_LINK_BEAD
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END_
User Manual 2 - 427
SIMULIA
Tosca Structure
Objective Function
Realization within the Tosca ANSA environment
7.4
Objective Function
minimized.
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SIMULIA
Tosca Structure
Bead Optimization
7.4.1
Overview
Bead optimization is mostly used to maximize stiffness of a structure or
improve the dynamical properties of a shell structure. As already noted (chapter 7.2.3 Differences between bead optimization algorithms) Tosca Structure.bead has two different optimization approaches. The differences have
already been discussed in general. The possible design responses in the
objective function is one of the major differences which becomes obvious
looking at the following Table 28.
Static analysis
Gravity / Inertia
Frequency
response
DISP_ABS
CENTER_GRAVITY_X
FS_ACCEL_X
DISP_X
CENTER_GRAVITY_Y
FS_ACCEL_Y
DISP_X_ABS
CENTER_GRAVITY_Z
FS_ACCEL_Z
DISP_Y
INERTIA_XX
FS_DISP_ABS
DISP_Y_ABS
INERTIA_XY
FS_DISP_X_ABS
DISP_Z
INERTIA_XZ
FS_DISP_Y_ABS
DISP_Z_ABS
INERTIA_YY
FS_DISP_Z_ABS
ROT_X
INERTIA_YZ
FS_VELOCITY_X
ROT_Y
INERTIA_ZZ
FS_VELOCITY_Y
ROT_Z
FS_VELOCITY_Z
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STRAIN_ENERGY*
Modal analysis
DYN_FREQ*
DYN_FREQ_KREISS
EL
Table 28
Possible design responses in the objective function for Tosca

Structure.bead. All terms are allowed in BEAD_SENSITIVTY,
for BEAD_CONTROLLER only the terms marked with a * are
allowed
User Manual 2 - 429
SIMULIA
Tosca Structure
Typical Optimization Tasks for Linear Static Analysis
Remarks:
1. Only design responses marked with * are allowed in controller based algorithm (BEAD_CONTROLLER).
2. BEAD_HEIGHT is not allowed in sensitivity algorithm. Use DVCON_BEAD
instead.
3. The Gravity / Inertia design response types are only usable if at least one
design response of the other types is used in the objective function or
constraints.
In the following chapters typical optimization tasks are described which can
be solved with Tosca Structure.bead.
7.5
Typical Optimization Tasks for Linear Static

Analysis
This section deals with the typical optimization tasks for linear static analysis
types. Only some very common tasks are described here.
7.5.1
Maximize stiffness with controller based algorithm

BEAD_CONTROLLER
To maximize stiffness of the structure the compliance - or sum of strain
energy - should be minimized. The design response should be defined like
the following:
ID_NAME
TYPE
DEF_TYPE
UPDATE
EL_GROUP
GROUP_OPER
LC_SET
=
=
=
=
=
=
=
dresp_compliance
STRAIN_ENERGY
SYSTEM
EVER
ALL_ELEMENTS
SUM
Static,1,All
END_
Remarks
1. Compliance is defined as the sum of the energy of all the elements in the
FE-model regardless how large your design domain may be.
2. The algorithm is based on element stress tensors. Therefore these must be
requested in the FE-analysis, but Tosca Structure for most solvers adds
these result request (see Vol.I Chapter 13).
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DRESP
SIMULIA
Tosca Structure
Bead Optimization
Definition of the objective function

OBJ_FUNC
ID_NAME
DRESP
TARGET
= minimize_compliance
= dresp_compliance
= MIN
END_
7.5.1.1 Combining static load cases (controller based algorithm)

BEAD_CONTROLLER
If more load cases and/or sub-steps are present in the FE-analysis, Tosca
Structure.bead will try to combine all these load cases. The "best-practiceway", however, is to define each load case separately in its own DRESP.
Thereby one can easily give the load cases different weights in the objective
function:
OBJ_FUNC
ID_NAME
DRESP
DRESP
TARGET
=
=
=
=
minimize_compliance
dresp_compliance_1, 0.90
MIN
END_
Here, the first design response is weighted 10% less than the norm, and the
second 10% more than the norm. The norm (1.0) is default.
Remarks
1. It is highly recommended only to combine linear static load cases!
2. It is recommended to look up the definition of load cases in (DRESP).
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3. Reference value has no effect in controller algorithm.

If one DRESP references all load cases:
DRESP
ID_NAME
DEF_TYPE
EL_GROUP
TYPE
GROUP_OPER
LC_SET
=
=
=
=
=
=
dresp_min_compliance
SYSTEM
ALL_ELEMENTS
STRAIN_ENERGY
SUM
All,All,All
END_
Tosca Structure.bead will try to combine All load cases in the finite element
calculation with the weighting of 1.0. Once again, this method is NOT recom-
User Manual 2 - 431
SIMULIA
Tosca Structure
Typical Optimization Tasks for Linear Static Analysis
mended and the former mentioned method of defining the load cases separately and then combining them in the objective function is emphasized.
7.5.2
Linear static sensitivity based optimization

BEAD_SENSITIVITY
The sensitivity based bead optimization offers a large range of responses for
static analysis. But note that the controller based bead algorithm will often be
superior and more effective in pure minimization of compliance designs. Of
course, if you need more control of displacements of certain nodes within
your model you will be better of using the sensitivity based algorithm.
7.5.2.1 Minimize compliance

To minimize the compliance of a shell structure the command structure is
similar to the controller based algorithm. Define a compliance design
response and reference it in the objective function.
DRESP
ID_NAME
DEF_TYPE
EL_GROUP
TYPE
GROUP_OPER
LC_SET
=
=
=
=
=
=
dresp_compliance
SYSTEM
ALL_ELEMENTS
STRAIN_ENERGY
SUM
Static,1,All
END_
ID_NAME
DRESP
TARGET
= min_compliance
= dresp_compliance
= MIN
END_
Explanation:
A design response with name "dresp_compliance" is defined for the first
static load case. Note that the design response is defined using
GROUP_OPER = SUM over ALL_ELEMENTS which is also the correct
definition because compliance must be equal to the outer work (force x displacement). The compliance design response is minimized (TARGET=MIN) in the object function.
Note that no constraint is necessary, but remember to add a DVCON_BEAD
which constrains the nodes in positive and negative normal direction.
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OBJ_FUNC
SIMULIA
Tosca Structure
Bead Optimization
7.6

Analysis
This section deals with the typical optimization tasks for modal analysis types.
Some very common tasks are described here.
7.6.1
Maximization of the lowest natural frequency (controller)

BEAD_CONTROLLER
The natural frequency may be optimized by using the maximization the
dynamic frequency response.
Remark
It should be emphasized that the sensitivity based algorithm
(BEAD_SENSITIVITY) is usually superior for this task, see Fig. 241).
An example of maximization of first natural eigenfrequency is shown here:
DRESP
ID_NAME
DEF_TYPE
TYPE
LC_SET
=
=
=
=
dresp_max_eigenfrequency
SYSTEM
DYN_FREQ
Modal,All,1
END_
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OBJ_FUNC
ID_NAME
DRESP
TARGET
= maximize_eigenfrequency
= dresp_max_eigenfrequency
= MAX
END_
Explanation:
The type of the design response is DYN_FREQ (eigenfrequency). To
choose the first eigenfrequency the third argument in the item LC_SET is
set to 1. This design responses ID_NAME is referenced in the OBJ_FUNC
where it is set to be maximized.
User Manual 2 - 433
SIMULIA
Tosca Structure
Remarks
1. To consider for example the second eigenfrequency, the LC_SET parameter has to be set as follows: LC_SET = Modal, All, 2. More information can
be found in Commands manual (see volume 3: DRESP).
2. Warning: Do NOT define the third argument in the LC_SET command as
All (e.g. LC_SET=Modal,1,all). The algorithm will then try to combine All
modes from the modal analysis, which normally will NOT lead to good
results for the controller based algorithm.
7.6.2
Sensitivity based eigenvalue optimization

BEAD_SENSITIVITY
The eigenvalue optimization of the sensitivity based bead optimization has
shown to be superior to the controller based algorithm. Its not only possible
to optimize the first eigenfrequency, but following tasks can also be done:
maximize (or minimize) an eigenmode
maximize (or minimize) a range of modes
move a certain eigenmode higher or lower using mode-tracking
maximize band gaps (distance between modes) using the special MINMAX
function
force eigenvalue to achieve a certain value
BEAD_SENSITIVITY
The definition of a maximization of an eigenvalue problem could be done similar to the controller based bead algorithm. But this is not recommended.
In the sensitivity based algorithm we have more control over the modes. A
problem you usually want to avoid when optimizing eigenmodes is modeswitching because it destabilizes the optimization algorithm. The typical problem is by maximizing the first eigenmode it may "overtake" the second mode hence, the modes switch place (previous second mode becomes the first
mode) and sensitivity algorithm must suddenly take a new mode into consideration.
Mode tracking can of course be used (chapter 7.8.2.3 Optimization parameters for mode tracking), but the computationally cheapest way to push the first
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7.6.2.1 Maximize the first natural mode (first eigenvalue)
SIMULIA
Tosca Structure
Bead Optimization
eigenmode up is to use the Kreissel-Meier Steinhauser formulation (TYPE =

DYN_FREQ_KREISSEL):

= --- ln
k
j = 1 e
kf j
In the formulation f j is the eigenfrequency, e the base of the natural logarithm and and k are constants.
In the following the formulation will enforce the 5 first modes to keep their
sequence. This is usually sufficient to avoid mode switching among the first
couple of modes. See also Fig. 241 at iteration 13-14 where modes almost
switch, but do not because of this formulation.
DRESP
ID_NAME
DEF_TYPE
TYPE
LC_SET
=
=
=
=
dresp_eig_kreissel
SYSTEM
DYN_FREQ_KREISSEL
Modal,All,1-5
END_
OBJ_FUNC
ID_NAME
DRESP
TARGET
= max_dresp_eig_kreissel
= dresp_eig_kreissel
= MAX
END_
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Explanation
The definition above will enforce the 5 first modes to keep their sequence.
This is usually sufficient to avoid mode switching among the first couple of
modes. The first mode is maximized (TARGET=MAX) until it comes near
the higher modes in which case they are being considered as well.
7.6.2.2 Maximize a range of modes

BEAD_SENSITIVITY
Maximizing a range of modes can be done in following simple way:
DRESP
ID_NAME
DEF_TYPE
TYPE
LC_SET
=
=
=
=
dresp_eigs_1-5
SYSTEM
DYN_FREQ
Modal,All,1-5
END_
OBJ_FUNC
User Manual 2 - 435
SIMULIA
Tosca Structure
ID_NAME
DRESP
TARGET
= max_dresp_eigs_1-5
= dresp_eigs _1-5
= MAX
END_
Explanation
Here, the 5 first modes are summed in one design response (dresp_eigs_15). This sum is being maximized (TARGET=MAX).This solution often has the
pitfall that the higher modes usually are weighted higher than the lower ones.
One way to circumvent this is to define a design response for each eigenmode:
DRESP
ID_NAME
DEF_TYPE
TYPE
LC_SET
=
=
=
=
dresp_eig1
SYSTEM
DYN_FREQ
Modal,All,1
=
=
=
=
dresp_eig2
SYSTEM
DYN_FREQ
Modal,All,2
END_
DRESP
ID_NAME
DEF_TYPE
TYPE
LC_SET
END_
DRESP
ID_NAME
= dresp_eig...
OBJ_FUNC
ID_NAME
DRESP
DRESP
DRESP
DRESP
DRESP
TARGET
=
=
=
=
=
=
=
max_dresp_eigs_1-5
dresp_eig1, 0.10, 100.
dresp_eig2, 0.05, 200.
dresp_eig3, 0.04, 250.
dresp_eig4, 0.0025,400.
dresp_eig5, 0.002, 500.
MAX
Hz
Hz
Hz
Hz
Hz
END_
Explanation
Here, each of the 5 first modes are multiplied by a weight (reciprocal value
of the initial eigenvalue) and then summed and maximized.
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...
SIMULIA
Tosca Structure
Bead Optimization
7.6.2.3 Maximize a certain mode

BEAD_SENSITIVITY
Sometimes it may be sufficient to only have interest for one single mode and
at the same time we do not want to regard the other modes. This can be done
using mode tracking.
DRESP
ID_NAME
DEF_TYPE
TYPE
LC_SET
=
=
=
=
dresp_eig2
SYSTEM
DYN_FREQ
Modal,All,2
END_
OBJ_FUNC
ID_NAME
DRESP
TARGET
= max_ dresp_eig2
= dresp_eig2
= MAX
END_
OPTIMIZE
ID_NAME
DV
STRATEGY
OBJ_FUNC
=
=
=
=
opt
my_design_nodes
BEAD_SENSITIVITY
max_ dresp_eig2
=
=
=
=
my_parameters
opt
ON
10
END_
OPT_PARAM
ID_NAME
OPTIMIZE
MODETRACKING
MODENUMBERS
Explanation:
The second mode is chosen to be maximized. The important difference is
that mode tracking is activated the optimization parameters (MODETRACKING= ON). Default by mode tracking in Tosca Structure is to take 5
modes into account, but this can be changed by the item MODENUMBERS.
This should not be set too high because of computational effort.
www.3ds.com/tosca
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END_
User Manual 2 - 437
SIMULIA
Tosca Structure
Fig. 249 Optimization displacements and convergence plots without (a)

and with (b) mode tracking
7.6.2.4 Adjust eigenvalue

BEAD_SENSITIVITY
The opposite of the former approach may also be the case -- that is to force
an eigenfrequency to achieve a certain value. This may be realized using
constraint functions.
ID_NAME
DEF_TYPE
TYPE
LC_SET
=
=
=
=
dresp_eig_2
SYSTEM
DYN_FREQ
Modal,All,2
END_
OBJ_FUNC
ID_NAME
DRESP
TARGET
END_
CONSTRAINT
2 - 438 User Manual
= max_dresp_eig_2
= dresp_eig_2
= MAX
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DRESP
SIMULIA
Tosca Structure
Bead Optimization
ID_NAME
DRESP
MAGNITUDE
LE_VALUE
=
=
=
=
con_dresp_eig_2_le_15Hz
dresp_eig_2
ABS
15.
=
=
=
=
=
opt
my_design_nodes
BEAD_SENSITIVITY
max_ dresp_eig2
con_dresp_eig_2_le_15Hz
END_
OPTIMIZE
ID_NAME
DV
STRATEGY
OBJ_FUNC
CONSTRAINT
END_
Explanation:
The second eigenmode will be maximized, but because of the constraint it
may not become higher than 15. Hz.
7.6.2.5 Maximize band gaps

BEAD_SENSITIVITY
For dynamic problems it is often problematic to have an eigenvalue at some
frequency. This can be done with the special form Tosca Structure handles
MINMAX-problems for eigenvalue. Here, the object function for eigenfrequencies by TARGET= MINMAX is given:
1
-----------------
fk fk
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By minimizing this expression the eigenfrequencies f will be moved away

*
from the value of f k . With as a constant the Tosca Structure commands
would be:
DRESP
ID_NAME
DEF_TYPE
TYPE
LC_SET
=
=
=
=
dresp_eig_2
SYSTEM
DYN_FREQ
Modal,All,2
END_
OBJ_FUNC
ID_NAME
DRESP
TARGET
= move_dresp_eig_2_from_15Hz
= dresp_eig_2, 1.0, 15.
= MINMAX
User Manual 2 - 439
SIMULIA
Tosca Structure
Constraints
END_
Fig. 250 Convergence of eigenvalues of a bandgap optimization (15 Hz)

Explanation:
The second eigenmode will be pushed away from 15.0 Hz. The weighting of
the design response is simply 1.0.
Remark:
1. Flat structures should first have the eigenvalues maximized before doing
the band-gap optimization because the optimizer must also be able to
move some eigenvalues down.
Constraints
The number of constraints allowed for BEAD_SENSITIVITY is almost as vast
as the possibilities for object function definition. For BEAD_CONTROLLER
the only allowed and necessary constraint is the BEAD_HEIGHT which is not
allowed in BEAD_SENSITIVTITY.
Static analysis
Gravity / Inertia
Frequency response
DISP_ABS
CENTER_GRAVITY_X
FS_ACCEL_X
DISP_X
CENTER_GRAVITY_Y
FS_ACCEL_Y
DISP_X_ABS
CENTER_GRAVITY_Z
FS_ACCEL_Z
DISP_Y
INERTIA_XX
FS_DISP_ABS
DISP_Y_ABS
INERTIA_XY
FS_DISP_X_ABS
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7.7
SIMULIA
Tosca Structure
Bead Optimization
DISP_Z
INERTIA_XZ
FS_DISP_Y_ABS
DISP_Z_ABS
INERTIA_YY
FS_DISP_Z_ABS
ROT_X
INERTIA_YZ
FS_VELOCITY_X
ROT_Y
INERTIA_ZZ
FS_VELOCITY_Y
ROT_Z
FS_VELOCITY_Z
STRAIN_ENERGY
Independent of
analysis type:
BEAD_HEIGHT*
Table 29
Modal analysis
DYN_FREQ
Possible design responses for constraints for Tosca Structure.bead.

* BEAD_HEIGHT is only allowed in BEAD_CONTROLLER
but not in BEAD_SENSITIVITY. For sensitivity algorithm
same functionality is achieved using DVCON_BEAD instead.
Remark:
1. The Gravity / Inertia design response types are only usable if at least one
design response of the other types is used in the objective function or
constraints.
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7.8
Settings
Each OPT_PARAMcommand has a unique name (ID_NAME parameter) and
references a previously defined optimization job (OPTIMIZE parameter). The
specified parameters only relate to the given optimization task. A typical
OPT_PARAM command appears as follows:
OPT_PARAM
ID_NAME
OPTIMIZE
...
= param_for_bead_optimization
= bead_optimization
END_
The following parameters may be set in bead optimization:

BEAD_CONTROLLER:
Direction of the optimization displacement
User Manual 2 - 441
SIMULIA
Tosca Structure
Settings
Update of normal vectors (optimization displacement vector)

Influence on bead width
Number of iterations
Minimum stress for a optimized area
Maximum membrane stress for a optimized area
Mesh enhancing parameters
BEAD_SENSITIVITY
Filtering of sensitivities
Move limit
MMA asymptote update
Sensitivity calculation
Optimization parameters for mode tracking
Optimization parameters for frequency response
- damping parameters
- Q-factor
Remarks
1. IMPORTANT: The parameters for controller are ignored for the sensitivity
based algorithm and vice versa.
3. Please note that BEAD_WIDTH and BEAD_ITER has no effect in sensitivity

based optimization. Therefore always define a STOP-command;
ITER_MAX = 20 is recommended.
BEAD_CONTROLLER
Example of setting the SCALE parameter for controller based bead optimization:
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2. The OPT_PARAM command is also used in shape and topology optimization. However, the optimization parameters that can be set, depend upon
the given type of optimization. The only parameters that can be set here
are those allowable for bead optimization. Topology and shape optimization parameters cannot be set.
SIMULIA
Tosca Structure
Bead Optimization
Tosca
Structure
Task
|
PRE-PROCESSING
BEAD_OPTIMIZATION_<type> | [New] | [SETTINGS]
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BEAD_SENSITIVITY
Example of setting the FILTER_RADIUS parameter for sensitivity based
bead optimization:
Tosca
Structure
Task
|
PRE-PROCESSING
|
BEAD_OPTIMIZATION_<type> | [New] | [SETTINGS]

BEAD_CONTROLLER
User Manual 2 - 443
SIMULIA
Tosca Structure
Settings
Example of setting the SCALE parameter for controller based bead optimization:
7.8.1
Parameters for controller based bead optimization

The controller based bead optimization has be given numerous default settings (OPT_PARAM) that produce satisfactory results for various optimization
models. Usually, these default settings do not need to be changed by the
user. However, by specifically configuring the controller for a given optimization task, the controller response and consequently the optimization procedure can be improved. The user can set several optimization parameters
using the OPT_PARAM command and thereby influence the controller
response.
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BEAD_SENSITIVITY
Example of setting the FILTER_RADIUS parameter for sensitivity based
bead optimization:
SIMULIA
Tosca Structure
Bead Optimization
7.8.1.1 Scaling of displacements (SCALE)

BEAD_CONTROLLER
By default, the positive normal vector of the elements in the design domain is
used as an optimization displacement direction. This direction depends on
the orientation of the finite elements in the design domain.
To invert the displacement direction, a negative SCALE parameter can be
defined. Correspondingly, the absolute value of the optimization displacement
is then applied in the negative direction.
The value of the scaling parameter is not needed by Tosca Structure. Only
the sign is needed in order to determine direction.
OPT_PARAM
...
SCALE
...
= -1
END_
7.8.1.2 Update of optimization displacement vectors (VECTOR)

BEAD_CONTROLLER
As explained in vol.2 chapter 7.3, an optimization displacement vector is
determined by the optimization algorithm for every design node. This vector
graphically corresponds to the outer surface unit normal of the nodes and
indicates the optimization displacement direction. Restrictions influencing the
direction (DVCON_BEAD with CHECK_DOF and CHECK_BC) are included when
calculating the optimization displacement vectors. The VECTOR parameter
enables the user to specify the design cycle which determines the optimization displacement vectors:
OPT_PARAM
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...
VECTOR
...
= FIRST
END_
The optimization displacement direction of the start model is used in bead

optimization. As bead designed sheet metal structures are manufactured by a
deep drawing process generated undercuts would lead to a non-manufacturable design. This may be avoided by updating the optimization displacement
direction with each iteration (VECTOR = EVER).
7.8.1.3
Bead width (BEAD_WIDTH)

BEAD_CONTROLLER
A geometric parameter for the stiffeners is the bead width. The optimization
system automatically determines a bead width based on the element edge
length
and
the
thickness
of
the
shell
structure.
Default
User Manual 2 - 445
SIMULIA
Tosca Structure
Settings
BEAD_WIDTH=2*max(2*height_of_bead, 3.2*mean_edge_length) of the elements attached to design nodes. The user can define own values for the
bead width by the OPT_PARAM command.
Remarks
1. The value for the bead width is used for internal filtering. The generated
beads will not have the exact width specified by the user.
2. Because bead optimization is a very ill-posed optimization problem (many
"optimal" solutions), it is recommended that a couple of optimizations is
done with different BEAD_WIDTHs.
7.8.1.4 Number of iterations (BEAD_ITER)

BEAD_CONTROLLER
The number of iterations modifies the stepsize of the optimization. The number of recommended iterations is 2.
7.8.1.5 Penalty conditions (BEAD_MIN_STRESS and

BEAD_MAX_MEMBRANE)
BEAD_CONTROLLER
Two penalty functions are available in Tosca Structure.bead:
BEAD_MIN_STRESS
= <penalty_value>
BEAD_MAX_MEMBRANE = <penalty_value>
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The functions make sure that the areas that either have very low stresses or
a low bending/membrane stress ratio are disregarded by the optimization.
2 - 446 User Manual
SIMULIA
Tosca Structure
Bead Optimization
The BEAD_MIN_STRESS penalty value is the relative to the maximal Von

Mises stress in the design area. If a element has a lower Von Mises stress
than this value, the element is left out of the optimization.
Load
Load
Fig. 251 The penalized elements are dark blue. Left is the
BEAD_MIN_STRESS criteria used, and right is the
BEAD_MAX_MEMBRANE used.
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The BEAD_MAX_MEMBRANE is based on the ratio between the highest principal

of the two tensors, Differential Stress Tensor and Membrane Stress Tensor,
respectively. The Differential Stress Tensor is a mesure for the bending of a
plate whereas the Membrane Stress Tensor is a mesure for inplane stress.
Load
Load
Fig. 252 Left with no penalization criteria used and right with both.
User Manual 2 - 447
SIMULIA
Tosca Structure
Settings
Remarks
1. The default settings are:
BEAD_MIN_STRESS
= 0.001
BEAD_MAX_MEMBRANE = 1.0
This means that if an element has less than 0.1% of the Von Mises stress or
the membrane stress is higher than the bending stress, it will not be optimized.
2. Both penalty conditions can be shut of by setting the parameters to zero:
BEAD_MIN_STRESS
= 0.0
BEAD_MAX_MEMBRANE = 0.0
3. After optimization or after a run of the type TEST2 (vol.2 chapter 12.2.8),
the penalized areas can be visualized by generating a bead_ctrl vtfx-file
(vol.2 chapter 10.2). The penalized areas for BEAD_MAX_MEMBRANE and
BEAD_MIN_STRESS have the "Bead-values" -3 and -4, respectively in the
resulting bead_ctrl-plot.
7.8.1.6 Mesh enhancing parameters

(CURV_SMOOTH and BEAD_NODE_SMOOTH)
a)
b)
c)
Fig. 253 CURV_SMOOTH for values 1.0 (a), 5.0 (b) and 10.0 (c).
The node smoothing (BEAD_NODE_SMOOTH) ensures that the optimization
displacement of neighbouring nodes does not become too great. This is
especially an issue near boundaries or active design variable constraints.
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These two parameters control the filter radius of two mesh enhancing features in Tosca Structure.bead. It is recommended not to change these
parameters.
Curvature smoothing (CURV_SMOOTH) filters the optimization direction, so
that normals in areas with high curvature do not cross, which results in poor
or useless mesh. Default is 5.0, which means the filter size is 5 times the middle element edge length. In case of mesh problems try setting this value
higher, eg. CURV_SMOOTH = 10.0.
SIMULIA
Tosca Structure
Bead Optimization
Default is 0.25*BEAD_WIDTH. Values between 0.0*BEAD_WIDTH and

0.5*BEAD_WIDTH (entered as absolute values in mm) are allowed.
a)
b)
c)
Fig. 254 BEAD_NODE_SMOOTH for values 0.0*BEAD_WIDTH (a),

0.25*BEAD_WIDTH (b) and 0.49*BEAD_WIDTH (c).
7.8.2
Optimization parameters (sensitivity based bead

optimization)
BEAD_SENSITIVITY
The following is a description of different optimization parameters
(OPT_PARAM). It should not be necessary to change any for basic use.
7.8.2.1 Filtering (FILTER_RADIUS)

BEAD_SENSITIVITY
To avoid known problems of fluctuations in sensitivity values one should
define a filter radius:
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OPT_PARAM
...
FILTER_RADIUS = <filter_radius> , <unit_type>
END_
Default value is 4.0, REL. First item is the filter radius. Second option is
whether the radius is relative to the medium edge length of elements in the
design area (REL). Radius may also be set to an absolute value (ABS), fx. :
FILTER_RADIUS = 5.0, ABS
7.8.2.2 MMA parameters

The mathematical optimizer MMA is used to determine the new nodal positions. Following parameters may be set:
User Manual 2 - 449
SIMULIA
Tosca Structure
Settings
Move limit (NODAL_MOVE)

BEAD_SENSITIVITY
A move limit adjusts the change in the nodal coordinates per iteration. The
relative move limit of the nodal optimization displacement for each iteration is
set by the optimization parameter.
NODAL_MOVE = <REAL_VALUE>
Default value is NODAL_MOVE = 0.1. The value must be between 0.0 and
1.0. The absolute move limit is the maximum possible optimization displacement times NODAL_MOVE.
MMA asymptote update (NODAL_UPDATE)
BEAD_SENSITIVITY
The optimization parameter NODAL_UPDATE can be used to control the
update of asymptotes in MMA. The value of nodal update may be conservative (NODAL_UPDATE =CONS) which is default or normal
(NODAL_UPDATE =NORM).
Only advanced users should change this parameter.
Sensitivity calculation (ONLY_DES_NODES)
BEAD_SENSITIVITY
Tosca Structure.bead calculates sensitivities only for design nodes:
ONLY_DES_NODES = YES
In the opposite case (ONLY_DES_NODES = NO) Tosca Structure is forced to

calculate sensitivities for ALL_NODES which is not recommended.
Only advanced users should change this parameter.
7.8.2.3 Optimization parameters for mode tracking
MODETRACKING=<ON/OFF>, <NODE_GROUP>
MODENUMBERS =<NUMBER_MODES>
Mode tracking is activated by setting the optimization parameter MODETRACKING= ON. The second item on MODETRACKING can be used to with a
(small) node group which is used for the mode tracking which can improve
performance. Default by Tosca Structures mode tracking is to take 5 modes
into account, but this can be changed by the item MODENUMBERS =
<number_modes>. This should not be set too high because of computational
effort.
7.8.2.4 Optimization parameters for frequency response

BEAD_SENSITIVITY
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Mode tracking is controlled by two optimization parameters
SIMULIA
Tosca Structure
Bead Optimization
Following optimization parameters are only active by frequency response

models.
DAMP_STRUCTURAL_MASS =
<real>
! Structural mass
! damping
DAMP_STRUCTURAL_STIFF = <real> ! Structural stiffness

! damping
DAMP_VISCOUS_MASS = <real>
! Viscous mass
! damping
DAMP_VISCOUS_STIFF = <real>
! Viscous stiffness
! damping
SUM_Q_FACTOR = <real>
! Exponent to emphasize
! high values Q
All damping factors are zero and SUM_Q_FACTOR = 6 by default.
7.9
Check run (TEST_BEAD)

The test run in bead optimization is controlled by the TEST_BEAD command.
A test run is always based on a previously defined optimization job that is referenced in the OPTIMIZE command. The format information for postprocessing is specified with the parameter FORMAT. The name of the file, which the
postprocessing data is written into, is specified with the parameter
FILE_NAME. The test displacement in a specified direction (DIRECTION) is
applied in a number of increments (INCREMENT parameter) defined by the
user until reaching a specified maximum displacement (DISPLACEMENT
parameter). A typical TEST_BEAD command appears as follows:
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TEST_BEAD
OPTIMIZE
FORMAT
FILE_NAME
DIRECTION
DISPLACEMENT
INCREMENT
=
=
=
=
=
=
<name_of_optimize>
ONF
<name_of_output_file>
GROW
<value_of_max_displacement>
<number_of_increments>
END_
Remarks
1. If all information entered by the user is correct, the TEST_BEAD command
is executed immediately after it is entered. The command does not have its
own name with which it can be referenced, i.e. all command data is only
temporarily active during the execution of the command.
User Manual 2 - 451
SIMULIA
Tosca Structure
2. Referencing a previously defined optimization task (OPTIMIZE command)

is mandatory. The test displacements are applied to the design nodes of
the optimization job.
3. Specification of a format (FORMAT parameter) is mandatory. This can either
be FORMAT=ONF for the Tosca Structure specific optimization neutral
format to generate a vtfx sequence or FORMAT=VRML for vrml 2.0 output.
4. Specification of a file name (FILE_NAME parameter) is optional. By default
the file name TEST_BEAD is used. An increment number is always
attached to the file names (for example, 000, 001, 002 etc.) to enable identification of the results from the various increments.
5. Specification of a displacement direction (DIRECTION parameter) is
optional. The default setting is GROW. Two possibilities can be selected to
specify the displacement direction: uniform growth of all design nodes in
the optimization group outwards (DIRECTION=GROW) or non-uniform
randomly controlled displacement of the design nodes in the optimization
group (DIRECTION=RANDOM). For sensitivity based algorithm DIRECTION=SHRINK does also make sense.
6. Specification of the maximum absolute displacement (DISPLACEMENT
parameter) is optional. If no maximum absolute displacement is specified
by the user then a maximum absolute displacement depending upon the
FE mesh will automatically be determined.
8. If DIRECTION=RANDOM is selected, it is possible that the design node

with the maximum displacement will have a smaller absolute displacement
than specified in the DISPLACEMENT parameter. Here, the maximum specified displacement only represents an upper limit that does not need to be
achieved due to the randomly controlled distribution of the displacements.
Example:
The optimization task named bead_optimization should be subjected to a test
run. Patran neutral file format is the selected output format. The file names
have the name test_grow. In the growth direction five displacement increments should be applied with a maximum displacement of 1.5 length units,
i.e. the displacements are applied in increments of 0.0, 0.3, 0.6, 0.9, 1.2 and
1.5.
TEST_BEAD
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7. Specification of a number of increments (INCREMENT parameter) is

optional. The default value is INCREMENT=1. If the user specifies 5 increments, for example, 6 results files are generated, whereby the first result
file has the file extension 000 and represents the initial state.
SIMULIA
Tosca Structure
Bead Optimization
OPTIMIZE
FORMAT
FILE_NAME
DIRECTION
DISPLACEMENT
INCREMENT
=
=
=
=
=
=
bead_optimization
MSC/PATRAN
test_grow
GROW
1.5
5
END_

Example TEST_BEAD with 5 steps to show the maximal displacement of 5.0:
[New] |
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[TEST_BEAD_CHECK]
User Manual 2 - 453
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3. To view results directly afterwards use Tosca Structure Task |

CHECK_INPUTS | [New] | [VTF_VISUALIZATION]
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2.Tosca Structure Task | CHECK_INPUTS | TEST_BEAD_CHECK |

[New] | [TEST_BEAD]
SIMULIA
Tosca Structure
Bead Optimization

Change module to Start Tosca Structure. Choose Type test1 as run type
and Start Tosca Structure.
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7.10 Stop Condition

For most tasks it is not necessary to change the stop condition for bead optimization - especially not for BEAD_CONTROLLER because the main change is
done in the first iteration (although this is difficult to see for the user). The
default of 3 iterations for controller based algorithm should normally not be
changed.
For BEAD_SENSITIVITY the default NODAL_MOVE in OPT_PARAM is 10%
(0.10) of the maximal allowed nodal optimization displacement. This implies
that in most cases the maximum bead height should be reached in the 10th
iteration. Nevertheless, the sensitivity based algorithm usually improves the
design remarkably until the 20th iteration. Therefore, this value is the default
setting. For some difficult optimization problems where the convergence is
bad, a lower NODAL_MOVE can be chosen and it is necessary to use more
than 20 iterations.
Command syntax
Changing the maximum number of optimization steps to 30.
STOP
ID_NAME
ITER_MAX
= MY_STOP
= 30
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END_
User Manual 2 - 455
SIMULIA
Tosca Structure
Special Remarks Using Sensitivity Based Algorithm
Realization within Tosca ANSA environment

Tosca
Structure
Task
|
GLOBAL_STOP_CONDITION | [Edit]
PRE-PROCESSING
7.11 Special Remarks Using Sensitivity Based

Algorithm
BEAD_SENSITIVITY
The sensitivity based algorithm uses semi-analytical sensitivities based on a
finite difference of the stiffness and mass element matrices:
-----Kjk
K = K +
x
where
K0 + p K0
K = -------------------------x
Where K is the stiffness matrix, K 0 is the original matrix and K 0 + p is the perturbed matrix when one of the nodes is moved. The first term in the above
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Realization within Tosca Structure.gui
SIMULIA
Tosca Structure
Bead Optimization
equation is necessary to calculate the sensitivity for most of the design

responses that are available in Tosca Structure.bead. To get this term we utilize a "matrix-step" (see Fig. 255).
Fig. 255 Matrix step work flow

This matrix step's only purpose is to perturb all design nodes to get these pertubed matrices - the original matrix is obtained in the last perturbation (PERTURBATION = 0) where also the results of the FE-problem is wanted.
To avoid too long optimization run times it is important to understand this
workflow. It has two potential pitfalls which may slow the optimization tremendously:
1. Too long calculation during matrix steps
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2. Too many pseudo loads

1. The first case is discussed in more detail in the chapters concerning the
specific solvers, chapter 11 Solver Specific Features. But in short, the problem is that some solvers have no possibility of only writing the element matrices without solving the whole system. The number of matrix steps usually
varies between 4-8 which in worst case leads to 9 full solvers runs every iteration.
2. The second case is a mutual problem with almost every sensitivity based
optimization algorithm; using the adjoint method to calculate sensitivities one
has to solve the adjoint problems. The adjoint problems are added as
"pseudo loads" or extra load cases which are added to the original input deck.
The number of these pseudo loads depends on the types of design
responses and how they are defined.
It would demand a lengthy discussion to explain in detail exactly when and
why which loads are added but some rules of thumb is given here:
User Manual 2 - 457
SIMULIA
Tosca Structure
References
Compliance and eigenvalue optimization do not add pseudo loads (self

adjoint problems) and are therefore preferable optimization quantities.
Avoid the DRESPs without any direction (DISP_ABS, FS_DISP_ABS etc.).
These design responses lead to three pseudo loads (in all 3 dimensions)
whereas the single directional (DISP_X, DISP_X_ABS, FS_DISP_X_ABS,
etc.) only lead to one pseudo load.
Define the load case of interest directly in the DRESP definition using
LC_SET. If only one load case is referenced Tosca Structure will only add
one pseudo load. If LC_SET = ALL,ALL,ALL (which is default!) Tosca
Structure will add a pseudo load for each load case found in the original
input deck.
7.12 References
Barthelemy, B. and Haftka, R.T. (1988). Accuracy analysis of the semi-analytical method for shape sensitivity analysis. AIAA Paper 88-2284: Proc.
AIAA/ASME/-ASCE/ASC 29th Structures, Structural Dynamics
and Materials Conference. 1: 562-581. Also Mechanics of Structures and Machines.18:407-432 (1990).
Bletzinger, K.-U., Firl, M. and Daoud, F. (2006). Approximation of derivatives
in semi-analytical structural optimization. III ECCM Lisbon, Portugal.
June 5-8.
Clausen, P. and Pedersen, C.B.W. (2006): Non-parametric large scale structural optimization for industrial applications. III ECCM Lisbon, Portugal. June 5-8.
Emmrich, D. (2004): Entwicklung einer FEM-basierten Methode zur Gesaltung von Sicken fr biegebeanspruchte Leitsttzstrukturen im Konstruktionsprozess. Forschungsberichte
des
Instituts
fr
Produktentwicklung. 13. Karlsruhe
Svanberg, K. (1987). The Method of Moving Asymptotes -A New Method For
Structural Optimization. International Journal for Numerical
Methods in Engineering.24:359-373.
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Bletzinger, K.-U., Daoud, F. and Firl, M. (2006). Filter techniques in shape

optimization with cad-free parametrization. III ECCM Lisbon, Portugal.
June 5-8.
SIMULIA
Tosca Structure
Sizing Optimization
Sizing Optimization
Fig. 256 Sizing for chassis components
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8.1
General Information
less fixed.
areas.
User Manual 2 - 459
SIMULIA
Tosca Structure
eigenfrequencies;
weight, volume;
center of gravity;
moment of inertia.
Different constraints can be defined, like member size constraints, freezing of
parts, symmetry and different coupling constraints.
8.2

In Tosca Structure a sensitivity based approach is used for solving sizing
problems. This algorithm uses the sensitivities of the design variables with
regard to the objective function and the constraints. Tosca Structure uses an
algorithm based on the Method of Moving Asymptotes from Krister Svanberg
(Sweden). In one optimization run approximately 10 to 15 iterations are
required - much fewer compared to the sensitivity based approach for topology optimization. The number of iterations as well as the CPU-time is independent of he number of shell element thicknesses chosen as design
variables.
Tosca Structure.sizing supports the responses of linear static (non-conservative forces) and linear eigenfrequency (not allowed to be prestressed) finite
element analysis. Temperature loading is allowed for Abaqus and ANSYS.
Non-linearities
Tosca Structure.sizing supports contact for Abaqus and ANSYS.Furthermore,
prescribed displacements are allowed in the CAE model for static sizing optimization. However, prescribed displacements are not allowed for modal and
frequency response analysis.
Model
Tosca Structure.sizing supports only single layered shells (admitted for sensitivity based opimization). For specific aspects regarding supported element
types please refer to chapter 11 Solver Specific Features. Contact for Abaqus
and ANSYS is supported in and outside the design area.
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Analysis types
SIMULIA
Tosca Structure
Sizing Optimization
Outside the design area all sorts of constitutive non-linear modeling is

allowed, e.g. a non-linear spring. In the design area constitutive non-linear
material is not supported. Geometrical non-linearities are not supported.
Further, constant temperature loading is supported.
Allowed objective functions and constraints
For sizing a variety of combinations of objective functions and constraints can
be selected
Static load cases:
Stiffness (= compliance)
Displacements
Forces
Modal eigenfrequency load cases:
Eigenfrequencies
Frequency response
Also vibroacoustic
Mass
Several constraints and several terms for the objective function for an arbitrary number of load cases can be specified.
8.2.1
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The following describes the general procedure for defining an optimization

task. These procedures are supported by the command tree in Tosca Structure.pre screen of Tosca Structure.gui (GUI), but they are not supported by
Tosca ANSA environment yet. For more information about Tosca Structure.gui see vol.1 chapter 2.1.2. The CAE analysis model must previously be
completely defined.
Analysis Model
GUI: Choose your model file in FEM_INPUT.
Design Area
2. Question: Which part of the FE model should be selected as the design
space?
Procedure: Assign an element group to the design area.
GUI: Choose or define the element group for the selected design area
(GROUP_DEF) and define the design variables (DV_SIZING).
User Manual 2 - 461
SIMULIA
Tosca Structure
3. Question: Are there elements in the design space which have to have
certain restrictions (e.g. symmetry and manufacturing restrictions)? How
can these restrictions be described?
Procedure: Define design variable constraints for element group.
GUI: Choose or define element groups with restrictions (GROUP_DEF).
Define the restrictions using DVCON_SIZING command.
GUI: Create a LINK_SIZING condition and reference it in the restriction
command (LINK_SIZING).
Objective Function
values be minimized or maximized or otherwise combined using the
minmax formulation? Are any special weighting factors or target values
required?
Procedure: Choose the terms for optimization (design responses) and the
target type.
GUI: Define the design response (DRESP) and assign it to the objective
function (OBJ_FUNC).
Constraint
Optimization Task
Procedure: If necessary, make the additional definitions and prepare the
optimization job.
Stop Condition
8. Question: Should the stop condition be modified?
Procedure: Modify stop condition
GUI: STOP.
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6. Question: Which terms describe the constraint? What value should the
constraint have?
Procedure: Choose the term for the constraint and set the target value or
upper/lower boundary.
constraint (CONSTRAINT).
SIMULIA
Tosca Structure
Sizing Optimization
Completion
9. Question: Is all required data specified?
GUI: Save as <jobname>.par
The essential commands required for the optimization model for sizing are
described in the following.
Fig. 257 Block structure of sizing commands
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8.3
Design Area
8.3.1
Design variables
For each optimization problem, the design variables represent the values to
be changed during the optimization. The elemental thicknesses of shell elemenents are the design variables for the sizing optimization in Tosca Structure.
User Manual 2 - 463
SIMULIA
Tosca Structure
Design Area
The thicknesses change during the optimization in order to fulfill the optimization goals.
Fig. 258 Design variables for sizing
Valid design elements are the most typical shell elements. The list of valid
element types for sizing is given in vol.2 chapter 11, Solver Specific Features
for the different FE solvers.
Design variable definition in Tosca ANSA environment
Fig. 259 DV_SIZING definition in the Tosca ANSA environment
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In order to choose the design element group, the command Edit should be
applied on the item DESIGN_AREA. Then, pressing "?" key in GROUP_DEF
field (after the field EL_GROUP is set to GROUP_DEF) opens the window SET
HELP where all existing groups are listed; if needed, a new element group
can be created by using New command of this window.
SIMULIA
Tosca Structure
Sizing Optimization
Design variable definition in Tosca Structure.gui

The DV_SIZING command is used to assign a previously defined element
group to be the design element group for the sizing optimization. The element
group has to be a group of elements which are allowed as design elements
for the sizing optimization.
Fig. 260 DV_SIZING definition in Tosca Structure.gui

The resulting command is the DV_SIZING command. For further details
please refer to DV_SIZING in the command manual.
DV_SIZING
ID_NAME
EL_GROUP
= dv_design_elem
= design_elem
END_
8.3.2
Manufacturing conditions and geometrical restrictions

For sizing with Tosca Structure, it is possible to define constraints
(DVCON_SIZING) that have a direct influence on the individual design variables(DV_SIZING). This allows the manufacturing restrictions or geometrical
design aspects to be taken into consideration in the sizing optimization. The
different restrictions are listed below:
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Frozen area
Element fixing by exclusion from the optimization group.
Element fixing by freezing elements (CHECK_TYPE = FROZEN).
Shell thickness control
Upper and lower bounds for shell thicknesses (CHECK_TYPE =
THICKNESS_BOUNDS).
Clustering of element areas with the same shell thickness
(CHECK_TYPE = CLUSTER)
Symmetry control
Area linking (LINK_SIZING)
Symmetry restriction(LINK_SIZING)
User Manual 2 - 465
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Tosca Structure
Design Area
Member size control

minimum cluster width control (CHECK_TYPE =
MIN_CLUSTER_WIDTH)

Sometimes it is required to maintain material in certain parts of the design
area, such that they remain unchanged in the optimized model. Element
groups describing these parts can be defined as frozen area. This option is
used to exclude the so-called frozen elements from being modified during the
optimization, even though these elements are included in the design space.
This is the case, e.g., when the elements are used in order to fix the component and therefore should be preserved independently of their internal loads.
The inclusion into the design space may be necessary, e.g., to control the target volume (see constraints absolute volume or relative volume, Bd.1,
Chapter 5.5.1).
Defining a frozen area in Tosca ANSA environment
Fig. 261 Workflow for the definition of FROZEN_AREA

Defining a frozen area in Tosca Structure.gui
The DVCON_SIZING command has to be selected in Tosca Structure.pre
screen when defining the design variable constraints. The name of the element group that is to be frozen follows after the obligatory ID_NAME field. If
the element group is not already defined, it is necessary to define it in
advance using GROUP_DEF command.
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Manufacturing constraints are defined using DV_CONSTRAINTS item. Each of

these restrictions relates to an element group that is either the design area or
a subset of it. For the definition of the frozen area, only an element group is
necessary. No further properties have to be set.
SIMULIA
Tosca Structure
Sizing Optimization
Choose Type = Frozen.
Fig. 262 Definition of a FROZEN design variable constraint for an existing

element group
DVCON_SIZING
ID_NAME
EL_GROUP
CHECK_TYPE
= frozen_area
= frozen_grp
= FROZEN
END_

Shell thicknesses can be controlled to vary between a lower or upper bound

(CHECK_TYPE = THICKNESS_BOUNDS). For the definition of the thickness
bounds, either an absolute or relative value for the upper and lower bound
can be defined. In case of relative bounds a real number is specified for each
bound which is multiplied with the initial value for the shell thickness to get the
absolute upper and lower bounds.
The parameter MAGNITUDE defines if the lower and upper bound are
defined as absolute or relative values.
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8.3.2.2 Shell thickness bounds
User Manual 2 - 467
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Tosca Structure
Design Area
Defining a thickness bound in Tosca ANSA environment

Thickness bounds are defined using DV_CONSTRAINTS item. The restriction
relates to an element group that is either the design area or a subset of it.
Fig. 263 Workflow for the definition of THICKNESS_BOUNDS

Defining thickness bounds in Tosca Structure.gui
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screen when defining the design variable constraints. Choose your element
group for the thickness bounds below the obligatory ID_NAME field. If the element group is not already defined, it is necessary to define it in advance using
GROUP_DEF command.
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Sizing Optimization
Choose Type = Thickness_bounds and define a relative (REL) or absolute

(ABS) upper and lower value..
Fig. 264 Definition of thickness bounds for an existing element group

DVCON_SIZING
ID_NAME
EL_GROUP
CHECK_TYPE
MAGNITUDE
LOWER_BOUND
UPPER_BOUND
=
=
=
=
=
=
dvcon_thickness_bounds
my_group
THICKNESS_BOUNDS
REL/ABS
END_
8.3.2.3 Cluster groups

Shell thicknesses can be clustered to remain the same in certain areas during
the optimization (CHECK_TYPE = CLUSTER_GROUPS). Clustering reduces
the number of design variables (without influence on calculation time).
Defining cluster groups in Tosca ANSA environment
Cluster groups are defined using DV_CONSTRAINTS item. Each of these
restrictions relates to an element group that is either the design area or a sub-
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User Manual 2 - 469
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Tosca Structure
Design Area
set of it. For the definition of the frozen area, only an element group is necessary. No further properties have to be set.
Fig. 265 Workflow for the definition of Cluster groups

Defining cluster groups in Tosca Structure.gui
Fig. 266 Definition of a design variable constraint to "cluster" shell thicknesses of an existing element group
DVCON_SIZING
ID_NAME
EL_GROUP
EL_GROUP
EL_GROUP
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=
=
=
=
cluster_area
cluster_grp_1
cluster_grp_2
cluster_grp_3
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screen when defining the design variable constraints. Choose your cluster
groups below the obligatory ID_NAME field. If the element group is not
already defined, it is necessary to define it in advance using GROUP_DEF
command.
Choose Type = Cluster Groups.
SIMULIA
Tosca Structure
Sizing Optimization
...
CHECK_TYPE
= CLUSTER_GROUPS
END_
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In general clustering areas correspond to areas made from one sheet metal.
Nevertheless performing the optimization without clustering may give you
ideas where to construct borders between (i.e. where to combine or cut) your
single sheets.
Fig. 267 Example with free sizing optimization and clustering (below) for
certain (approx. 200) areas.
8.3.2.4 Width control (minimum cluster width)

Small sheet parts in the resulting structure are often undesirable. Defining a
minimum sheet width (minimum cluster width) avoids the creation of small
substructures in the final result. The minimum cluster width is often applied
User Manual 2 - 471
SIMULIA
Tosca Structure
Design Area
for avoiding high oscillations in the thickness distribution and that the structure has subcomponents with a minimum width.
Additionally, the minimum cluster width for the width control can partly circumvent the two following problems:
1. First, checkerboards might appear if one is applying a minimal value of the
lower bound of the thickness and applying lower order shell elements as 3
node triangular shell elements. When using higher order shell elements or
the lower bound of the thickness is not minimal then checkerboards are not
frequent.
2. Secondly, a minimum cluster width ensures uniqueness of the optimization
solution independent upon the mesh size and discretization. A coarse
mesh and a fine mesh lead to the same optimized structure if the minimum
cluster widths for both cases are set to the same absolute size. Please
note that the size in both cases should be larger than the average element
edge length.
Fig. 268 minimum cluster width for sheet structures

Remark
1. Note, thin sheet thickness is controlled by lower and upper bound settings
and not by the filter which controls the width.
Defining a minimum cluster width in Tosca ANSA environment
Fig. 269 Minimum cluster width restriction
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For the definition of the minimum cluster width, the element group and the
desired minimum width should be entered in CLUSTER_WIDTH dialog.
SIMULIA
Tosca Structure
Sizing Optimization
Defining a minimum cluster width in Tosca Structure.gui
Fig. 270 Minimum cluster width definition

The minimum cluster width is defined using the DVCON_SIZING command:
DVCON_SIZING
ID_NAME
EL_GROUP
CHECK_TYPE
WIDTH
thickness>
=
=
=
=

MIN_CLUSTER_WIDTH
<minimum width of areas of same shell
END_
8.3.2.5 Definition of symmetry conditions

Different symmetry conditions can be defined for an optimization in Tosca
Structure. They can be used for obtaining symmetrical results using non-symmetrical meshes, saving the processing time for the FE-calculation. Furthermore, symmetrical load cases can often be reduced in the FE model.
The following symmetry conditions are available with Tosca Structure:
reflection symmetry
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point symmetry
rotational symmetry
cyclic translational symmetry (replication of an area with a given distance)
link condition (coupling of arbitrary areas of the model)
User Manual 2 - 473
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Tosca Structure
Design Area
Fig. 272 Example of rotational symmetry (left) and cyclic translational

symmetry (right)
Defining the symmetry condition in Tosca ANSA environment
is
defined
using
DV_CONSTRAINTS
Fig. 273 Workflow for definition of a symmetry condition

The following settings should be entered in the dialog SYMMETRY_CONTROL
in order to define a symmetry condition:
1. Reflection symmetry (TYPE = PLANE_SYM): the symmetry plane is identified by a point (ORIGIN_1..ORIGIN_3) and the normal direction
(DIRECTION_1..DIRECTION_3).
2. Rotation symmetry (TYPE = ROTATION_SYM): the rotation axis is defined
by a point (ORIGIN_1..ORIGIN_3) and the direction
(DIRECTION_1..DIRECTION_3); the field ANGLE is the rotation angle.
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A symmetry condition
SYMMETRY_CONTROL.
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Sizing Optimization
3. Cyclic symmetry (TYPE = CYCLIC_SYM): the translation direction is

defined by a point (ORIGIN_1..ORIGIN_3) and the direction
(DIRECTION_1..DIRECTION_3); the field TRANSLATION is the translation distance. Note that although the origin has no influence, it should be
specified because Tosca Structure requires that the direction is an axis of a
coordinate system. In this case, this coordinate system is created automatically by Tosca ANSA environment.
In each case, EL_GROUP is the element group that the symmetry condition
applies to.
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Defining the symmetry condition in Tosca Structure.gui
Fig. 274 Symmetry definition using LINK_SIZING and DVCON_SIZING

Symmetries are defined with the command LINK_SIZING and are applied to
an element group using the DVCON_SIZING command. The LINK_SIZING
command is used to define the type of symmetry, the coordinate system and,
if necessary, the rotation angle (in case of rotation symmetry) or the translation distance (in case of cyclic symmetry). The symmetry definition can also
be extended to frozen areas by selecting the corresponding checkbox.
User Manual 2 - 475
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Tosca Structure
Design Area
The frozen elements of one area are also considered as frozen for the linked
areas if Frozen checkbox is checked.
LINK_SIZING
ID_NAME
CS
TYPE
TRANSLATION
ANGLE
= <Name of LINK_SIZING object>

= <Name of the reference coordinate
system>
= <Type of symmetry>, <axis>
= <Translation for cyclic symmetry>
= <Segment angle for rotation symmetry>
END_
DVCON_SIZING
ID_NAME
EL_GROUP
CHECK_TYPE
CHECK_LINK
=
=
=
=
<Name of DVCON_SIZING object>

LINK_SIZING
<Name of LINK_SIZING definition>
END_
More than one symmetry condition can be defined for an element group.
Geometrically, different combinations have to be feasible.
Remark
1. The FE meshes do not have to be symmetric. The restriction can also be
applied to unstructured meshes or to tetrahedron meshes. The elements
should have nearly the same size because the result is the resolution of the
coarsest part of the mesh. It is possible that the linked elements are not
determined correctly if the size of the elements differs too much.
1. The element group for a certain restriction should be a subset of the design
element group. If this is not the case, Tosca Structure will stop the optimization.
2. The DVCON_TOPO ID_NAME has to be referenced in the OPTIMIZE
command in order to activate the restriction. In Tosca ANSA environment
all commands which are not disabled in the task manager are added automatically to the optimization task. In Tosca Structure.gui the DVCON_TOPO
entry has to be activated in the OPTIMIZE mask.
OPTIMIZE
...
DVCON
...
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= name_of_dvcon_entry
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8.3.2.6 Tips on defining restrictions
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Sizing Optimization
END_
3. Each geometrical restriction reduces the possibilities of the solution. Thus,

it is necessary to add only the restrictions needed for solving the problem.
It is still possible to find a solution if too many restrictions are defined, but
the result will most probably be suboptimal compared to the optimal
design. Therefore, the first step for the user is to perform an optimization
without restrictions to obtain knowledge about the restrictions needed for
the specific problem.
- It is not possible to combine all manufacturing constraints at random. The
user has to be careful when combining conflicting restrictions.
8.4
Objective Function
minimized.
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8.4.1
Overview
the FE analysis. Therefore, the values of interest must be derived from the FE
results in order to define an objective function and functional constraints. The
results of the FE analysis (total displacement, energy, etc.) for determining
the objective function and functional constraints are called design
responses. A single value from the design response must be specified for the
definition of the objective function using the command DRESP (DESIGN
RESPONSE). For details about design responses refer to chapter 4.4 Design
Responses. General comments about the definition of objective functions can
be found in chapter 4.2 Objective Function.
8.4.2
Minimization or maximization of an objective

The following tables describe which design response types are valid as the
terms of an objective function that is to be minimized or maximized:
User Manual 2 - 477
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Objective Function

objective

for objective
for objective
+C k
+ ( V V )
+f k

--- ln
k

for objective
j = 1 e
+R i
+F i
+ i
+M i
+M i
+ R i
2
Internal force terms for

objective
+u i
+ u i
kf j
+ F i
2
+ u x + u y + u z
+ R x + R y + R z
+ F x + F y + F z
+ ( u i ,1 u i ,2 )
+ ( R i ,1 R i ,2 )
+ ( F i ,1 F i ,2 )
+ ( u i ,1 u i ,2 )
+ ( R i ,1 R i ,2 )
+ ( F i ,1 F i ,2 )
Center of gravity
terms for objective
Moment of inertia
terms for objective
+i i
+I ij
In this table, the indices i and j indicate a direction of an axis (x, y or z) of the
global or a local coordinate system. The compliance, eigenfrequencies, displacements and forces can be based upon results from different load cases.
The reference values marked with "*" are defined in DRESP parameter of
OBJ_FUNC command. By default, the reference values are zero. The reference values can be set individually for each term in the objective function.
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objective
SIMULIA
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Sizing Optimization
The weight factors are defined by the user in DRESP parameter of

OBJ_FUNC command. The weight factors are set individually for each term of
the objective function. By default, the weight factors are set to 1.
In the example below, the weight factor is set to 1.5 and the reference value is
set to 4.0:
OBJ_FUNC
...
DRESP
...
= id_dresp, 1.5, 4.0
END_
Remarks
1. A minimization optimization task can be converted into a maximization optimization task (or vice versa) by changing the sign of the weighting factors
in the definition of the objective function.
8.4.3
Multidisciplinary objective (minmax formulation)

The following tables describe which terms and response types are valid in the
Min-Max formulation

in Min-Max
in Min-Max
( C k C k )
( V V )
1
-----------------
fk fk
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Compliance terms in
Min-Max
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Objective Function
Displacement terms in Min-Max
Reaction force terms in Min-Max
( u i u i )
( )
( R i R i )
(M M )
( u i u i )
( R i R i )
( u x + u y + u z u )
((u u ) u )
( R x + R y + R z R )
((R R ) R )
( ( u i , 1 u i , 2 ) u i )
2
( ( R i ,1 R i ,2 ) R i )
i ,1
i ,2
i ,1
i ,2
Center of gravity
terms in Min-Max
Moment of inertia
terms in Min-Max
i C i C
I ij I ij
where the index i and j are indicating one of the x-y-z-directions. The compliance, eigenfrequencies, displacements and reaction forces can be from different load cases.
The REFERENCE values marked with the star "*" are defined by the use in
the DRESP command in OBJ_FUNC. Normally, the reference values are zero.
Hence, by default all reference values are set to zero. The reference can be
set individually for each term in the objective function.
The WEIGHT factors are defined by the user in the DRESP command in
OBJ_FUNC. The weight factors can be different for each individual term in the
objective function. By default the weighting factors are all set to one. Hence,
by default all weighting factors are set to one.
The reference value and weight factor can be changed, e.g. to 2.5 and 14.0
for response id_dresp in the following way:
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OBJ_FUNC
...
DRESP
...
= id_dresp, 2.5, 14.0
END_
The main difference between the scheme in vol.2 chapter 8.4.2 and the present scheme is the way the frequency terms are defined in the objective.
8.5
Constraints
Constraints are fundamental parts of the definition for an optimization task,
see also chapter 4.3 Constraints. The purpose of having constraints is to
ensure that the optimized design is feasible. The following two tables
describe which design response types are valid as constraints. These design
responses can be constrained using lower equal constraint or greater equal
constraint as explained in chapter 4.3 Constraints. Moreover, new combinations using VAR_OPER or GROUP_OPER for the DRESP can also be
applied in the constraints as described in chapter 4.3 Constraints:

constraints

for constraints
C k C k
V V
[ V V ]
[ C l C l ]
for constraints
f k f k
f l f l
[ f k f l f ]
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f k f l f
User Manual 2 - 481
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Constraints

constraints

for constraints
Internal force terms

for constraints
u i u i
R i R i
F i F i
u i u i
R i R i
F i F i
i i
M i M i
M i M i
i i
M i M i
M i M i
2
u i u i
R i R i
2
F i F i
2
[ u i u i ]
[ R i R i ]
[ F i F i ]
u x + u y + u z u
2
R x + R y + R z R
2
F x + F y + F z F
2
[ u x + u y + u z u ]
2
2
2
2
2
2
[ R x + R y + R z R ] [ F x + F y + F z F ]
u i ,1 u i ,2 u i
R i ,1 R i ,2 R i
F i ,1 F i ,2 F i
u i ,1 u i ,2 u i
R i ,1 R i ,2 R i
F i ,1 F i ,2 F i
( u i ,1 u i ,2 ) u i
2
[ ( u i ,1 u i ,2 ) u i ]
2
( R i ,1 R i ,2 ) R i
2
( F i ,1 F i ,2 ) F i
2
[ ( R i ,1 R i ,2 ) R i ] [ ( F i ,1 F i ,2 ) F i ]
2
i ,1 u i ,1 + i ,2 u i ,2 + u i
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Center of gravity
terms for
constraints
Moment of inertia
terms for
constraints
i i i i
I ij I ij
i i i i
I ij I ij
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i ,1 u i ,1 + i ,2 u i ,2 + u i
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Sizing Optimization
8.6

This section deals with the typical tasks fr linear static analysis types. Only
some very common tasks are described here.
8.6.1
Minimizing mass with stiffness restrictionst

If the structure with the minimal volume (mass) subject to displacement constraints (corresponding to a restriction on the mechanical stiffness) is sought,
the optimization task is formulated as follows:
min Vol
i = 1, n
u j u restrict,j
j =1...m
where Vol is the relative material volume of an element in the design area, u j
is the nodal displacement and u restrict ,j is the restriction for the nodal displacement of the node j.
A model for the minimization of the relative material volume under the displacement of the loaded nodes is presented in the example below
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The following figures show different load cases with its constraints and the
corresponding formular. The amplitude of the distortion is defined by two variables: u1 and u2 gives the displacement at the two pints where the load is
User Manual 2 - 483
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applied. The indices x and z are directions in local or global coordinate systems.
Bending stiffness
u z, 2 + u z, 1
arg et
------------------------- u tbending
2
u z, 2 u z, 1
arg et
------------------------- u ttorsional
2
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Torsional stiffness
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Sizing Optimization
Axial stiffness
u x, 2 + u x, 1
arg et
-------------------------- u taxial
2
Two design responses are needed:
2. The second design response is the displacement of the loaded node. The
absolute displacement is used in this case. Alternatively, the displacement
in the direction of the load (in the example it is Z- or X-direction of a local
coordinate system) can be used. The restriction to one direction reduces
the number of load cases generated by the optimization system because
using absolute displacement leads to the need of 3 additional load cases in
order to calculate the sensitivities while the displacement in Z-direction only
requires one additional pseudo-load case for the calculation of the sensitivities. The constraint is then defined as an inequality constraint with an
absolute value for the displacement value.
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1. The first design response is the design response representing the relative
material volume of the design area. This design response is the objective
function that is to be minimized.
User Manual 2 - 485
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less mass for

same stiffness
Iterations
Fig. 275 Objective function: Minimize mass (mass normalized)
Bending
Axial
Torsional
Iterations
In Fig. 275 you can see the gradient of the normalized mass about 15 Iterations. In this example the reduction amounts about 15%. Illustrated in Fig.
276 are the gradients of the normalized three stiffness constraints for the
three loadcases (bending, axial and torsional). What you can see is, that they
are fullfilled.
8.7

Analysis
Often the design target is to increase the first eigenfrequencies in an eigenfrequency spectrum. It is important to consider more than the first natural
eigenfrequency as illustrated in Fig. 277 (b) when increasing the natural fre-
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Fig. 276 Constraints: Stiffness restrictions (normalized)
SIMULIA
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quencies using optimization. Otherwise, the first and secondary mode might
switch during the optimization as shown in Fig. 277 (a).
For some optimization problems it can be desirable that a sudden eignefrequency is increased whereas the other eigenfrequencies are allowed to
decrease as shown in Fig. 277 (a).
In chapter 8.7.1 Maximization of the first eigenfrequencies is described how
several lowest eigenfrequencies are increased (Fig. 277 (b)) and chapter
8.7.2 Maximizing the torsional modal eigenfrequency addresses how a specific eigenfrequency in an eigenfrequency spectrum is optimized using mode
tracking (Fig. 277 (a)).
In chapter 5.7.4 Constraining an eigenfrequency is shown how an eigenfrequency can be applied in a constraint, e.g. when maximizing the stiffness
under the condition that the first eigenfrequency is above 100 Hz or when
minimizing the mass under the condition that the eigenfrequencies are be
below or above certain specified values.
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Fig. 277 Optimizing all the lowest eigenfrequencies using the Kreisselmaier-Steinhauser formulation (b) and the single lowest eigenfrequency using mode tracking (a)
8.7.1

The following shows how several lowest eigenfrequencies are increased.
It is important to consider more than the first natural eigenfrequency as illustrated in Fig. 277 (b) when increasing the natural frequencies using optimization. At least the next two first natural frequencies should be considered in the
optimization.
All natural eigenfrequencies requested in the FE model are applied in the
optimization if ALL option is applied in the LC_SET parameter.
During the optimization, the various natural frequencies are automatically
weighted by their distance from the lowest natural frequency, i.e., when the
other natural frequencies approach the first natural frequency during the optimization, the more they will be weighted. Generally, the first natural frequency
is always maximized.
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The design response is defined using the Kreisselmaier-Steinhauser formulation as described in chapter 4.4.6 Eigenfrequency.
Any number of natural frequencies in the design response can be specified
using the DRESP command.
The optimization task is to maximize the lowest modal eigenfrequencies with
a volume constraint of 100%.
Model:
f=20.4Hz:
f=25.8Hz:
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f=22.1Hz:
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f=26.4Hz:
f=30.6Hz:
f=35.0Hz:
Fig. 278 Modal eigenfrequencies and corresponding eigenmodes
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In Fig. 278 you can see the model and the first six modal eigenfrequencies.
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Higher Eigenfrequency
Iterations
Fig. 279 Objective function: Maximize eigenfrequencies
Fig. 280 Constraint: Mass (normalized)

Illustrated in Fig. 279 is the gradient of three eigenfrequencies over 15 iterations and in Fig. 280 that the mass constraint is fullfilled.
In this example, all calculated natural frequencies are considered for the
objective function using the Kreisselmaier-Steinhauser formulation, and the
definition is as follows:
DRESP
ID_NAME = all_lowest_eigenfrequencies
DEF_TYPE = SYSTEM
LC_SET = MODAL, ALL, ALL
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Iterations
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END_
OBJ_FUNC
ID_NAME = maximize_eigenfrequencies
DRESP = all_lowest_eigenfrequencies
TARGET = MAX
END_
If one has requested 10 eigenfrequencies in the finite element input model

but only the first 5 eigenfrequencies are to be used in the optimization definition, then the design response for 5 eigenfrequencies is defined as follows:
DRESP
ID_NAME = all_lowest_eigenfrequencies_1_5
DEF_TYPE = SYSTEM
LC_SET = MODAL, ALL, 1-5
END_
OBJ_FUNC
ID_NAME = maximize_eigenfrequencies_1_5
DRESP = all_lowest_eigenfrequencies_1_5
TARGET = MAX
END_
8.7.2
Maximizing the torsional modal eigenfrequency

The optimization task is to maximize the second torsional modal eigenfrequency with a volume constraint of 100% and without any boundaries.
Model:
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Often it is needed to increase a specific eigenfrequency in the eigenfrequency spectrum belonging to a certain eigenmode as illustrated in Fig. 277
(a). In this case, a specific eigenfrequency is defined using TYPE =
DYN_FREQ, see also chapter 4.4.6 Eigenfrequency.
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f=21.6Hz:
f=25.8Hz(has to be maximized):
f=29.6Hz:
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f=36.3Hz:
f=37.5Hz:
Fig. 281 Modal eigenfrequencies and corresponding eigenmodes
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In Fig. 281 you can see the model and the first six modal eigenfrequencies.
User Manual 2 - 493
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Results
Higher original 2nd eigenfrequency

Iterations
Fig. 282 Objective function: Maximize torsional eigenfrequency: the original mode 2 is now mode 4
When optimizing a specific eigenfrequency, the order of the eigenfrequencies
might change during the optimization iterations as shown in Fig. 277 (b).
Consequently, the eigenfrequencies might have to be tracked during the optimization iterations.
The tracking is done using mode tracking as described in chapter 4.4.6.2
Mode tracking and chapter 8.8.1 Mode tracking.
By default the modes are not tracked during the optimization. Mode tracking
is activated in OPT_PARAM command:
ID_NAME = 2nd_lowest_eigenfrequency_1
DEF_TYPE = SYSTEM
TYPE = DYN_FREQ
END_
OBJ_FUNC
ID_NAME = maximize_single_eigenfrequency
DRESP = 2nd_lowest_eigenfrequency_1
TARGET = MAX
END_
OPT_PARAM
ID_NAME = opt_params
OPTIMIZE = maximize_single_eigenfrequency
MODETRACKING = ON
MODENUMBERS = 8
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DRESP
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END_
For this example, at least 8 eigenfrequencies should be requested in the finite

element input model defined by the user.
8.8
Settings
Different settings can be made to control speed and convergence behaviour
of the sizing optimization algorithms. Default values are available which have
been tried and tested on many occasions.
Other algorithm settings for the various optimization algorithms can be
selected using the OPT_PARAM command.
8.8.1
Mode tracking
It is possible to apply a simple mode tracking function for the modal analysis
using the modal assurance criterion (MAC) including a mass weighting.
The modes of the different eigenfrequencies are compared in the modal
assurance criterion (MAC) for identifying if the eigenfrequencies from optimization iteration to optimization iteration have been switching yielding
2
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MAC i ,j
( { } i [ Mass ] { initial } j )
= ---------------------------------------------------------------------------------------------------------------------( { } i [ Mass ] { } i ) ( { initial } j [ Mass ] { initial } j )
where the initial modes are equal to the modes of the first iteration. The
modes in the first optimization iteration are used for identifying the eigenfrequencies through the optimization iterations. The MAC matrix is equal to the
unity matrix if the initial modes are equal to the modes in a given optimization
iteration. However, this is only the case in the first optimization iteration due to
the optimization changes. The largest components of the MAC matrix are
determined in each optimization iteration for determining if any mode switching should be present. If significant off-diagonal terms exist in the MAC matrix,
it indicates that the mode switching is present. The MAC matrix is printed in
the TOSCA.OUT file. Then the user can see how close to 1 the components
of the MAC matrix are and whether mode switching is present. If all the values in the MAC matrix are significantly below 1, it indicates that the applied
mode set does not contain enough modes for mode tracking.
According to the above equation, mode tracking can lead to a significant
increase in CPU-time. First, all modes of the eigenfrequencies have to be
cross-checked with each other. Sometimes a high number of cross-checks is
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Settings
required. Second, more eigenfrequencies have to be calculated by the finite

element solver.
Mode tracking is defined in OPT_PARAM command as in the example below:
OPT_PARAM
ID_NAME
OPTIMIZE
MODETRACKING
MODENUMBERS
=
=
=
=
opt_params
id_of_optimize
ON
15
Setting the command MODETRACKING equal to ON activates the mode tracking. Default for MODETRACKING is OFF. Consequently, mode tracking will
only be applied if the user requests mode tracking. The value of MODENUMBERS specifies how many eigenfrequencies should be used in the mode
tracking. The default value of mode tracking is 5. In the above example,
MODENUMBERS is set to 15 meaning that 15 eigenfrequencies will be used
for the mode tracking. If, e.g., one maximizes the first eigenfrequency, this
eigenfrequency will be compared to the 15 specified eigenfrequencies in the
MODETRACKING command. It is important that the modal analysis file specified by the user also leads to an analysis having the same or more eigenfrequencies than specified in the MODENUMBERS parameter. For this example,
the user should specify at least 15 eigenfrequencies in the finite element file.
Sometimes it happens that many local modes having a low eigenfrequency
appear during the optimization iterations. Normally, this will lead to high number for MODENUMBERS which is not desirable because of high CPU-time.
However, this can be partly circumvented by setting a number in the input
finite element file avoiding the lower eigenfrequencies to be calculated. E.g.,
if it is known that the initial eigenfrequency is around 200 Hz, then it should be
specified in the finite element input file that the eigenfrequencies over 50 Hz
only are to be calculated.
To improve the performance, it is additionally possible to restrict mode tracking to a certain group of nodes in the model (e.g., every fifth node on the surface of the model) or nodes where lumped and rigid masses are attached. In
this case, the node group is referenced in the MODETRACKING parameter
as follows:
OPT_PARAM
ID_NAME
OPTIMIZE
MODETRACKING
MODENUMBERS
END_
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=
=
=
=
opt_params
id_of_optimize
ON, node_group
15
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END_
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When a node group is applied in the mode tracking, then the modal assurance criterion (MAC) yields
2
MAC i ,j
( { } i { initial } j )
= -------------------------------------------------------------------------------( { } i { } i ) ( { initial } j { initial } j )
where the modes are not scaled with the mass. Therefore, the nodes of the
applied group are often chosen to be the nodes of frozen elements, lumped
or rigid masses.
Remarks
1. The finite element input file specified by the user should contain a modal
analysis containing at least as many eigenfrequencies as the value of
MODENUMBERS parameter.
2. A general rule for keeping the MODENUMBERS low and thereby saving
CPU-time is to specify a lower bound for the calculated eigenfrequencies in
the finite element file. Choosing 25% of the expected eigenfrequency as
the lower bound usually suffices. E.g., if the initial eigenfrequency of
interest in the first optimization iteration is around 100 Hz, then it can be
specified that only the eigenfrequencies over 25 Hz are to be calculated.
3. The mode tracking feature can not be guaranteed to work for all examples.
4. Mode tracking is not recommended for the Kreisselmaier-Steinhauser
formulation.
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5. Mode tracking can increase the CPU-time significantly both for finite
element solver and Tosca Structure. Restrict mode tracking to a smaller
representative group of nodes to gain performance.
8.8.2
Update strategy of the method of moving asymptotes

The shell thicknesses of the structure are updated using the method of moving asymptotes (MMA), see Svanberg (1987). Normally, the update method
suggested in Svanberg (1987) is stable. However, if the design responses are
very sensitive, it is suggested to use a more conservative update method that
requires more optimization iterations. The update strategy is changed using
the
parameter
THICKNESS_UPDATE.
The
default
value
of
THICKNESS_UPDATE is NORMAL. Setting THICKNESS_UPDATE to CONSERVATIVE leads to a conservative update of the design variables:
OPT_PARAM
ID_NAME
= opt_params
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Settings
OPTIMIZE
= id_of_optimize
THICKNESS_UPDATE=CONSERVATIVE
END_
It is recommended to use the conservative update method if it is problematic

to fulfill the constraints used in the optimization formulation.
The user also has the possibility to use a more aggressive update of the
design variables in order to reduce the number of optimization iterations by
setting THICKNESS_UPDATE to AGGRESSIVE:
OPT_PARAM
ID_NAME
= opt_params
OPTIMIZE
= id_of_optimize
THICKNESS_UPDATE=AGGRESSIVE
END_
This may lead to unstable optimization or prevent the convergence.
Settings of the mesh filter

Similar to topology optimization (see chapter 5.8.2.6 Settings of the mesh filter) numerical instabilities resulting in checker-board effects can be controlled
using filtering. Checkerboard structures cannot be manufactured in practice.
The user also wants to obtain a mesh-independent result from the optimization. Due to these demands, Tosca Structure has a filter technique implemented to avoid mesh dependence. A specification of a filter radius
(FILTER_RADIUS parameter) is necessary for applying the filter. If the radius
of the filter is not specified, the optimization is performed using a filter having
a default radius. This radius might be too large for coarse meshes. If the
radius is too large, the optimization result will not show a detailed structure. A
small value of the radius leads to a fine structure.
It is recommended to choose the filter radius equal to twice the mean element
edge length.
The filter radius is defined in OPT_PARAM command as follows:
OPT_PARAM
ID_NAME
OPTIMIZE
= id_of_optimize
...
FILTER_RADIUS = 5.
END_
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8.8.3
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Sizing Optimization
8.8.4
FILTER_TYPE
The filter technique for the objective function can be changed using the
parameter FILTER_TYPE in the optimization settings (OPT_PARAM command). Changing the filter technique for the objective function is mainly interesting for stiffness optimization problems.
The FILTER_TYPE can be set to STANDARD and LOW, respectively. The filter for FILTER_TYPE = LOW is a relaxation of the STANDARD filter. It is useful for coarse meshes yielding a clearer design and a lower number of
optimization iterations.For reasonable and fine meshes FILTER_TYPE equal
to LOW would often cause checkerboard.
FILTER_TYPE equal to LOW might also be useful for stabilizing dynamic
problems like modal eigenfrequency optimization.
Remarks:
1. Changing the filter option has no effect when the objective is to minimize
the mass.
2. Changing the filter option has no effect when manufacturing constraints are
present.
8.9
Stop Condition
Stop conditions are necessary to ensure that the optimization terminates.
These stop criteria can either simply allow a certain number of loops or
depend on the convergence behaviour of the optimization.
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8.9.1
Convergence Criteria
For checking if the sensitivity based sizing optimization has converged two
stop criteria are implemented.
The user can specify if both stop criteria should be fulfilled or just one of the
stop criteria has to be fulfilled for the optimization algorithm to stop. Default is
that both criteria should be fulfilled before the optimization algorithm stops. To
specify that just one of the criteria has to be fulfilled set
STOP_CRITERION_LEVEL equal to SINGLE. The default value for
STOP_CRITERION_LEVEL is BOTH.
E.g. the optimization algorithm should stop when just one of the criteria is fulfilled
OPT_PARAM
ID_NAME
= opt_params
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Stop Condition
OPTIMIZE
= id_of_optimize
STOP_CRITERION_LEVEL = SINGLE
END_
Convergence Criteria are defined in the SETTINGS window of Tosca ANSA

environment and the OPT_PARAM command in Tosca Structure.gui respectively.

A second stop criterion is a measurement based upon the change in the
objective function from one optimization iteration to the next optimization iteration. This stop criterion is defined by
n n 1
---------------------------- STOP_CRITERION_OBJ
n
STOP_CRITERION_OBJ the stop criterion is fulfilled. The default for
STOP_CRITERION_OBJ is 0.001. The value can be changed by the user,
e.g.
OPT_PARAM
ID_NAME
= opt_params
OPTIMIZE
= id_of_optimize
STOP_CRITERION_OBJ = 0.01
END_
This could be desirable when the number of optimization should be reduced.
The third stop criterion is based upon the change in the thicknesses (design
variables) in each element from one optimization iteration to the next optimization iteration and is defined by
Number of elements
n n 1
----------------------------------------------------------------------- STOP_CRITERION_THICKNESS
Number of elements
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8.9.1.2 Stop criterion: change in element thickness
SIMULIA
Tosca Structure
Sizing Optimization
STOP_CRITERION_THICKNESS the stop criterion is fulfilled. The default for
STOP_CRITERION_THICKNESS is 0.005. The value can be changed by the
user, e.g.
OPT_PARAM
ID_NAME
= opt_params
OPTIMIZE
= id_of_optimize
STOP_CRITERION_THICKNESS = 0.0001
END_

The two above convergence criteria are not checked before a specified number of optimization iterations have been executed. Meaning that the optimization will always be executed until STOP_CRITERION_ITER is reached. The
number is set by the number of STOP_CRITERION_ITER. If
STOP_CRITERION_ITER is changed to e.g. 2.
OPT_PARAM
ID_NAME
= opt_params
OPTIMIZE
= id_of_optimize
STOP_CRITERION_ITER = 2
END_
The default value for STOP_CRITERION_ITER is 4.
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8.9.2
Global Stop Criterion (Number of iterations)

reached the optimization algorithm always stops independent upon the values of the two previously mentioned criteria. The allowed maximum number
of optimization iterations can be increased or decreased by the user. This is
done by modifying ITER_MAX in the STOP command
STOP
ID_NAME
ITER_MAX
= global_stop
= 55
END_
where ITER_MAX is increased to 55.
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Stop Condition
Remark:
command whereas the convergence criteria are defined in the optimization
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number of iterations this cannot be achieved).
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Stop Condition
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Result Transfer and Validation

Run
In the previous chapter, the visualization of unprocessed optimization results
is discussed. Still, in order to be able to use the optimization results, they are
to be processed ("smoothed"). In case of a 3-dimensional model, the first processed result is the isosurface generated by Tosca Structure.smooth, that
can be either further modified and remeshed in Tosca ANSA environment or
written in a required format directly by Tosca Structure.smooth. If the starting
model is 2-dimensional, the workflow remains basically the same except that
the surface simply gets modified and no remeshing is needed.
Using Tosca Structure.view, one is able to view the processed optimization
results via VTFX files that are also generated by Tosca Structure.smooth.
Tosca ANSA environment is also suitable for analyzing the result of the optimization visually. A complete analysis of a finished optimization task can be
only achieved by the validation run of the FE solver corresponding to the initial model. The possibility to create the model for the validation run is provided by Tosca ANSA environment. Alternatively, external postprocessors
can be used to generate a model for finite element analysis, using the results
of Tosca Structure.smooth as starting point.
9.1
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Version 8.1.0 Rev. 1 - 05.2014
Tosca Structure.smooth takes the ONF files produced during the optimization
as input, generates the smooth isosurface or the model surface (depending
on settings and optimization type) and saves the surface in one or several
output formats so that it can be used for following reasons:
1. Validation run (only available with Tosca ANSA environment): surface for
remeshing and generation of validation model (Reconstruct).
2. Transfer to CAD: surface in STL or IGES format, slices in IGES or CLI
format.
3. Representation of the surface in solver formats (INP, BDF, CDB).
4. Visualization of the processed optimization results in VTFX format.
Also, when started from within Tosca ANSA environment, the surface is
saved in ONF format and loaded into Tosca ANSA environment so that it can
be viewed and processed further. Please note: Reconstruct (generation of
validation models) in Tosca ANSA environment only supports one material in
the design area.
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Tosca Structure
Tosca Structure.smooth reads the names of input files and other parameters
form a Tosca Structure parameter file. Although it is possible to set up the
parameter file manually and start Tosca Structure.smooth in command line, it
is recommended to use Tosca ANSA environment (or, to lesser extent, Tosca
Structure.gui) to generate the parameter file and to call the Tosca Structure.smooth executable.
9.1.1
Starting Tosca Structure.smooth (Tosca ANSA

environment)
In Tosca ANSA environment, Tosca Structure.smooth is represented by
RUN_SMOOTH item in Task Manager located under Tosca Structure Task |
SMOOTH | SMOOTH_INSTANCE (Fig. 283). In order to define Tosca Structure.smooth parameters, right click the item and select Edit in order to set or
modify the parameters for Tosca Structure.smooth; select Update to run
Tosca Structure.smooth and load its results into Tosca ANSA environment.
When Tosca Structure.smooth is successfully finished, the produced VTFX

file is opened in Tosca Structure.view when View command is applied on
VTF_VISUALIZATION item under SMOOTH_INSTANCE.Note that you need
to close Tosca Structure.view in order to proceed with Tosca ANSA environment.
There are two ways to choose the input files for Tosca Structure.smooth in
Tosca ANSA environment. One switches between them by selecting an entry
of a drop down list in SMOOTH RUN PARAMETERS window opened by Edit
command on SMOOTH_INSTANCE item (Fig. 284). If "Based on current optimization" is chosen, the results are read from the job directory that is named
after the parameter file name (by default, Output) created in the same directory as the input model; this is where Tosca Structure is started using Tosca
Structure Task | START_OPTIMIZATION | RUN item. If the optimization
results are placed in another directory, its name should be entered in Jobname folder field that appears when one changes to "Read jobname folder
with optimization results" option. The only requirement for Tosca Structure.smooth results to be read into Tosca ANSA environment is that the input
model is loaded; it is not necessary that the optimization with Tosca Structure
has been actually started from within Tosca ANSA environment. It might be
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Fig. 283 Tosca ANSA environment: RUN_SMOOTH and

VTF_VISUALIZATION items
SIMULIA
Tosca Structure
useful to disable START_OPTIMIZATION item in order not to repeat the optimization.
Fig. 284 Tosca ANSA environment: SMOOTH RUN PARAMETERS window.
9.1.2
Starting Tosca Structure.smooth (Tosca Structure.gui)
Fig. 285 Tosca Structure.gui: SMOOTH command in Tosca Structure.pre

screen
Second, Tosca Structure.smooth can be started stand-alone from Tosca
Structure.smooth screen of Tosca Structure.gui by clicking Start Tosca
Structure.smooth button (Fig. 286). Once Tosca Structure.smooth finishes, if
needed, the parameters can be modified and Tosca Structure.smooth started
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In Tosca Structure.gui, there are two ways to define and run a Tosca Structure.smooth task. First, in Tosca Structure.pre editor, a SMOOTH block can be
inserted in Tosca Structure parameter file so that Tosca Structure.smooth is
called from Tosca Structure automatically once the optimization ends. To
define it, select Command | SMOOTH in Tosca Structure.pre screen (Fig.
285). Multiple SMOOTH blocks are allowed in a single Tosca Structure parameter file.
User Manual 2 - 507
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again. The button View Result opens a dialog for the resulting VTFX file to
be opened in Tosca Structure.view.
Fig. 286 Tosca Structure.gui: Tosca Structure.smooth screen

Finally, the command
tosca_smooth <parameter_file>.par
starts Tosca Structure.smooth in command line. A suitable parameter file has
the format
SMOOTH
<parameter1> = <value1>
<parameter2> = <value2>
...
Note that in this case, the names of input ONF files should be supplied using
relative or absolute paths, while Tosca ANSA environment and Tosca Structure.gui usually fill in the correct file names automatically.
9.1.3
Starting Tosca Structure.smooth (Tosca Extension for

ANSYS/Workbench)
To start Tosca Structure.smooth in Tosca Extension for ANSYS/WB first add a
Smooth Result to the Solution section in the Tree Outline (click
Results | Smooth Result). The Smooth Result is needed for the Validation Run.
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END_
SIMULIA
Tosca Structure
Fig. 287 Add a Smooth Result to the Tree Outline.

Adding a Smooth Result is possible either before or after an optimization run,
but an Optimization Result existing in the Solution section of the
Tree Outline is mandatory. It is not important whether it has been solved
or not by then.
Fig. 288 An Optimization Result - solved or not - is mandatory for a

smoothing run
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To solve the project and to start the smoothing run, click Solve having the
Smooth Result selected or use the right mouse button on Smooth
Result and choose Solve.
Fig. 289 Start the smoothing run either with the right mouse button or
using the Solve-button
User Manual 2 - 509
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9.1.4
Defining the parameters for Tosca Structure.smooth

As described in the previous section, there are 4 different screens (one in
Tosca ANSA environment, Tosca Extension for ANSYS/WB and two in Tosca
Structure.gui) where essentially the same parameters can be defined. In
Tosca ANSA environment, the window is opened by Edit command at Tosca
Structure Task | SMOOTH | SMOOTH_INSTANCE | RUN_SMOOTH item of
Task Manager (Fig. 290):
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Fig. 290 Tosca ANSA environment: RUN_SMOOTH item
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In Tosca Structure.pre screen of Tosca Structure.gui, the parameters of

SMOOTH block are edited in the following form (Fig. 291):
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Version 8.1.0 Rev. 1 - 05.2014
Fig. 291 Tosca Structure.gui: SMOOTH command in Tosca Structure.pre

screen
User Manual 2 - 511
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Tosca Structure
The Tosca Structure.smooth screen of Tosca Structure.gui looks as follows:
Fig. 292 Tosca Structure.gui: Tosca Structure.smooth screen

The following table summarizes the Tosca Structure.smooth parameters and
the corresponding fields in Tosca ANSA environment and Tosca Structure.gui:
Tosca Structure.smooth parameters

Tosca ANSA
environment field
Tosca Structure.gui
pre
smooth
ID_NAME
Set to the name

of the sub item of
SMOOTH item
(SMOOTH_
INSTANCE by
default)
ID_NAME
ID Name
ID name, also serves

as the default value
for OUTPUT_FILE
TASK
TASK
Task
Task
Defines what kind of

(iso-)surface is to be
generated
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Parameter
name
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Version 8.1.0 Rev. 1 - 05.2014

Parameter
name
Tosca ANSA
environment field
Tosca Structure.gui
Description
pre
smooth
MODEL
ONF file name

found in Jobname Folder
Inserted
automatically
FEM-File
Name of the ONF file

containing the model
RESULT
Result File
(if blank, set to a
file name found
in Jobname
Folder)
Inserted
automatically
Optimization Results
Name of the ONF file

(or a prefix) containing the optimization
results
OUTPUT_
FILE
Automatically set
to
"TOSCA_POST/
<ID_NAME>"
Output
File
Output File
Name
Base file name for all

output files
ISO_VALUE
ISO_VALUE
Iso Value
ISO-Value
Isovalue defining the

position of the isosurface
TARGET_
VOLUME
TARGET_
VOLUME
Target
Volume
Volume
Target volume; when

specified, the correct isovalue is found
automatically
SMOOTH_
CYCLES
SMOOTH_
CYCLES
Smooth
Cycles
Smooth
Cycles
Number of surface
smoothing cycles
REDUCTION_
RATE
REDUCTION_
RATE
Reduction Rate
Reduction
Rate (%)
Percentage of triangular faces to be

removed during data
reduction
REDUCTION_
ANGLE
REDUCTION_
ANGLE
Reduction Angle
Angle
Limiting angle
parameter used in
data reduction
SELF_
INTERSECTION_
CHECK
SELF_
INTERSECTION
_CHECK
Self Intersection
Self Intersection
Check
Defines whether
(and what kind of)
self-intersection
check is to be performed
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Tosca ANSA
environment field
Tosca Structure.gui
pre
smooth
MIN_ANGLE
Min Angle
Minimal allowed
angle of surface triangles
MIXED_MESH
Mixed
Mesh
Mixed Mesh
Triangles or mixed
(triangles and quadrangles)
FORMAT
Output Format
(Format = ONF
is added automatically)
Output
Formats
Output Format
Output format;
multiple entries are
allowed
OUTPUT_
SURFACE
Output
Surface
Isotype
Defines what surfaces (new, original

or both) are to be
saved
VTF_
ORIGINAL_
MODEL
VTF_
ORIGINAL_
MODEL
Show
Original
Model in
Vtf
Original
Model
Defines whether the

original model is to
be saved to VTFX
file
IGES_UNIT
iges_unit
Iges Unit
Unit for output in

IGES format (including slices)
SLICE_
NUMBER
SLICE_
NUMBER
Number
of Slices
#Slices
Number of section
planes for slices
SLICE_
NORMAL
SLICE_
NORMAL
Slice Normal
<x,y,z>
Sl_Normal
Normal direction for

section planes; multiple entries are
allowed but not supported in GUI
SLICE_
FORMAT
SLICE_
FORMAT
Slice Format
Format
Output format for

slices
BORDER
BORDER_
OUTPUT
Border
Selectable
in Slices
Defines whether the

border of 2D model
is to be saved in slice
format
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Parameter
name
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Parameter
name
Tosca ANSA
environment field
Tosca Structure.gui
Description
pre
smooth
GROUP_FILE
Inserted
automatically
Group File
ONF file containing

the groups
GROUP_
EXCLUDE
Name in
drop down
list right
from Group
File when
delete is
chosen
Name of the group to

be removed; multiple entries are
allowed but not supported in GUI
GROUP_
INCLUDE
Element
Group
Name in
drop down
list right
from Group
File when
plot is
chosen
Name of the group to

be added (after other
groups are
removed); multiple
entries are allowed
but not supported in
GUI
GROUP_
SURFACE
The original surface

of this group is calculated; multiple
entries are allowed.
ISO_VALUE_
GROUP
Specifies the isovalue for a single

group
TARGET_
VOLUME_
GROUP
Specifies the target

volume for a single
group
ISO_
SEQUENCE
Incremental Iso
Sequence
Defines the isovalues when saving isosurfaces of all

iterations
EXCLUDE_
LOADED
EXCLUDE_LOA
DED (Default:
YES)
Exclude
Loaded
Elements
(Default
NO)
Forces the loaded

elements to be
removed
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Parameter
name
Tosca ANSA
environment field
Tosca Structure.gui
pre
smooth
ORIGINAL_
SURFACE_
SMOOTHING
Orig. Surf.
Smoothing
Orig Surf
Smooth
Defines whether the

original surface is to
be smoothed
RESULT_
FILTERING
Set to Full automatically
Result Filtering
Result Filtering
Defines if the "densities" are to be filtered
KEEP_CONNE
CTION_NODES
KEEP_CONNEC
TION_NODES
Keep Conn.
Nodes
Keep nodes on the

border towards an
excluded area
SHRINKAGE_C
ORRECTION
Shrinkage
Correction
Prevent shrinkage
effects caused by the
laplacian smoothing
COMPONENT_
LIMITING_SIZE
Set to 0.05 automatically
Component
Limit Size
Defines if small
unconnected parts
are to be removed
Table 30
Tosca Structure.smooth parameters.
Processing results of topology optimization

Tosca Structure.smooth allows processing the design suggestion obtained by
topology optimization in Tosca Structure. As the input, it takes the ONF model
file and the ONF optimization result file (see vol.2 chapter 9.1.4), and produces the isosurface saved in one or more formats, suitable as input in CAD
systems (STL, IGES and other) or as means for visualization (VTFX, VRML).
Fig. 294 illustrates the process. First, starting from the original model, Tosca
Structure calculates the optimal material distribution, represented by the
block-like structure. It contains solid or shell finite elements, and therefore
might be unsuitable for CAD systems; furthermore, it may contain many elements in the inside that are not important since the shape is defined by the
surface of the solid model only. The surface itself is rough, especially in case
of a tetrahedral mesh, and therefore the smoothing is needed.
Now, the model file and the optimization result file containing the optimized
material density are loaded by Tosca Structure.smooth. Using these data, the
isosurface separating the elements with zero and nonzero density is found.
Then, the surface smoothing is done by displacing the nodes of the surface.
Finally, the data reduction may be performed; it is turned off by default. All
these steps are shown in Fig. 293. For a shell element model, the same
actions are performed, with the difference that the smoothing is applied to the
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9.1.5
Comp.
Limiting
Size
Description
SIMULIA
Tosca Structure
border nodes only. In both cases, the smoothing can be turned off, though it is
not recommended.
Original model
(MODEL_fem.onf)
Topology optimization
result generated by Tosca
Structure.report (TP_015.onf)
Isosurface generated by
(no smoothing, no reduction)
Isosurface after smoothing

(no reduction)
Isosurface after smoothing

and data reduction
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Fig. 293 Topology optimization and smoothing. Original model, optimized

model, isosurface, smoothed isosurface, final result.
In order to calculate a single isosurface, the setting
TASK = iso
should be used along with
MODEL = <model file name>.onf
RESULT = <optimization result file name>.onf.
Note that MODEL parameter is inserted automatically in Tosca ANSA environment; RESULT is set to the ONF result file from the last iteration, unless
User Manual 2 - 517
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another ONF file is chosen in Result File field. For additional information
about RESULT parameter as well as parameters controlling the isocut and the
smoothing, see vol.2 chapter 9.1.7. The parameters for data reduction are
discussed in vol.2 chapter 9.1.8. Finally, vol.2 chapter 9.1.9 deals with parameters defining the output formats. All output files are created in the same
directory, and their names are constructed as some common part plus the
corresponding suffix (if needed) and extension. The parameter
OUTPUT_FILE defines both the directory and this common part.
Example: using
OUTPUT_FILE = c:\MyDirectory\MyOutput
with the output in VTFX and IGES format for slices using cubic splines results
in the files
c:\MyDirectory\MyOutput.vtfx
c:\MyDirectory\MyOutput_slices.igs.
In Tosca ANSA environment, OUTPUT_FILE is set automatically to
<jobname>/TOSCA_POST/<SMOOTH item name>, where <SMOOTH item
name> is the name of the item in Task Manager (SMOOTH_INSTANCE by
default). If this parameter is omitted in the parameter file, it is set to
<directory of ONF model>/<ID_NAME>.
There is also the possibility to visualize the optimization process by generating the isosurfaces for all optimization iterations and saving them in an animation sequence in a VTFX file. This feature is not supported in Tosca ANSA
environment. This is done if the parameter file contains following lines:
In this case, "Task" field in Tosca Structure.gui (Tosca Structure.smooth

screen) should be set to "Create Isosurface from all steps of the ONF files". If
the same model file is used for all iterations, the file name (e.g.
MODEL_fem.onf) should be specified as the value of MODEL parameter. Otherwise, the input model files are <model>_<NNN>.onf, where <model> is the
value of MODEL parameter and <NNN> is the number of the iteration written in
3 digits, starting with 000. Similarly, the optimization result file names are
<result>_<NNN>.onf with <result> being the value of RESULT parameter.
Typically, <model> is MODEL_fem.onf for non-adaptive calculations or
MODEL for adaptive calculations; <result> usually is set to TP. The iteration
numbers <NNN> run from 0 to the first number such that the result file for the
following iteration does not exist. The resulting VTFX file gets the suffix _all;
all other output files are generated for each iteration, each time with the suffix
_<NNN>, where <NNN> is the current iteration number.
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TASK = all_iterations
MODEL = <model file name>.onf or <model file name base>
RESULT = <optimization result file name base>
SIMULIA
Tosca Structure
Note that these model and result file names should be entered manually in
the Tosca Structure.smooth screen of Tosca Structure.gui. In Tosca Structure.pre screen of Tosca Structure.gui, it suffices to set Task field to
all_iterations.
The isovalues (see vol.2 chapter 9.1.7) for the isosurfaces generated at each
iteration are either constant or linearly increasing. In the first case, the parameter ISO_SEQUENCE should be set to const (this is its default value); the isovalue then is specified by ISO_VALUE parameter. In the second case,
ISO_SEQUENCE = incr should hold, and the isovalue for iteration i is
iso_value * (i+1)/ (n+1), where iso_value is the value of ISO_VALUE
parameter and n is the number of the last iteration.
9.1.6
Processing results from shape or bead optimization

In the case of shape or bead optimization, Tosca Structure.smooth generates
the surface of the model with calculated optimization displacements. Therefore, the model file name and the optimization result file name should be
specified in the parameter file, and the task should be set to surface:
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TASK = surface
MODEL = <model file name>.onf
RESULT = <optimization result file name>.onf
In Tosca ANSA environment, it suffices to choose TASK = SURFACE (note
that by default TASK = ISO) and the file names will be inserted automatically.
In Tosca Structure.gui (Tosca Structure.smooth screen), use "Create Surface
+ Optimization displacements (Shape and Bead optimization)" value of Task
field and choose appropriate model and optimization result files.
Additionally, there is the possibility to generate the surface of the input model,
without applying the optimization displacements. This works for the models
used in topology optimization as well. In this case, RESULT field should be
omitted in the parameter file; in Tosca ANSA environment as well as in Tosca
Structure.pre screen of Tosca Structure.gui, this is the case for the topology
optimization, while for shape and bead optimization the surface with optimization displacements is always generated. In Tosca Structure.smooth screen of
Tosca Structure.gui, choose "Create Surface Model from ONF File" as the
value of Task field.
After the surface is generated, the data reduction can be performed; it is
turned off by default. See vol.2 chapter 9.1.8 for the description of data reduction parameters. Both data reduction and the output in various formats (see
vol.2 chapter 9.1.9) are done in the same way as when processing the topology optimization results.
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9.1.7
Isosurface and smoothing parameters

Following parameters control the generation and the smoothing of the isosurface. They are used when the isosurfaces of the material distribution resulting
from topology optimization are calculated: in this case, the parameter TASK is
set to iso (single isosurface) or all_iterations (isosurfaces for all iterations). Additionally, the parameters SELF_INTERSECTION_CHECK and
MIN_ANGLE are used during the data reduction that is described in details in
the next section.
Isosurface generation and smoothing parameters of Tosca Structure.smooth

Parameter
Value
Description
Supported by
TS.pre
TS.smooth
TExt
ISO_
VALUE
Real value between

0 and 1
Default: 0.3
Isovalue; is used to determine

the positions on the element
edges where the new nodes
are created. Larger values lead
to models with smaller volume.
See below for an example.
SMOOTH_
CYCLES
Non-negative
integer number
Default: 5
Number of smoothing cycles; if

set to 0, no smoothing is performed. Larger values lead to
smoother models, but may
cause the narrowing of thin
components.
ORIGINAL_
SURFACE_
SMOOTHING
off
(original surface is
not smoothed)
shrink
(limited original
surface smoothing)
full
(original surface is
smoothed)
default: off
Defines if the smoothing of the

original surface is to be performed. If set to shrink, the
original surface gets smoothed
by moving its nodes towards
the inside of the model only, so
that the restrictions on the
design region are not violated.
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GUI
SIMULIA
Tosca Structure
Isosurface generation and smoothing parameters of Tosca Structure.smooth

Parameter
Value
Description
Supported by
TAE
TS.pre
TS.smooth
TExt
GUI
SELF_
INTERSECTION_
CHECK
off
(no checks)
check
(check once)
runtime
(check always)
iterative
(first run without
check, rerun if
needed)
Default: iterative
Defines if the self-intersection

checks are to be performed
during the isocut, smoothing
and data reduction. See below.
MIN_ANGLE
Real value between

0 and 90
Default: 15
Defines the minimal angle of

the triangles that result from
the smoothing and data reduction; triangles with smaller
angles may be present if they
are created during the isocut.
Too large value may prevent
the smoothing; too small value
may lead to degenerated triangles.
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Table 31
Isosurface generation and smoothing parameters of Tosca

Structure.smooth.
* TAE=Tosca ANSA environment, TS=Tosca Structure,
TExt=Tosca Extension for ANSYS/WB
** x = supported, - = unsupported
All parameters have default values that are useful in most cases. However,
these parameters affect the appearance of the isosurface as described
below.
The isovalue specified using the parameter ISO_VALUE defines the position
between the elements with zero and maximal material value where the isosurface is constructed. More precisely, the interpolated material values are
first found for each node, and then the new nodes are constructed on the
edges that have varying material values (i.e., material value for one end is
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less than and for the other one larger than the isovalue). The ratio in which
the edge is subdivided by the new node is defined by the iso-value in respect
to the material values of the ends of the edge, but is limited to a range from a
to 1-a with a constant value a (currently 0.3) in order to prevent edges of very
small lengths. As the result, increasing the isovalue leads to shifting the isosurface towards the inside of the model, thus the model volume decreases.
For the structures with thin components, it is not recommended to use large
isovalues (larger than 0.7), since the structure might become disconnected.
See Fig. 294 for an example of how the isovalue influences the result.
isovalue = 0.2
isovalue = 0.8
In case that the structure becomes disconnected, it is advised to repeat the

calculation with smaller isovalue. Still, if the model contains a single layer of
elements or a string of elements connected by nodes only, the isosurface will
probably be disconnected for any isovalue. In this case, it is recommended to
repeat the topology optimization with adjusted minimal thickness of components that can be specified by choosing the minimal member size in
DVCON_TOPO. Another possible solution is to use a refined mesh.
After the isocut is done, the surface smoothness is generally not sufficient.
Therefore, the iterative smoothing is performed by displacing the nodes created in the isocut. The smoothing is done in cycles; the number of cycles is
determined by the parameter SMOOTH_CYCLES. The conditions for a node
displacement to be accepted is that the angles of resulting triangles are larger
than a certain value specified by the parameter MIN_ANGLE, and, if
requested, that no surface self-intersections occur after the displacement.
The second check is not done if SELF_INTERSECTION_CHECK parameter is
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Fig. 294 Isosurfaces and smoothing parameters in Tosca Structure.smooth. Isosurfaces for the isovalues 0.2 and 0.8.
SIMULIA
Tosca Structure
set to off or check; the difference in these cases is that, in case this parameter is set to check, the self-intersection test is performed once for the entire
model after the smoothing and data reduction are made, and the user
receives the information about the number of intersecting faces as well as a
VRML
file
containing
these
faces.
In
case
that
SELF_INTERSECTION_CHECK parameter is set to iterative, the smoothing is first performed without the self-intersection checks, and then is redone
if the self-intersections appear after the smoothing. Note that in case of
SELF_INTERSECTION_CHECK parameter set to iterative or runtime,
similar self-intersection checks are done for isocut and data reduction as well;
however, in rare cases, self-intersections that occur during the isocut cannot
be prevented, and they are likely to remain after the smoothing and data
reduction are done.
In order to achieve smoother surfaces, higher value of SMOOTH_CYCLES
parameter should be used. However, this leads to the increase of the computation time that might be noticeable especially in the case that the self-intersection test is turned on. In practice, 5 to 10 smoothing cycles are usually
sufficient. Further smoothing might have a negative effect of contracting thin
components; in certain cases, the smoothing has to be turned off by setting
SMOOTH_CYCLES to 0. See Fig. 295 for an example of smoothing with various numbers of smoothing cycles.
0 smoothing
cycles
(smoothing turned
off)
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3 smoothing
cycles
10 smoothing
cycles
Fig. 295 Isosurfaces and smoothing parameters in Tosca Structure.smooth: 0, 3 and 10 smoothing cycles
User Manual 2 - 523
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A higher number of smoothing cycles can cause some shrinkage effects on

the surface that is being smoothed. Especially areas with a high curvature
can be changed drastically. If you want to prevent these effects, the parameter SHRINKAGE_CORRECTION can be set to YES. Activating the correction
will reduce the shmoothing efficiency slightly. A higher number of smoothing
cylces may be necessary.
shrinkage correction deactivated
shrinkage correction activated
Fig. 296 Effects of shrinkage correction with 10 smoothing cycles
ORIGINAL_
SURFACE_
SMOOTHING =
off
ORIGINAL_
SURFACE_
SMOOTHING =
shrink
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The parameter ORIGINAL_SURFACE_SMOOTHING defines if the original surface (that is the part of the surface of original elements, in contrast to the new
surface produced by isocut) should be smoothed.
SIMULIA
Tosca Structure
ORIGINAL_
SURFACE_
SMOOTHING =
full
Fig. 297 Isosurfaces and smoothing parameters in Tosca Structure.smooth: 0, 3 and 10 smoothing cycles
If it is set to off, the original surface remains unchanged. In most cases, this
is desired since the surface nodes might have some additional information
(e.g. forces or boundary conditions) associated with them. However, the
resulting surface will be smoother if the original surface gets modified as well.
To do this, set ORIGINAL_SURFACE_SMOOTHING to full. The third option
ORIGINAL_SURFACE_SMOOTHING = shrink allows modifying the original
surface, but in a way that the new surface does not occupy the region beyond
the initial design. This is achieved by prohibiting the nodes to be moved
towards the outside of the model.
Note that the surface of the frozen regions that are chosen using
GROUP_SURFACE commands is not modified even if the original surface
smoothing is turned on.
Reduction parameters
Using the data reduction, the number of surface triangles can be reduced, or
the triangles can be pairwise united in quadrilaterals. Data reduction is applicable to any surfaces generated by Tosca Structure.smooth; it also affects the
original surface, but does not modify loaded nodes. By default, data reduction
is turned off.
Following parameters guide the data reduction:
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User Manual 2 - 525
SIMULIA
Tosca Structure
Data reduction parameters of Tosca Structure.smooth

Parameter
Value
Description
Supported by
TS.pre
TS.smooth
TExt
REDUCTION_
RATE
Real value between 0

and 100
Default: 0.3
Defines the percent of

faces that should be
removed during the data
reduction; if set to 0, no
data reduction occurs. If
set to 100, the data reduction stops when no faces
can be removed (that is
checked using
REDUCTION_ANGLE
parameter).
REDUCTION_
ANGLE
Real value in degrees

between 0 and 90
Default: 15
Defines the maximal

angle between adjacent
faces at a node such that
the node may be removed
during the data reduction.
MIXED_
MESH
yes
(unite triangles to
quadrilaterals)
no
(no change)
default: no
If set to YES, then the

quadrilaterals are formed
from adjacent triangles;
applies to VTFX, ONF,
IGES and WRL output formats only.
SELF_
INTERSECTION_
CHECK
off
(no checks)
check
(check once)
runtime
(check always)
iterative
(first run without check,
rerun if needed)
Default: iterative
Defines if the self-intersection checks are to be

performed during the isocut, smoothing and data
reduction. See below.
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Tosca Structure
Data reduction parameters of Tosca Structure.smooth

Parameter
Value
Description
Supported by
www.3ds.com/tosca
Version 8.1.0 Rev. 1 - 05.2014
Table 32
TExt
Defines the minimal angle

of the triangles that result
from the smoothing and
data reduction; triangles
with smaller angles may
be present if they are created during the isocut.
Too large value may prevent the smoothing; too
small value may lead to
degenerated triangles.
TS.smooth
Real value between 0

and 90
Default: 15
TS.pre
MIN_ANGLE
TAE
GUI
Data reduction parameters of Tosca Structure.smooth.

* TAE=Tosca ANSA environment, TS=Tosca Structure,
Note that SELF_INTERSECTION_CHECK and MIN_ANGLE parameters are

also used during isosurface generation and smoothing.
The data reduction consists in decreasing the number of surface triangles; it
might be needed in case that the surface is produced from a very fine FE
model or simply has too many faces. The data reduction can be applied to
isosurfaces as well as surfaces of models with or without optimization displacements. During the data reduction, the adjacent triangles with nearly
coinciding planes get united and subsequently subdivided so that a triangular
surface with smaller number of faces is obtained. This process is repeated
until the decrease of the number of triangles reaches a certain percentage of
the starting number of triangles; this percentage is the value of the parameter
REDUCTION_RATE. If set to 0 (default), no data reduction is performed; if set
to 100, the data reduction is repeated until the number of triangles cannot be
decreased further. The conditions that define if a local data reduction can be
made are as follows:
the angle between the normals of adjacent triangles is less than the value
of REDUCTION_ANGLE parameter (default value is 15);
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Tosca Structure
the angles of triangles after the reduction are larger than the value of
MIN_ANGLE parameter;
no self-intersection occurs after the reduction (only checked if
SELF_INTERSECTION_CHECK parameter is set to iterative or runtime).
REDUCTION_RATE = 0 (default)
REDUCTION_ANGLE = 15 (default)
4842 faces (100%)
REDUCTION_RATE=100
REDUCTION_ANGLE =15 (default)
REDUCTION_RATE = 50
REDUCTION_ANGLE = 15 (default)
2420 faces (50.0%)
REDUCTION_RATE = 100
REDUCTION_ANGLE = 45
480 faces (9.9%)
Fig. 298 Reduction parameters in Tosca Structure.smooth. Data reduction

for various values of REDUCTION_RATE and
REDUCTION_ANGLE.
Data reduction can also achieved by generating the mixed triangular-quadrilateral surface. If the parameter MIXED_MESH is set to yes, then the quadrilaterals are formed from adjacent triangles. The triangles can only be united
when the resulting quadrilateral is convex and non-degenerated, and the
angle between the normals of the triangles is smaller than a certain constant
value (currently 15). An example of using the MIXED_MESH parameter is
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As seen from the example shown in Fig. 298, in order to achieve maximal
data reduction, REDUCTION_RATE parameter should be set to 100 and
REDUCTION_ANGLE parameter to a large value (e.g. 45). However, the surface then becomes coarse. By changing the REDUCTION_ANGLE parameter,
the surface with sufficient smoothness and reasonably small number of triangles can be obtained.
The parameters MIN_ANGLE and SELF_INTERSECTION_CHECK usually do
not influence the number of triangles remaining after the data reduction,
unless MIN_ANGLE is set to a large value (30 or more; default value is 15).
Note that these parameters are also used in the surface smoothing.
SIMULIA
Tosca Structure
presented in Fig. 299. Note that the output of a mixed surface is only available for certain output formats (namely VTFX, ONF, IGES and WRL). In case
of other formats, the triangular surface is always saved, thus the parameter
MIXED_MESH has no influence on the result. Also, the triangular surface is
always used for the generation of the slices and the border.
MIXED_MESH = no (default): 4842 triangles
MIXED_MESH = yes: 2642 triangles, 1100 quadrilaterals
The generation of the mixed mesh can be combined with the data reduction
described above; it is performed after the data reduction is finished.
9.1.9
Output parameters
After the surface is generated and (if necessary) the smoothing and data
reduction are finished, it can be saved to the output file(s) in various formats.
The output is controlled by following parameters:
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Fig. 299 Reduction parameters in Tosca Structure.smooth. Example of

using MIXED_MESH parameter.
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Tosca Structure
Output parameters of Tosca Structure.smooth

Parameter
Value
Description
Supported by
TS.pre
TS.smooth
TExt
FORMAT
See Table 34
Output file format; one or more

FORMAT entries can be specified. In case that the isosurfaces
for all iterations are calculated,
one file for each iteration in each
mentioned format (except VTFX)
is saved; additionally, a VTXF file
containing the isosurfaces for all
iterations is generated.
OUTPUT_
FILE
<name>
In case of a single generated

(iso)surface, the output file name
for a format with extension
<ext> is <name>.<ext>; in case
of isosurfaces for all iterations, it
is <name>_<NNN>.<ext>, where
<NNN> is the number of
the iteration (3
digits).
Specifies what should be saved

to the output files: the original
surface (original), the surface
generated by isocut (new), or the
complete surface (both). The
parameter has no influence for
shell element models, and is
ignored for the generation of
slices.
If set to yes, the original FEM

model will be saved to the VTFX
output file (displayed semi-transparent) in addition to the (iso)surface
default:
<model>_smooth,
where <model> is
the name of input
model file without
extension
OUTPUT_
SURFACE
original
new
both
default: both
VTF_
ORIGINAL
_MODEL
yes
no
default: no
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TAE
GUI
SIMULIA
Tosca Structure

Parameter
Value
Description
Supported by
TExt
Unit used for output in IGES format.
TS.smooth
in: inches
mm: millimeters
ft: feet
mi: miles
m: meters
km: kilometers
mil: mils
um: microns
cm: centimeters
uim: microinches
TS.pre
IGES_UNI
T
TAE
GUI
Note that the same unit is used in

the case that the slices or border
are generated and saved in IGES
format.
default: mm
Table 33
Output parameters of Tosca Structure.smooth.

* TAE=Tosca ANSA environment, TS=Tosca Structure
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Using FORMAT parameter, the user requests the saving of the generated surface(s) to various output formats that are intended to be used with following
programs:
FORMAT parameter values for different applications

Program
FORMAT
parameter
File name, comments
Abaqus/CAE
inp
iges1
<name>.inp
<name>.igs (IGES using block 114)
ANSYS
cdb
iges3
<name>.cdb
<name>_3.igs (IGES using block 128)
CATIA
stl
iges3
obj
<name>.stl (STL as design draft)

<name>.obj (Wavefront .obj file)
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SIMULIA
Tosca Structure
Program
FORMAT
parameter
File name, comments
GLView Inova
vtfx
<name>.vtfx
MEDINA
stl
<name>.stl
(using FEM formats is also possible)
MSC Nastran
bdf
<name>.bdf
Patran
out
<name>.out (Patran neutral format)
Pro/E
iges1
Rapid Prototyping applications
stl
<name>.stl
Solid Works
iges2
<name>_2.igs (IGES with explicit point

information)
vtfx
<name>.vtfx
NX
stl
<name>.stl
Graphic (animation) programs
obj
<name>.obj (Wavefront .obj file for 3D model

exchange)
Other pre/postprocessors
See
above
Use out, inp, bdf, cdb; see above for file

names. Also supported by CATIA.
Tosca ANSA
environment
ONF
<name>.onf and <name>_groups.onf:

needed to transfer the information from
Tosca Structure.smooth to Tosca ANSA
environment, requested automatically
Table 34
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9.1.10 Slices through 3D models and border of 2D models

Equidistant slices through the 3D model are often useful for a better postprocessing of optimization results.
The location of slices is decided by the parameters SLICE_NORMAL and

SLICE_NUMBER. For each SLICE_NORMAL entry, a series of parallel planes
orthogonal to the vector given by this parameter is generated. The model is
spanned between the first and the last section planes, and the remaining
planes are located equidistantly between them. The total number of planes in
each direction is given by SLICE_NUMBER parameter.
Then, if SLICE_FORMAT = igs_polygon or SLICE_FORMAT = cli is
specified, the polygons resulting from the intersection of the model with the
section planes are saved in IGES or CLI format resp. In case of
SLICE_FORMAT = igs_curves, the points of the polygons are used as the
support points for uniform cubic B-splines, that are in turn saved in IGES format.
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Fig. 300 Tosca Structure.smooth. Equidistant slices through a model.
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SIMULIA
Tosca Structure
Parameter
Value
TAE
TS.pre
TS.smooth
TExt

Description
Supported by
SLICE_
NUMBER
Nonnegative integer;
default: 0
Number of parallel section

planes that define the slices. If
set to 0, no slices are saved
SLICE_
NORMAL
<x>,<y>,<z>
with real
values x, y, z
Normal to the section planes.

The real values x, y, z that are
not all equal to zero should be
separated by commas; spaces
before or after the commas are
allowed. Multiple
SLICE_NORMAL parameters
are allowed: slices in all directions that are specified by
SLICE_NORMAL are saved
together to the output file.
SLICE_
FORMAT
default:
igs_polygon
The format used for saving the

slices
igs_polygon
(file name:
<name>_slices.igs)
igs_polygon: polygons
saved using cubic parametric
splines for each segment
(IGES block 112)
igs_curves
(file name:
<name>_slices_spl.igs)
igs_curves: curves obtained

by interpolation using uniform
cubic splines (IGES block 126)
cli
(file name:
<name>_slices.cli)
cli: polygons saved in common layer interface format
all
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all: save in all formats mentioned above
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SIMULIA
Tosca Structure
Parameter
Value
TAE
TS.pre
TS.smooth
TExt

Description
Supported by
BORDER
yes
no
default: no
If set to yes, the border of the

shell element model will be
saved according to the format
defined by SLICE_FORMAT
parameter; the file name is the
same as for slice output, with
slices replaced with border.
IGES_
UNIT
in: inches
mm: millimeters
ft: feet
mi: miles
m: meters
km: kilometers
mil: mils
um: microns
cm: centimeters
uim: microinches
Unit used for output in IGES

format.
GUI
Note that the same unit is used

in the case that the model is
saved in IGES format.
default: mm
Output parameters of Tosca Structure.smooth.
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Table 35
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For shell element models, using will BORDER

=
yes setting with
SLICE_FORMAT = igs_polygon or SLICE_FORMAT = igs_curves
results in saving the border (outline) of the resulting model in IGES format.
Fig. 301 Tosca Structure.smooth. Outline of 2D Isosurface as interpolated

cubic B_spline.
Note that the generation of slices is only available for solid models, and is
skipped for shell element models. Accordingly, the output of the border can
only be done for shell element models. Also, if the slices are used along with
the output in VTFX format, the section planes are included in VTFX files so
that the slices can be visualized using Tosca Structure.view: it suffices to
open the VTFX file and to hide the surfaces using Display | Part
Attributes... menu command.
Note: operations with groups are not supported in Tosca ANSA environment.
In order to restrict the isocut and/or the surface calculation to certain areas of
the model, the user may specify the groups of elements that should be used.
The groups are read from the ONF file specified by the parameter
GROUP_FILE. Then, the group names defined in the file, and, additionally,
the group ALL containing all elements, can be used as values of following
parameters:
GROUP_EXCLUDE: the elements of the group are ignored for all operations;
GROUP_INCLUDE: the elements of the group are marked as normal and
are used for the (iso)surface calculation;
GROUP_SURFACE: the surface of the elements will be calculated even if
they would be deleted or cut otherwise.
Any number of these commands can be specified. If an element belongs to
several groups mentioned in the commands, the last command applies. For
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9.1.11 Processing of groups
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Tosca Structure
example, in order to restrict the isocut to a single group MY_GROUP, following

parameters should be specified, in the following order:
GROUP_EXCLUDE = ALL
GROUP_INCLUDE = MY_GROUP.
Group names are case insensitive.
Note that the ONF group file must be compatible with the model file. In case
of adaptive calculations, the ONF group file should be updated using
fem2onf applied to the FEM file for the required iteration.
Support of group operations in Tosca Structure.gui is limited. Using Tosca
Structure.smooth screen, the ONF group file should be loaded first, so that
the group names appear in the combo box to the right. After choosing a group
from the list, it is possible to restrict the operations to it (by checking "plot"
radio button) or to remove it from the model (by checking "delete" radio button). In Tosca Structure.pre screen of Tosca Structure.gui, one can only
choose one group to restrict all operations to. All further group operations
have to be input manually.
The example shown in Fig. 302 contains two design regions DESIGN_ELEM1
and DESIGN_ELEM2, the first being the lower part of the model and the other
one the upper part. Using group commands, various results can be obtained,
as shown in the figure.
GROUP_EXCLUDE
= all
GROUP_INCLUDE
= DESIGN_ELEM2
(upper part only)
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model)
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IGROUP_EXCLUDE
= all
GROUP_INCLUDE
=DESIGN_ELEM1
GROUP_SURFACE
=DESIGN_ELEM2
(lower part and the
surface of the
upper part)
Fig. 302 Tosca Structure.smooth. Isosurfaces obtained by using various
group commands; the original model is shown in gray.
9.1.12 Volume control

If the task specified by the user is iso or all_iterations, the result of calculation is the isosurface generated by isocut and possibly modified by the
smoothing and data reduction. After these operations are successively finished, the user gets the message that looks as follows:
For solid models, the volume displayed in this message is the ratio of the volume of solid(s) defined by the isosurface to the original volume, which is the
sum of volumes of all solid elements used in the topology optimization, except
those excluded using the group commands. The original volume is also equal
to the volume of the solid(s) defined by the surface produced from the same
model file using surface task, provided that the data reduction is turned off.
For shell element models, the definition is the same except that "volume"
should be replaced with "area". If the model contains both solid and shell elements, only the solid elements are considered.
In order to achieve required relative volume, the user may change the isovalue and recalculate the isosurface, keeping in mind that larger isovalues
usually lead to smaller volumes, as illustrated in Fig. 294. The same result
can be achieved using the automatic approach implemented in Tosca Structure.smooth. In order turn it on, the parameter TARGET_VOLUME should be
set to a value between 0 and 1. Then, the isovalue specified by ISO_VALUE
parameter is ignored and an iterative equation solving method is used to
determine the isovalue that leads to specified target relative volume. If this
volume is larger than the volume for isovalue equal to zero or smaller than
the volume for isovalue equal to 1, an error message is produced; in this
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Iso-surface successfully generated

- iso-value: 0.300
- relative volume: 57.3%
SIMULIA
Tosca Structure
case, it is unlikely that the required relative volume can be achieved for any
isovalue between 0 and 1. Otherwise, the convergence to a solution is guaranteed unless the dependence of target volume on isovalue is noncontinuous, that sometimes occurs for small models. The maximal number of
iterations is fixed (currently 20); if the iterations fail to converge before this
number is reached, an error message will be produced. In this case, it is recommended to run Tosca Structure.smooth again using the isovalue obtained
in the last iteration, although the resulting relative volume would probably differ from the value used initially. The iterations are treated as having converged if the difference between the calculated and the desired values is less
than 10% of the desired value, and, in the same time, less than 1%.
If the model contains several design areas, different target relative volumes
might be needed for one or more regions. For this reason, the possibility to
define isovalues and target volumes differently for each group is implemented
in Tosca Structure.smooth; however, it is not supported neither in Tosca
ANSA environment nor in Tosca Structure.gui. The command
TARGET_VOLUME_GROUP = <group
volume>
name>, <target
relative
with <group name> being a name of a group defined in an ONF group file
defines the relative volume for this group. Then, for each such command, the
isovalue for the group will be found first by using the iterative method applied
to this group alone, after excluding the elements marked as deleted. For other
groups, the isovalue can be specified directly using
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Version 8.1.0 Rev. 1 - 05.2014
ISO_VALUE_GROUP = <group name>, <isovalue>

command. For the rest of the material, the default isovalue given by
ISO_VALUE command (or, equivalently, ISO_VALUE_GROUP command for
the group all) is used. Note that the groups for which the target relative volumes or the isovalues are defined must be disjoint; in particular, the command TARGET_VOLUME (or, equivalently, TARGET_VOLUME_GROUP for the
group all) is not allowed as long as TARGET_VOLUME_GROUP or
ISO_VALUE_GROUP commands with groups not equal to all are used.
After the isovalues for all groups with specified target relative volumes are
calculated, they are interpolated to get the nodal isovalues, which are then
used for the isocut. Therefore, in an area between two regions with different
isovalues the average values are used. This leads to smooth transition
between the regions, but also might change the relative volumes of the
regions; additional error might be introduced by the surface smoothing. However, the number of elements in the transition region is usually relatively
small, therefore the error can be neglected.
Note that if the resulting model contains holes completely surrounded by
material, the calculated volume will be incorrect.
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9.1.13 Correction of defects in topology optimization results

In some cases, the topology optimization results contain small irregularities
that are generally not desired. In order to deal with them, the filtering of the
material distribution as well as the possibility to remove small unconnected
components are implemented.
Filtering and repair parameters of Tosca Structure.smooth
Parameter
Value
Description
Supported by
TS.pre
TS.smooth
TExt
RESULT_
FILTERING
off:
no filtering
moderate:
one filtering cycle
full:
5 filtering cycles
default: off
Defines the number of filtering

cycles that are applied in order
to make the material distribution homogeneous
COMPONENT_
LIMITING_
SIZE
Real value
between 0 and 0.5
Default: 0
Defines the minimal allowed relative size of a connected component (calculated using its number
of faces). All components with the
relative size below this value are
removed. Default: 0
Table 36
Filtering and repair parameters of Tosca Structure.smooth.

** x = supported, - = unsupported, a = auto
The result filtering averages the material values ("densities") in the places
where it affects the isosurface most, and therefore it may account for large
changes of the surface geometry. See Fig. 303 for the influence of the result
filtering on the geometry in various cases.
No result filtering
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moderate result filtering

(one cycle)
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Small isolated
components are
removed
Narrow "bridges"
are removed
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Narrow caverns
and small holes
(including the
holes inside the
model) are
removed
Fig. 303 Tosca Structure.smooth. Influence of RESULT_FILTERING

parameter on the isosurface.
When the parameter COMPONENT_LIMITING_SIZE is set to a positive number, all connected components with the number of faces below the product
<number of all faces> * COMPONENT_LIMITING_SIZE are removed.
By definition, in a connected component, each two faces can be connected
by a chain of other faces, so that two consequent faces in the chain have a
common side. Note that only the connectivity of the surface is checked; a
User Manual 2 - 541
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hole inside the model that is completely surrounded by material is considered

as a separate connected component. The removal of small connected components takes place directly after the isocut. If more than one connected component remains, the user gets a message:
Surface is disconnected; the number of connected components
is N,
where N is the number of remaining connected components (each inner hole

counts as a component as well).
Unfeasible target relative volume. If this value lies outside of the range of
relative volumes attained at isovalues equal to 0 and 1, an error message
is produced since it is unlikely that such relative volume will be attained at
any isovalue. The error message suggests what values may be used as
the target relative volume.
Models with "jumps" of relative volume. In some cases, the relative volume
depends non-continuously upon the isovalue, and therefore it may happen
that a certain target relative volume cannot be obtained. Typically, it happens when the target volume is larger than the total volume of all nonempty elements of the model, or otherwise in small models. The iterations
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When Tosca Structure.smooth is started from Tosca ANSA environment or

Tosca Structure.gui, the warnings and error messages are written in the file
TOSCA.OUT in the subdirectory TOSCA_POST of the job directory. In Tosca
Structure.gui, this information is also displayed in the lower part of "Start
Tosca Structure" screen (if Tosca Structure.pre screen is used for defining
Tosca Structure.smooth parameters) or, otherwise, in Tosca Structure.smooth
screen. These warnings and error messages describe the problems that
occurred during the run of Tosca Structure.smooth, such as wrong parameter
file syntax, missing input files or problems with creating output files. The
parameter file for Tosca Structure.smooth created by Tosca ANSA environment or Tosca Structure.gui is located in the job directory and has the name
<jobname>_smooth.par; the information in TOSCA.OUT file refers to the
values from this parameter file.
Besides the syntax mistakes, misspelled file names and invalid values of
parameters, following problems may also lead to erroneous behavior of Tosca
Structure.smooth:
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Tosca Structure
do not converge and stop when the maximal number of iterations (currently
20) is reached:
Preparations
-- Iteration
-- Iteration
-- Iteration
-- Iteration
-- Iteration
-- Iteration
...
-- Iteration
-- Iteration
for iso-cut finished

1: iso_value = 0.000,
2: iso_value = 1.000,
3: iso_value = 0.625,
4: iso_value = 0.419,
5: iso_value = 0.261,
6: iso_value = 0.135,
rel.
rel.
rel.
rel.
rel.
rel.
volume
volume
volume
volume
volume
volume
=
=
=
=
=
=
1.000
0.040
0.105
0.218
0.260
0.326
19: iso_value = 0.001, rel. volume = 1.000

20: iso_value = 0.001, rel. volume = 0.355
**** TOSCA Structure Smooth ERROR ****

Target volume not attained; the isosurface is not saved
Inconsistent meshes. Tosca Structure.smooth assumes that the mesh is

conforming or can be made conforming by simple operations, like subdividing a quadrangle into two triangles. In this case, a mesh is considered to be
conforming if any two elements that have an area contact have exactly one
entire common face. Some meshes contain degenerated elements or irregularly subdivided elements and in result violate this rule, and then Tosca
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In this example, the target volume has been equal to 0.4. Here, one can only
attain relative volumes either between 0.04 and 0.355 or equal to 1.0 (this
happens if the isovalue is below 0.001: the surface of the whole model is produced since all elements have material values above 0.001). Here, the solution might be to set the target volume to 0.355 or lower, or set a fixed isovalue
(e.g. to 0.135 in order to get relative volume equal to 0.326).
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Validation Run in Tosca ANSA environment
Structure.smooth is not able to complete the isocut. An error message typically looks like this:
**** TOSCA Structure Smooth ERROR ****

Error in SurfaceGenerator::RemeshPolygonsFromEdgeList: a
node has more than 2 adjacent nodes
Report this problem and the circumstances under which it
arose to your customer support representative, making any
PARAMETER FILE and FE SOLVER INPUT FILE available as part of
the report.
Meshes with inner holes. If the model contains an empty domain that is
completely surrounded by material, the calculated volume will be incorrect
as the volume of this hole will be added to the total volume instead of being
subtracted. Otherwise, this has no effect on Tosca Structure.smooth. It
might be suspected that the inner holes exist if a message "Surface is disconnected; the number of connected components is.." is produced and the
number of connected components is too large. The parameters
RESULT_FILTERING and COMPONENT_LIMITING_SIZE are designed to
solve this problem.
If an error occurs during the generation of an output file, a warning instead of
an error is produced so that the remaining output files could be generated.
Such warnings might help understand why the files cannot be saved
9.2

In Tosca ANSA environment, once RUN_SMOOTH command finishes, the elements of the input model are replaced with the smooth isosurface representing the optimization result (with the exception of loaded elements that remain
unchanged). At this point, the model can be saved in the format of the desired
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Self-intersecting surfaces. Although Tosca Structure.smooth is able to prevent new self-intersections, those that are present in the original model are
likely to remain. Coplanar faces with common inner points also count as
intersecting; thus, a warning of large number of self-intersections happens
e.g. if a wall inside of a solid structure exists and is remeshed differently
from both sides. This wall will also remain inside of the resulting surface. In
Tosca ANSA environment, the self-intersections of a surface might remain
after RECONSTRUCT (in rare cases, RECONSTRUCT creates new self-intersections), that in turn makes SOLID_MESH fail.
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Tosca Structure
solver using File | Output | <solver name> menu command. However, this model will only contain the geometry information, namely the
smooth isosurface (or model surface) generated by Tosca Structure.smooth
plus the loaded elements copied from the original model. In order to construct
an optimized model suitable for the validation run, following actions are provided by Tosca ANSA environment:
1. BATCH_RECONSTRUCT or MANUAL_RECONSTRUCT: modification of the
surface
2. SOLID_MESH: remeshing of the volume defined by the modified surface
3. VALIDATION_OUTPUT or MODIFICATION_FILES: saving the remeshed
model and the information copied from the original model in solver format.
If needed, FE analysis of the produced model by the selected solver can be
started from within Tosca ANSA environment using VALIDATION_RUN. This
option is available only when the verification model was created using the
VALIDATION_OUTPUT command.
Due to specific aspects of ANSYS models not supported by ANSA, in this
case the generation of validation models using modification files is required.
The validation run can then be started manually in your familiar solver environment (ANSYS workbench). This is also an alternative if the standard way
using VALIDATION_OUTPUT does not work.
BATCH_RECONSTRUCT and MANUAL_RECONSTRUCT

Before the model can be remeshed, the surface calculated by Tosca Structure.smooth needs to be modified. In general, this modification attempts to
make the surface homogeneous by distributing the elements evenly. In contrast to the surface smoothing done by Tosca Structure.smooth, the nodes
and elements of the surface get replaced so that the topology of the surface
changes as well as the geometry. However, the nodes with boundary conditions or loads either remain unchanged or (in case of SPC nodes) are modi-
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fied in a way that complies to the conditions. Additionally, the user can freeze
the SPC nodes manually.
Fig. 304 Tosca ANSA environment: BATCH_RECONSTRUCT item and

RECONSTRUCT PARAMETERS dialog
Both BATCH_RECONSTRUCT and MANUAL_RECONSTRUCT items in Task
Manager provide basically the same functionality of surface modification. In
the dialog opened by Edit in the BATCH_RECONSTRUCT folder (Fig. 304),
the following settings are available:
Preview (checked by default) tells Tosca ANSA environment if the preview dialog that requests the user confirmation of the reconstructed surface
is to be shown.
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Automatic feature line recognition at

SMOOTH_CUT_ELEMENTS area (unchecked by default): when switched
on, the new surface will follow the feature lines of the surface generated by
Tosca Structure.smooth; this usually leads to better surface quality in problematic places (and sometimes is required in order to prevent the self-intersections) but leads to uneven distribution of element sizes. The safer
option is to switch it on.
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Freeze SPC Nodes: Freezes the nodes with applied single point constraints.
Fig. 305 Tosca ANSA environment: Mesh Parameters dialog
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The command Parameters applied on BATCH_RECONSTRUCT item opens

Mesh Parameters dialog containing the advanced surface reconstruction
parameters. For most applications, the default values suffice.
On Shell Mesh tab, the element type for your resulting surface mesh (tria,
quad or mixed) is set. Using QUAD is not recommended since it does not
work for the majority of models.
The Target Length section defines the element length used by the reconstruct function. The user may set a required value for the element length
(entry field option, see Fig. 306), maintain the existing average element
length (average option), maintain the existing local length (local option) or
impose no guideline (free option).
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Information about other settings can be found in the tool tips of the corresponding fields.
Using Update command on BATCH_RECONSTRUCT item starts the reconstruction of the entire model surface.
If it is needed to modify only a part of the surface, MANUAL_RECONSTRUCT
item should be used. In this case, the command Edit opens Shell Mesh
Parameters dialog; after using Update command, the desired shell elements are to be selected first and then the selection confirmed by clicking the
middle mouse button; then, select or deselect the edges of the feature lines (if
needed) and click the middle mouse button again. Then, the selected region
will be reconstructed and a preview window shown; after confirming the modification, repeat the process with other regions or press Escape key (or click
the middle mouse button once more) if finished.
In order to undo the surface modifications made by BATCH_RECONSTRUCT or
MANUAL_RECONSTRUCT, and, if needed, to repeat it with different settings,
the most simple way is to repeat Tosca Structure.smooth run. To do it, apply
Change command on RUN_SMOOTH item in order to remove the results of
Tosca Structure.smooth and to reload the initial model. Then, run Tosca
Structure.smooth again using Update command.
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Fig. 306 Tosca ANSA environment: Target length for edge size
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Tosca Structure
9.2.2
SOLID_MESH
The remeshing of the solid model defined by its surface is done using the
item SOLID_MESH (Fig. 307).
Fig. 307 Tosca ANSA environment: SOLID_MESH item
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Select Update command in order to start the automatic remeshing of all

regions. Note that, although it is not required that BATCH_RECONSTRUCT or
BATCH_RECONSTRUCT are done before SOLID_MESH, this is recommended.
Moreover, these actions will be performed automatically if the corresponding
items are available and appear unchecked.
Remeshing of a solid model cannot be done if the surface contains self-intersections. The remeshing is done with tetrahedra, or, in case of mixed surface
(or the surface consisting entirely of quadrilaterals), with tetrahedra and 4sided pyramids; the order of elements matches the highest order of the surface triangles. E.g., if a triangular surface contains at least one 2nd order triangle, the entire solid model will consist of 2nd order tetrahedra.
If the model contains both solid and shell elements, SOLID_MESH fails. A
workaround is to hide the shell elements using View | Show Only command on RUN_SMOOTH item right before starting SOLID_MESH; when the
remeshing is done, the shell elements can be shown again using All button
on General Buttons panel.
9.2.3
Generating the model for validation run

The model for validation run combines the geometry produced by
SOLID_MESH (or, in case of a shell element model, by RECONSTRUCT) with
the loads, boundary conditions, materials etc. from the initial model. Note that
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Fig. 308 Tosca ANSA environment: VALIDATION_OUTPUT item

For models with shell elements, these elements get a default property created by Tosca ANSA environment; this is because Tosca Structure.smooth
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the node-related information is only conserved for the nodes that are common to the original model and the surface generated by Tosca Structure.smooth. E.g., since the intermediate nodes of quadratic elements are not
taken into account by Tosca Structure.smooth, any loads assigned to them
are lost. The only exception to this rule is that the new nodes placed between
two SPC nodes by Tosca Structure.smooth get SPC status as well.
For 3D models, Tosca Structure.smooth replaces the solid elements with the
isosurface but leaves the loaded elements unchanged. Therefore, the only
element-related information that remains in the model for validation run is
restricted to the loaded elements. The loaded nodes (but not SPC nodes) are
automatically marked as remaining by Tosca Structure.smooth, so that they
are necessarily present in the isosurface, unless they belong to a small isolated
part
that
gets
removed
(see
the
description
of
COMPONENT_LIMITING_SIZE parameter of Tosca Structure.smooth).
The model for validation run is written in the same solver format as the original model using the item Tosca Structure
Task
|
SMOOTH
|
SMOOTH_INSTANCE | VALIDATE | VALIDATION_OUTPUT (Fig. 308).
Choosing New | VALIDATION_OUTPUT on VALIDATE item opens a file
saving dialog; after the file is chosen, its name is used as the name of the
VALIDATION_OUTPUT item. To change the file name, apply Edit command
on this item. Further solver specific settings may be available. Select Update
to generate the model. For the models with solid elements, it is recommended
to save the model after applying SOLID_MESH, since otherwise only the surface (plus the loaded elements) will be saved.
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Tosca Structure
does not preserve the information about element properties. Initially, the
default properties have DEFINED = NO as can be seen when applying Edit
command to such property in the window opened via Windows | Properties main menu command. Because of that, these properties are not saved
in the model for validation run, and thus it contains elements with undefined
properties and the solver run fails. A solution to this problem is to set DEFINED = YES manually to the automatically defined property (usually called
PSHELL 1) using the dialog opened by Windows | Properties main
menu command.
Using File | Output command, it is possible to save the model in any
available solver format; however, this method is not recommended since only
the model geometry and the groups are expected to be saved, and, also, the
shell elements should be removed manually if the result of SOLID_MESH
alone is to be saved.
Remark:
For the automatic generation of validation models in Tosca ANSA environment only one material can be supported in the design area.
Modification files
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The model for validation run is written in the same solver format as the original model using the item TOSCA Structure Task | SMOOTH |
SMOOTH_INSTANCE | VALIDATE | MODIFICATION_FILES (see Fig. 309).
In the appeared Save dialog, the user must specify the name of the verification model in the optimization neutral .onf format. However after choosing
MODIFICATION_FILES | Update the verification model will be created in the
solver format of the design space model.
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After creating a verification file using the MODIFICATION_FILE option, the

execution of the solver job from TAE is not possible. Please use your solver
specific environment for starting and postprocessing the verification job.
Fig. 309 Tosca ANSA environment: MODIFICATION_FILE item
Starting the validation run

After the model for the validation run is generated, the finite element analysis
can be started. When Update command is applied on Tosca Structure Task
| SMOOTH | SMOOTH_INSTANCE | VALIDATE | VALIDATION_RUN
item (Fig. 310), the solver corresponding to the input model is started. The
analysis results or any log files produced by the solver are not loaded into
ANSA; the only action that is performed is that the solver executable is
started in the directory where the output model is located. Instead of using
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VALIDATION_RUN item, the solver can be started from command line with
the same consequences.
Fig. 310 Tosca ANSA environment: VALIDATION_RUN item

The solver executables are configured in TOSCA.defaults file located in
.BETA/ANSA/version_<your ANSA version> subdirectory of your
home directory. In order to set the correct executable, please open this configuration file with a text editor and search for "<solver name>_COMMAND"
entry, where <solver name> is one of Nastran, Abaqus, ANSYS or PERMAS, and enter the name of the executable including its full path after "="
symbol. For the parameter ANSYS_COMMAND, the format is as follows:
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ANSYS_COMMAND = <executable with full path>,<product>

where <product> is the product name (e.g. "ansys"). Please note that no
space characters are allowed in paths to the executables; if this is the case,
please create a shortcut pointing to the executable placed in a directory such
that its path does not contain spaces, and use the shortcut in place of the
executable name.
9.3
Validation Run in Tosca Extension for ANSYS/

Workbench
After an optimization the optimization result can be checked in a subsequent
validation analysis. First, a smoothing step has to be performed to derive a
surface model of the smoothed surface. Based on this model, a solid model is
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Validation Run in Tosca Extension for ANSYS/Workbench
reconstructed and can be loaded with the original forces and supported with
the original boundary conditions.
Mesh generation for validation model:
Original design space.
Optimization result.
Smoothed optimization result.

This is a surface model only for visualization purposes.
Validation result.
The solid mesh is ready to be used and
can be loaded with loads and boundary
conditions again.
Remark:
After a smoothing run and an adjected validation run, there might be some
artifacts contained within the geometry. Once the validation model is opened
in the Mechanical application, it is possible to delete (suppress) any artifacts
easily by hand.
To delete such artifacts simply suppress all undesired parts of the geometry.
Attention: They might be small and not even noticable. They can only be sup2 - 554 User Manual
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Solid model.
The smooth model
gets remeshed to
a tetraeder solid
mesh.
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pressed because they are listed in the Geometry section in the Tree Outline window.
Starting the Validation Run:
As mentioned above, the solid model has to be reloaded within a Mechanical application for further use.
To apply the original loads and boundary conditions to the modified optimization result, there is an automatically copied Static Structural system to
reuse all defined loads and boundary conditions on the new model for a new
calculation. There are different steps and methods to set up the Validation.
1. Click Validation | Run to
start the optimization. The
process takes a few minutes
and is finished as soon as the
new Validation System is
opened.
Common Validation Procedure, reassigning Geometry:
2. The Validation System is a

Copy of the initial Analysis
System. Mesh Controls have
been deleted to make the solid
meshing possible. Forces,
boundary conditions and other
options, too, have to be reassigned again, due to the
changed Geometry.
Go through the items of the
Tree Outline and reselect
the corresponding Faces etc.
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The described procedure below works on condition that you dont want to
change the mesh of the Validation Model (e. g. not adding Mesh Controls
like Sizing, or using Virtual Topology to adjust the geometry) or if you
want to change the geometry or the mesh, and no errors occur during
remeshing. Otherwise, see "Remark 1 - Changing the Mesh is not possible".
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4. Click Validation | Import

Contacts to restore the intial
contact definitions. This step
deletes the existing Contacts in
the current Validation Analysis
and creates new ones based on
your initial settings. Importing
contacts might take a few
seconds and is finished as soon
as you can see the new names
in the Tree Outline. After
importing, you have to unsupress the Contacts and reassign the Geometry (Source and
Target faces).
5. As soon as the Geometry is
reassigned, the Validation
Model can be solved. Right
click on Solution | Solve.
Remark:
If you have several Analysis
Systems, you have to import
contacts and reassign the
Geometry for each analysis,
since they are not shared.
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3. If there are Contacts with Type

unlike Bonded in your Model,
they wont be copied properly
into the Validation System,
since Mechanical creates new
(Bonded) Contacts automatically.
Therefore, the Contact Definitions have been saved when
you have clicked Validation | Run. To reload the
saved Contact Definitions,
select Connections in the
Tree Outline of the Validation System.
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Remark 1 - Changing the Mesh is not possible:

If you want to change the Validation Mesh e. g. by adding Mesh Controls
or Virtual Topology, and ANSYS cannot remesh the geometry, there
might be so called "Problematic Faces" in your Model. The following
approach shows how to find and remove such faces.
1. Close the Mechanical Application, go to the Project Schematic and open the Model cell
of the Finite Element Modeler.
3. If there are any, select Skin

Detection Tool (SDT) in the
Tree Outline. In the
Details View, switch
Forbid Closed components to Yes.
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2. Check the Tree Outline for

Problematic Faces.
Remark:
If there are no Problematic
Faces, you can skip the
following steps. Add mesh
controls like a lower element
size (Mesh Controls |
Sizing) to make meshing
possible.
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4. Right click on Initial

Geometry | Generate to
create geometry with the
changed settings.
5. If Problematic Faces still exist,

it is additionally necessary to
reduce the Cut Angle or the
Tolerance Angle in the SDT
Details View. After changing
these angles, the geometry has
to regenerated again (Initial
Geometry | Generate).
7. Double click the Model cell of

the TOSCA Validation Analysis
System. When asked whether
to read the upstream data or
not, choose Yes, if you generated new Geometry in the FE
Modeler, otherwise click No.
After these steps remeshing
should be possible and the Validation can be continued.
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6. Close Finite Element Modeler

after dissolving the Problematic
Faces. Right click on the Model
cell of the FE Modeler and
choose Update.
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Remark 2 - Recreating Faces using Virtual Topology:

During the Validation a new Geometry was created. It is possible, that several
faces are merged into a bigger face, or one face is split up into multiple faces.
In the second case, you just have to reselect all faces which represent the initial face and assign it as geometry to your boundary condition.
Attention: After using Virtual Topology to adjust the Geometry, the
Mesh has to be regenerated (Tree Outline: Mesh | Generate Mesh).
1. Select multiple faces to
recreate your initial face selection.
If you want to split one face into several small faces or add an edge or vertex
at a specific location, you have to use Virtual Topology. The following
steps will give you a short introduction.
3. There are two possibilities to

create a new vertex. Either you
split an edge or you create a so
called "Hard Vertex" somewhere on a face.
To create a vertex on an edge,
activate the Edge-Selection-Tool.
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2. Select Model in the Tree

Outline and click on
Virtual Topology in the
upper Toolbar.
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4. Click on the location where you

want to split and press the
Split Edge at + button in
the Virtual Topology Toolbar
(Virtual Topology needs to
be selected in the Tree
Outline to make the Toolbar
visible).
The different colors of the edge
symbolize that there two edges
with a new vertex.
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5. To create a vertex somewhere

on a face, activate the FaceSelection-Tool and click on
the location where you want to
create the new vertex.
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6. Click on Hard Vertex at +

on the Virtual Topology Toolbar.
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7. To split a face, select two

vertices (Vertex-Selection-Tool) and click on
Split Face at Vertices.
9.4
Workarounds Using Other Environments

The optimization result has to be processed for further use. In particular for
topology optimization results the quality of the design proposal has to be
checked. Using Tosca ANSA environment a validation run can be set up and
started automatically following the task manager. In other environments, this
is also possible but requires some - sometimes time consuming - manual
work and is thus not recommended.
The procedure to set up a validation run for a solid mesh is as follows:
1. Create a smooth isosurface of your optimization results and exclude your
loaded elements from the isosurface result. Please note: this is only
User Manual 2 - 561
SIMULIA
Tosca Structure
Result Transfer
possible using Tosca ANSA environment (set automatically) or Tosca

Structure.pre (check "Exclude loaded Elements" box).
2. Output the isosurface to your solver format.
3. Load the isosurface into your preprocessor and add the original loaded
elements (plus all elements containing loaded or fixed nodes) including the
original loads and fixations.
4. Remesh your isosurface in your preprocessor.
5. Write the complete model to your solver format and start the solver run.
Please note: this workflow strongly depends on your preprocessor capabilities and may require manual corrections of the model from your part.
9.5
Result Transfer
If requested, Tosca Structure.smooth outputs the generated (iso)surface in a
format suitable for the result transfer. See vol.2 chapter 9.1.1 or vol.2 chapter
9.1.2 for details about how Tosca Structure.smooth can be started from Tosca
ANSA environment or Tosca Structure.gui.
Tosca Structure.smooth enables the output of the (iso)surface in IGES and
STL formats as well as the output of slices in IGES or CLI format. See vol.2
chapter 9.1.9 and, specifically, Table 34 for the detailed description.
Result transfer to CATIA RSO module

The results of the shape optimization can be transferred to the CAD model in
such a way that the results are used to deform/modify the geometry of the
CAD based component. All modifications added by the optimization system
will be applied. To obtain the modification file, a specific USERFILE definition
has to be activated in your parameter file. In your installation directory the
macro uf_shape_catia_rso.mac already contains the necessary output
request (see also chapter 10.5.4.2 Modification file for CATIA RSO module).
9.5.2
Result transfer to NX
macro uf_shape_nx_deform.mac already contains the necessary output
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9.5.1
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Tosca Structure
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Version 8.1.0 Rev. 1 - 05.2014
request (see also chapter 10.5.4.2 Modification file for CATIA RSO module).
In NX the function "global deformation/Point from File" can be used for further
processing.
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SIMULIA
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Result Transfer
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Tosca Structure
Postprocessing of Optimization Results
10 Postprocessing of Optimization
Results
Postprocessing of Tosca Structure optimization results consists mainly of
visualizing the model changes in the optimization process and regarding plots
and tables of optimization relevant values. These data can be combined and
provided using Tosca Structure.report. Visualization and processing is done
using Tosca Structure.view.
Certainly, the analysis results of the single optimization steps can be evaluated in your familiar FE-postprocessing system by reading the corresponding
solver result file from the SAVE.<ext> directory. Further, the results of your
validation run can also be processed in your postprocessing environment.
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10.1 Generation of Postprocessing Data

The result of topology optimization is the normalized material distribution in
the optimized model; in other words, for each element, its "density" is found.
These values are saved in a solver result file, or, for visualization reasons, in
vtfx files by the component Tosca Structure.report. Further, smoothed results
can also be processed in vtfx format.
Shape and bead optimizations result in displacements of the nodes in the
design area. In this case, too, Tosca Structure.report produces vtfx files containing the model with these displacements. Beside the optimization displacements, it is possible to write the controller input values from controller-based
shape or bead optimization to the output file in vtfx format for visualization.
Sizing optimization modifies the shell thicknesses in the model. Tosca Structure.report produces vtfx files containing the model with the modiied shell
thicknesses as well as the shell thickness changes as contourplot.
Morphing creates similar to shape optimization models with displaced nodes.
Tosca Structure.report produces vtfx files containing the model with these displacements for each morphing step. Beside the optimization displacements, it
is possible to write the controller input values from the assigned shape optimization task.
Additionally, optimization relevant values (scalar values of objective or constraint) and all design responses or variables defined in the optimization job
will be available in an history plot in the vtfx report.
Please Note: Conversion of optimization results to solver formats is no longer available. Tosca Structure.view remains the quickly accessible, easy-touse method for postprocessing of optimization results.
User Manual 2 - 565
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Tosca Structure
Generation of Postprocessing Data
Nevertheless, analysis and evaluation results of the optimized model are

available for postprocessing.
10.1.1 Tosca Structure.report in Tosca ANSA environment

In Tosca ANSA environment, Tosca Structure.report is associated with the
item Tosca Structure
Task
|
POST-PROCESSING
|
GENERATE_REPORT_FILE of the Task Manager.
Fig. 311 Tosca ANSA environment: GENERATE_REPORT_FILE
Fig. 312 Tosca ANSA environment: Job for report file

To create an animation sequence for postprocessing, choose New |
CONTOUR_PLOT and edit CONTOUR_PLOT PARAMETERS. Select Update
command to start Tosca Structure.report.GENERATE_REPORT_FILE | NEW
| VTF_VISUALIZATION | VIEW starts the produced VTFX report file in
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Edit opens REPORT_FILE_SETTINGS dialog in order to choose job for

report generation.
SIMULIA
Tosca Structure
Tosca Structure.view. Note that it is necessary to close Tosca Structure.view

window in order to continue working with Tosca ANSA environment.
Fig. 313 Tosca ANSA environment: CONTOURPLOT and

VTF_VISUALIZATION
CONTOUR_PLOT parameters
ALL | LAST
Iteration(s) added to report
TYPE_PROP
ERTY
ELEMENT
FILL FILTER
Topology optimization results (material distribution
NODAL CONTINUOUS
(SHAPE)
Shape optimization results (model with

optimization displacements), plus the controller input values as fringe plot
NODAL DISPLACEMENT(SHAPE
)
Shape optimization results (model with

optimization displacements), plus the optimization displacements as fringe plot
NODAL CONTINUOUS
(BEAD)
Bead optimization results (model with optimization displacements), plus the controller input values as fringe plot
NODAL DISPLACEMENT
(BEAD)
Bead optimization results (model with optimization displacements), plus the optimization displacements as fringe plot
MODEL
Initial geometry without groups
MODEL AND
SETS
Initial geometry and groups from

GROUPS.onf file
<value>
minimum and maximum value for filtering.

Applies only for TYPE_PROPERTY = ELEMENT FILL FILTER. No or both values
have to be set.
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ITERATION
FILTER
MIN (MAX)
User Manual 2 - 567
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Tosca Structure
CONTOUR_PLOT parameters
FRINGE
MIN (MAX)
Table 37
<value>
minimum and maximum value for fringe.

Applies for Shape and Bead results. No or
both values have to be set.
Tosca Structure.report: Contourplot Parameters in Tosca

ANSA environment
Fig. 314 Tosca ANSA environment: CONTOUR_PLOT PARAMETERS

Per default Tosca Structure produces a standard report file at the end of each
optimization run.The files produced by Tosca Structure.report are located in
the subdirectory TOSCA_POST of the job directory. The default name of the
output file is
If the item GENERATE_REPORT_FILE is renamed, the output file names will

contain the new name of the item instead of GENERATE_REPORT_FILE. This
way, it is possible to save the results of Tosca Structure.report generated with
different settings under different file names.
10.1.2 Tosca Structure.report in Tosca Structure.gui

Using Tosca Structure.report screen of Tosca Structure.gui, Tosca Structure.report is started with the button Generate Report (see Fig. 315). Once
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TOSCA_POST/GENERATE_REPORT_FILE.vtfx.
SIMULIA
Tosca Structure
the generation of postprocessing files is finished, press View Report button

to open eventually generated VTFX files in Tosca Structure.view.
In the field Jobname select the parameter file of the optimization job for which
the postprocessing report is to be generated. The Directory of the job is
shown for control reasons and is filled in automatically. The Output Name is
set automatically to <jobname>_report, but can be changed by the user.
Group selection allows to write the whole report restricted to one group chosen in the Select Group drop down dialogue. With this option you can
reduce the file size significantly and also focus the attention directly to special
preselected regions of interest.
The flag Original Model defines if the start model including groups is
added to the report. Additional parameters can be used to add command line
parameters manually and are mostly used for debug reasons.
When selecting your parameter file, all optimization results available for this
job appear in the result selection table. Per default, all results will be added to
the report and can be visualized as 3D animation sequences. To decrease
the report file size, several results can be excluded from the report generation.
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Version 8.1.0 Rev. 1 - 05.2014
Fig. 315 Tosca Structure.gui: Tosca Structure.report screen
User Manual 2 - 569
SIMULIA
Tosca Structure
Result Name
File
Generated visualization sequence
Controller
Input
TP
Controller Input from topology optimization

shown as fringe plot on corresponding
case
Material Distribution
(normalized)
TP
Relative material distribution from topology

optimization shown as fringe plot on corresponding case
Optimization
Displacements
SHAPE
Shape optimization displacements (i.e.

deformed model) shown on all cases with
scalar results as fringe plots
Controller
Input
SHAPE
Controller input values from shape optimization shown as fringe plot on corresponding case
Opt. Displacement
Values
SHAPE
Optimization displacement values from

shape optimization shown as fringe plot on
corresponding case
Optimization
Displacements
BEAD
Bead optimization displacements (i.e.

deformed model) shown on all cases with
scalar results as fringe plots
Controller
Input
BEAD
Controller input values from bead optimization shown as fringe plot on corresponding
case
Opt. Displacement
Values
BEAD
Optimization displacement values from

bead optimization shown as fringe plot on
corresponding case
Table 38
Tosca Structure.report: Result Names
Specific settings are available for some of the results to control colouring and
filtering.
Tosca Structure.report: Result Selection Parameters
ITER
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ALL | LAST
|<nr>
Iteration(s) added to report, a specific number can also be entered
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Tosca Structure.report: Result Names
SIMULIA
Tosca Structure

FILTER
MIN (MAX)
<value>
Minimum and maximum value for filtering.

Applies only for result = Material Distribution (normalized). No or both values have
to be set.
FRINGE
MIN (MAX)
<value>
Minimum and maximum value for fringe

visualization. Applies for shape and bead
controller input results. No or both values
have to be set.
ADD UNDEFORMED
MODEL
Table 39
Adds undeformed model (in blue) to all displacement views in the vtfx file.
10.1.3 Tosca Structure.report in Tosca Extension for ANSYS/

Workbench
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There is no need to use Tosca Structure.report when calculating with Tosca

Extension for ANSYS/Workbench.
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Tosca Structure
All optimization and smooth results are provided within the Mechanical application.
Fig. 316 Standard result visualization is done directly in Mechanical
Fig. 317 Use the Graph window to either create an iteration animation of
the optimization run or visualize single iteration steps
Tosca Structure.view can also be used since a vtfx-file is generated automatically during the optimization run. It is saved in the tosca-folder of the work
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An iteration animation is also possible using the standard graph window

within the Mechanical application. Single iteration steps are also possible for
visualization. Therefore use the right mouse button in the Graphs table and
select Retrieve this Result.
SIMULIA
Tosca Structure
directory. Find it using the right mouse button on solution and select Open
Solver Files Directory, then go to the folder tosca\TOSCA_POST.
Fig. 318 Use the right mouse button to find the files directory
10.1.4 Starting Tosca Structure.report in Commandline

The following command line options are most common used in Tosca Structure:
Input
--input_file
Option
parfilename
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--logstderr
Comment
parameter file name (with or without .par extension)
log to stderr instead of stdout
--loglevel
QUIET
CRITICAL
ERROR
WARNING
NOTICE
INFO
DEBUG
TRACE
DEVELOP
loglevel
--job
<string>
ID name of the REPORT command from the

parameter file. All REPORT-commands are processed as default.
--add_user
_data
<string>
Comma separated list of files to be added to the

UserData directory in the VTFX file. E.g. "-add_user_data plot.conf,plot.tab" will add the files
"plot.conf" and "plot.tab" to the UserData directory
of the VTFX.
--version
Displays version information and exits.
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Tosca Structure
Input
Option
--help
Comment
Displays usage information and exits.
The --input_file is required, all other parameters are optional.

Example:
--input_file, --add_user_data:
$ tosca_report --input_file tosca_report.par
--add_user_data plot.conf,plot.tab
The postprocessing files are generated and stored in the TOSCA_POST
directory.
10.1.5 Standard Reports

At the end of each optimization run, Tosca Structure generates standard postprocessing reports based on templates in the installation and OPTIONS
specified in your parameter file. The results are available as vtfx file <jobname>_report.vtfx in the directory <jobname>\TOSCA_POST. Tosca Structure generates automatically parameter files for each standard report like in
the examples below. The corresponding TOSCA command is described in
detail in REPORT command specification.
10.1.5.1 Tosca Structure.topology results

Per default, postprocessing reports for topology optimization show only one
case: the material distribution during the optimization. Further, the values of
objective function and constraint and eventually defined variables are shown
in result plots.
ID_NAME
= TOPO_MAT
TYPE_PROPERTY = ELEMENT_FILL_FILTER
TITLE
= "Relative Material Distribution,
soft elements filtered"
DESCRIPTION
= "TOSCA Structure.topology
Optimization Result"
FRINGE_RESULT = MAT_PROP_NORMALIZED
FILTER
= 0.05,1
ITERATION
= ALL
GROUP_FILE
= "SAVE.onf/GROUPS.onf"
END_
REPORT
ID_NAME
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= __JOBNAME___report
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CONTOURPLOT
SIMULIA
Tosca Structure
RESULT
MODEL
OUTPUT_FILE
CONTOURPLOT
=
=
=
=
"SAVE.onf/TP"
"SAVE.onf/MODEL_fem.onf"
__JOBNAME___report
TOPO_MAT
END_
A smoothed model can be added to the report automatically. Isovalue or target volume can be set in the OPTIONS command in the parameter file.
10.1.5.2 Tosca Structure.shape results

Standard postprocessing reports for shape optimization show two different
cases: the controller input on the deformed model during the optimization as
well as the absolute displacement values. Further, the values of objective
function and constraint (if available) as well as the history of design response
values are shown in result plots.
CONTOURPLOT
ID_NAME
= SHAPE_DISP
TYPE_PROPERTY = NODAL_DISPLACEMENT
TITLE
= "Nodal Displacement from
Shape Optimization"
DESCRIPTION
= "TOSCA Structure.shape
FRINGE_RESULT = DISP_OPT_VAL
DISP_RESULT
= DISP_OPT
ITERATION
= ALL
GROUP_FILE
END_
Version 8.1.0 Rev. 1 - 05.2014
CONTOURPLOT
ID_NAME
TYPE_PROPERTY
TITLE
DESCRIPTION
=
=
=
=
FRINGE_RESULT
DISP_RESULT
ITERATION
GROUP_FILE
=
=
=
=
SHAPE_CTRL
NODAL_CONTINUOUS
"Controller Input on deformed model"
"TOSCA Structure.shape
CTRL_INPUT(OPT.)eqv.
DISP_OPT
ALL
"SAVE.onf/GROUPS.onf"
www.3ds.com/tosca
END_
User Manual 2 - 575
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Tosca Structure
REPORT
ID_NAME
RESULT
MODEL
OUTPUT_FILE
CONTOURPLOT
CONTOURPLOT
=
=
=
=
=
=
__JOBNAME___report
"SAVE.onf/SHAPE"
__JOBNAME___report
SHAPE_CTRL
SHAPE_DISP
END_
Nodal displacement plots in normal direction

To request nodal displacement plots that show the node displacement in normal direction only, a special USER_FILE commando is required in the parameter file.
USER_FILE
ID_NAME
FORMAT
EL_GROUP
TYPE
FILE_NAME
WRITE
FILE_OPTION
END_
=
=
=
=
=
=
=
UF_SHAPE_NORM_DISP
ONF
ALL_ELEMENTS
SHAPE_NORM_DISP
SHAPE_NORMAL_DISP
EVER
VAR2
For generating the plots within a TEST_SHAPE run, the dispalcements of the
next iteration mus be requested and the test_shape FORMAT must be set to
user defined post processing output.
= UF_SHAPE_NORM_DISP
= SHAPE_NORM_DISP_N
TEST_SHAPE
OPTIMIZE = OPTIMIZE_SHAPE_CONTROLLER
DIRECTION = GROW
DISPLACEMENT = 10
INCREMENT = 5
USER_FILE
= UF_SHAPE_NORM_DISP
FORMAT
= USER_FILE
END_
Both commandos create a bunch of onf files in the SAVE.onf directory. Now,
TOSCA_GUI can be used to generate vtfx plots.
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USER_FILE
ID_NAME
! [...]
TYPE
END_
SIMULIA
Tosca Structure
10.1.5.3 Tosca Structure.bead results

Standard postprocessing reports for bead optimization show one case: the
optimization displacement value on the deformed model during the optimization. Further, the values of objective function and constraint (if available) as
well as the history of design response values are shown in result plots.
CONTOURPLOT
ID_NAME
= BEAD_DISP
TYPE_PROPERTY = NODAL_DISPLACEMENT
TITLE
= "Nodal Displacement from
Bead Optimization"
DESCRIPTION
= "TOSCA Structure.bead
DISP_RESULT
= DISP_OPT
ITERATION
= ALL
GROUP_FILE
END_
REPORT
ID_NAME
RESULT
MODEL
OUTPUT_FILE
CONTOURPLOT
=
=
=
=
=
__JOBNAME___report
"SAVE.onf/BEAD"
__JOBNAME___report
BEAD_DISP
END_
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10.1.5.4 Tosca Structure.sizing results

Standard postprocessing reports for sizing optimization show two different
cases: the shell thickness change on the model during the optimization as
well as the shell thickness distribution. Further, the values of objective function and constraint (if available) as well as the history of design response values are shown in result plots.
REPORT
ID_NAME
MODEL
RESULT
OUTPUT_FILE
CONTOURPLOT
CONTOURPLOT
CONTOURPLOT
=
=
=
=
=
=
=
"SAVE.onf\MODEL_fem.onf"
"SAVE.onf\SIZING"
"TOSCA_POST\GENERATE_REPORT_FILE"
SIZING_THICKNESS
SIZING_DELTA_THICKNESS
MODEL
END_
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CONTOURPLOT
ID_NAME
TYPE_PROPERTY
TITLE
DESCRIPTION
=
=
=
=
SIZING_THICKNESS
ELEMENT_THICKNESS
Thickness from Sizing Optimization
TOSCA Structure.sizing
Optimization Result
FRINGE_RESULT = THICKNESS
ITERATION
= ALL
GROUP_FILE
= "SAVE.onf\GROUPS.onf"
END_
CONTOURPLOT
ID_NAME
TYPE_PROPERTY
TITLE
DESCRIPTION
Result
FRINGE_RESULT
ITERATION
GROUP_FILE
=
=
=
=
SIZING_DELTA_THICKNESS
ELEMENT_DELTA_THICKNESS
Thickness Change from Sizing Optimization
TOSCA Structure.sizing Optimization
= DELTA_THICKNESS
= ALL
END_
10.1.5.5 Morphing results

Standard postprocessing reports for morphing results contain a contour plot
of the OBJ_FUNC value referenced by the assigned shape optimization and
the nodal displacement plots.
= SHAPE_DISP_XXX
= NODAL_DISPLACEMENT
= "Nodal Displacement from Shape Morphing"
= "TOSCA Structure.shape Optimization
Result...."
DISP_RESULT
= DISP_OPT
ITERATION
= ALL
GROUP_FILE
GROUP
= __GROUP_NAME__
END_
CONTOURPLOT
ID_NAME
TYPE_PROPERTY
TITLE
DESCRIPTION
= SHAPE_CTRL_XXX
= NODAL_CONTINUOUS
= "Controller Input on deformed model"
= "TOSCA Structure.shape Morphing Result.
..."
FRINGE_RESULT = CTRL_INPUT(OPT.)eqv.
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CONTOURPLOT
ID_NAME
TYPE_PROPERTY
TITLE
DESCRIPTION
SIMULIA
Tosca Structure
DISP_RESULT
ITERATION
GROUP_FILE
GROUP
END_
REPORT
ID_NAME
RESULT
MODEL
CONTOURPLOT
CONTOURPLOT
END_
= DISP_OPT
= ALL
= __GROUP_NAME__
= JOBNAME_report_XXX
= "SAVE.onf/TOSCA_MORPH"
= "SAVE.onf/MODEL_fem.onf"
= SHAPE_CTRL_XXX
= SHAPE_DISP_XXX
10.1.5.6 Sensitivity plots

To access sensitivity information, you can write them to an ONF-file which is
then evaluated in a sensitivity plot. Using the following command it is possible
to create all sensitivity plots and add them to your report file:
REPORT
ID_NAME = sens_plots
SENSITIVITY_PLOT = YES
END_
Remark:
1. The USER_FILE command writing the sensitivity data to ONF format must
be in the original parameter file, because Tosca Structure.control must
know all OBJ_FUNCs and CONSTRAINTs.
For generating the ONF Data with the sensitivities inside the following statement has to be placed in the parameter file:
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Bead optimization
The sensitivities are written to an ONF file with the following command:
USER_FILE
ID_NAME = UF_BEAD_ONF_SENS
FORMAT = ONF
EL_GROUP = ALL_ELEMENTS
TYPE = BEAD_DATA_SENS
FILE_NAME = BEAD_SENS
WRITE = EVER
FILE_OPTION = VAR2
END_
Instead of writing the command the corresponding macro can be included:
User Manual 2 - 579
SIMULIA
Tosca Structure
INCLUDE, UF_BEAD_SENS_ONF.MAC
The sensitivities can be written in original form:
USER_FILE
ID_NAME = UF_TOPO_ONF_SENS
FORMAT = ONF
EL_GROUP = ALL_ELEMENTS
TYPE = TOPO_WITH_SENS
FILE_NAME = TP_SENS
WRITE = EVER
FILE_OPTION = VAR2
END_
Instead of writing the command the corresponding macro can be included:

INCLUDE, UF_TOPO_SENS_ONF.MAC
10.2 Tosca Structure.view

Tosca Structure.view is a powerful viewer for Tosca Structure optimization
results in vtfx format. It allows for easy postprocessing of your optimization
task.
Tosca Structure.view is installed during the installation of Tosca Structure. It is

started in a Tosca Structure command shell using the corresponding shortcut
tosca_view or by starting the executable tosca_view.exe in the directory tosca_install_dir\bin\<os>. The viewer is also opened when
View Report button in Tosca Structure.report screen (see Fig. 319) or View
Result button Tosca Structure.smooth screen of Tosca Structure.gui is
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10.2.1 Starting and using Tosca Structure.view
SIMULIA
Tosca Structure
clicked. In Tosca ANSA environment, the viewer opens with the item
VTF_VISUALIZATION | View (see Fig. 320).
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Fig. 319 Starting Tosca Structure.view from Tosca Structure.report screen

of Tosca Structure.gui
Fig. 320 Starting Tosca Structure.view from Tosca ANSA environment
User Manual 2 - 581
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Tosca Structure
Vtfx files generated by Tosca Structure.report usually contain several optimization steps and result cases. Initially, the first step and case is displayed
(see Fig. 321).
10.2.2 User Interface Tosca Structure.view
Fig. 321 Shape optimization model opened in Tosca Structure.view.

At the top you have a menu and button panel. On the left the case panel is
activated in which the different cases included in the vtfx file are listed.
Related case information for the active case is shown at the bottom. To
access the case panel press the case button (marked in Fig. 321).
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The main window of Tosca Structure.view is shown in Fig. 321.
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Model navigation
In the main window in the middle you see the model (or result graph) of your
active case. To rotate or move the model you have to press Ctrl and use your
mouse as follows:
To rotate the model in space, move the mouse
while holding Ctrl + right mouse button.
To translate the model, move the mouse while
holding Ctrl + middle mouse button.
To rotate the model in plane, move the mouse
while holding Ctrl + left mouse button.
Use the mouse wheel to zoom in or out. Pressing F key scales the model to fit
in the current view.
Case Panel
On the case panel you can select another case by double click on it or you
pull by pressing left mouse button the other case in the main window. You can
select for example the origin model or, if you are in shape optimization you
can watch the displacements. But you can also select different graphs, for
example the convergence of the constraint. If you want to superpose two
cases press additionally Alt-key when pulling second case in the main window. More information about the case are shown in the lower part of panel.
Toolbar functions
Several useful items of the menu are created as buttons, which are arranged
in the button panel:
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Open file.
Capture active view, QuickCapture active view
(with previous settings) and Capture all view
cases to Tosca Structure Report Builder(see
chapter 10.4 Tosca Structure Report Builder).
Show or hide Info Box, Text and Legend. (See
also View menu).
Reset view: Restores the default view.
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Rubber Band Zoom: zooms in the selected

region.
Viewports: Select the number of viewports (one
to four) and their placement (vertical/horizontal
split)
Rotation and movement: Move as contour, move
more than one part synchronously, rotate around
an automatically chosen center and chose your
desired center of rotation yourself.
Select a part
or an element
or a node by clicking them with the mouse.
Selected objects are shown in the selection
panel.
Measure a distance and delete your measured
distance.
Full screen.
To display another step or to start the animation,

use the animation toolbar. The same actions are
accessible in main menu Animation group.
You can add or remove the case panel, the selection panel, the settings panel and the result
panel.
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Select one of the cases or go to the next or previous one.
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Selection Panel
The selection button on the toolbar enables the selection of parts
(such as the original and the new
surface in VTFX files generated
by Tosca Structure.smooth), elements or nodes by clicking them
with the mouse. The selected
object is shown in details in
Selection Panel activated by
a toolbar button
Settings Panel
Fig. 322 Settings Panel of Tosca Structure.view.
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The button Settings Panel displays the panel containing the list of parts
and groups (denoted "Element Sets"; the node groups are also shown via
artificial element sets). It allows to set visibility and drawing modes of parts
and element sets (see also chapter 10.2.3 Model and group visualization).
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Result Panel
In order to change the settings of
the fringe plot, display Results
Panel using a button on the
toolbar or Panels | Results
Panel main menu command. In
this window, the coloring scheme
can be changed in Legend
Settings panel; the values corresponding to the colors can be
changed by deselecting Automatic range settings
check box and entering the values in Minimum and Maximum
text fields or using the arrows
below.
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The information about remaining toolbar buttons appears in the help window
shown by Help | Help Contents command or when F1 key is pressed.
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Viewport settings
Tosca Structure.view allows to save the actual viewport and to reload existing
user defined viewports.
Right click in the view window
and choose View From |
User Defined | Save. A file
dialogue opens which allows the
saving of the actual viewport in a
.vcx file. This feature can also be
accessed using the menu View
| View From | User Defined | Save.
An existing viewport is loaded in
the same manner (right click in
the view window and choose
View From | User Defined
| Open...). All viewports
(.vcx files) saved in the same
folder as the vtfx file are directly
available in the submenu.
Export images and animations

Tosca Structure.view allows the export of images of the current view or of animations in avi format (avi-export for windows only).:
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Export of images or animations.
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Preferences
With View | Preferences general settings for Tosca Structure.view can be
saved. These include setting the plot line width.
10.2.3 Model and group visualization
In Parts tab of Settings Panel, the visibility of each part can be

switched on or off by checking the box. In Fig. 323, for example, only Part 1 is
visible. Change the draw style of selected parts (highlighted in Table of
Parts) using the radio buttons on the right side of the selection window.
Pressing Ctrl key and left click you can also select multiple parts. In Fig. 324,
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Fig. 323 Change the visibility of parts in Settings Panel of Tosca

Structure.view
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Tosca Structure
for example, Part 1 is visible, but the draw style can only be changed for Part
2, because Part 1 is not selected.
Fig. 324 Change the draw style of parts in Settings Panel of Tosca
Structure.view
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The part named Node Part refers to all nodes of the model represented by
little squares; it is only visible if Draw as filled surface or Draw as
points radio buttons are chosen in Draw Style. If you miss the Draw
Style panel right click in the field Table of Parts and activate As context menu.
Using the tab Element Sets, it
is possible to restrict the displayed objects to some element
or node groups. Note that the
parts that are hidden in Parts
tab are not shown regardless of
chosen groups in Element
Sets tab; therefore, in order to
visualize a node group, you need
to turn on Node Part in Parts
tab as shown above (it is turned
off by default).
In order to visualize a certain group alone, first make sure that all parts are
turned on in Parts tab, then click Show visible radio button in Element
Sets tab and check the group you wish to show. Show invisible displays
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all groups except the chosen ones. In the example below, the design area of
shape optimization (a node group MY_DESIGN_GROUP) is shown:
Fig. 325 Selecting Groups in Tosca Structure.view
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If, additionally, the group ALL_ELEMENTS is chosen and Draw as lines,

with hidden lines removed radio button in Draw Style panel of
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Parts tab is active for Part 1, the location of selected nodes is clearly
seen:
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Fig. 326 Selecting Groups in Tosca Structure.view

In the files generated by Tosca Structure.report, the groups from
GROUPS.onf file located in SAVE.onf directory are presented. This file contains the groups present in the input finite element model together with the
groups from Tosca Structure parameter file (defined, e.g., using Tosca ANSA
environment).
Note that if the model changes during the steps, the groups from the preprocessing can only be shown in the first step.
10.2.4 Visualization of topology optimization results

In case of topology optimization, the files produced by Tosca Structure.report
as described in chapter 10.1 Generation of Postprocessing Data contain all
optimization steps; in each step, only the elements with the material value
above a certain limit are displayed. This limiting value is set to 0.05 but it may
be changed in the parameters to Tosca Structure.report: in Tosca ANSA envi-
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Fig. 327 Example of material distribution in topology optimization
10.2.5 Visualization of shape optimization results

There are three variants of shape optimization results saved in VTFX file that
are accessible in Tosca ANSA environment:
1. Optimized geometry with the fringe plot of controller input values (items
under POST-PROCESSING | GENERATE_REPORT_FILE when
TYPE_PROPERTY = NODAL CONTINUOUS (SHAPE) selected at
CONTOUR_PLOT);
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ronment, it is the value of FILTER MIN field of CONTOUR_PLOT PARAMETERS dialog. See chapter 10.1 Generation of Postprocessing Data for details
about this parameter.
The following figure shows the first and the last iterations of a topology optimization:
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Tosca Structure
2. Optimized geometry with the fringe plot of displacements (items under

POST-PROCESSING | GENERATE_REPORT_FILE when TYPE_PROPERTY
= NODAL DISPLACEMENT (SHAPE) selected at CONTOUR_PLOT);
3. Geometry with test displacements and the fringe plot of displacements
(items under TEST_SHAPE_CHECK in CHECK_INPUTS).
Fig. 328 Optimized geometry (colored) with original surface (blue) and the
fringe plot of controller input for shape optimization results
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See chapter 10.1 Generation of Postprocessing Data for more details on

Tosca Structure.report, including the description of VTFX file generation from
Tosca ANSA environment and Tosca Structure.gui.
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In order to change the settings of

the fringe plot, display Results
Panel using a button on the
toolbar or Panels | Results
Panel main menu command. In
this window, the coloring scheme
can be changed in Legend
Settings panel; the values corresponding to the colors can be
changed by deselecting Automatic range settings
check box and entering the values in Minimum and Maximum
text fields or using the arrows
below.
10.2.6 Visualization of bead optimization results

There are three variants of bead optimization results saved in VTFX file that
are accessible in Tosca ANSA environment:
1. Optimized geometry with the fringe plot of displacements (items under
POST-PROCESSING | GENERATE_REPORT_FILE when TYPE_PROPERTY
= NODAL DISPLACEMENT (BEAD) selected at CONTOUR_PLOT);
2. Geometry with test displacements and the fringe plot of displacements
(items under TEST_BEAD_CHECK in CHECK_INPUTS);
3. Optimized geometry with the fringe plot of controller input values (items
under POST-PROCESSING | GENERATE_REPORT_FILE when
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The way to preset the minimal and maximal values for the fringe plot is to set
the values FRINGE MIN and FRINGE MAX in CONTOUR PLOT PARAMETERS
dialog of Tosca ANSA environment (see chapter 10.1 Generation of Postprocessing Data for the parameter names in Tosca Structure.gui). This way is
preferable in order not to need to modify the settings each time the VTFX file
is opened, e.g., when the file is imported in Microsoft PowerPoint presentation or a web page. Note that the viewer is not able to modify the files, so that
the settings are not saved in VTFX files.
SIMULIA
Tosca Structure
TYPE_PROPERTY = NODAL CONTINUOUS (BEAD) selected at

CONTOUR_PLOT).
See chapter 10.1 Generation of Postprocessing Data for more details on
Tosca ANSA environment and Tosca Structure.gui.
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Fig. 329 Optimized geometry with the fringe plot of optimization displacements
See the previous section about the possibilities to control the appearance of
the fringe plot.
10.2.7 Visualization of sizing results

There are two variants of sizing optimization results saved in VTFX file:
1. Optimized geometry with the fringe plot of shell thicknesses;
2. Optimized geometry with the fringe plot of shell thickness changes.
VTFX generation for sizing is not yet available with Tosca ANSA environment.
See the previous sections about the possibilities to control the appearance of
the fringe plot.
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See also chapter 10.1 Generation of Postprocessing Data for more details on
Tosca Structure.gui.
10.2.8 Visualization of morphing results

There are two variants of morphing results saved in VTFX file:
1. Optimized geometry with the fringe plot of displacements;
2. Optimized geometry with the fringe plot of controller input values.
For each morphing step one animation step is created in the vtfx file.
See the previous sections about the possibilities to control the appearance of
the fringe plot.
vtfx generation for morphing is not yet available with Tosca ANSA environment.
See also chapter 10.1 Generation of Postprocessing Data for more details on
Tosca Structure.report, including the description of vtfx file generation from
Tosca Structure.gui.
10.2.9 VTFX PlugIn for Office applications and Webbrowser

As an addition to Tosca Structure.view, Ceetron company provides a plug-in
for Microsoft PowerPoint, Microsoft Word and Microsoft Internet Explorer that
displays VTFX files in presentations and internet pages. The user can not
only animate the displayed model but also move it, turn it and zoom.
The plug-in is not included in the Tosca Structure installation package and
must be installed separately on each computer. It is realized as an ActiveX
component that can be embedded in a Microsoft PowerPoint presentation,
Microsoft Word document or html file. The plug-in loads a VTFX file generated by Tosca Structure and provides means for user interaction with the
sequence of models saved in the file.
The plug-in is compatible with the following software:
Microsoft Windows XP / Vista / 7
Microsoft Office 2007 and above
(for Office 2010 only 32bit versions are supported!)
Internet Explorer, Firefox or Chrome
For the operation of the plug-in, a graphic card that supports OpenGL (including actual driver software) is required.
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10.2.9.1 Prerequisites and installation
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The plug-in can be downloaded directly from the home page of FE-DESIGN
GmbH (http://www.fe-design.de) or Ceetron (http://www.ceetron.com).
10.2.9.2 Embedding the PlugIn into PowerPoint

Inserting the PlugIn
In order to insert a plug-in into a Microsoft PowerPoint presentation, do the
following:
1. Create a new slide in Microsoft PowerPoint.
2. Select the tab GLview 3DPlugin and click Insert..
Fig. 330 Tab GLview 3D Plugin with the buttons Insert and Load
VTFx
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3. The plugin should now look like this:
Easy setup of the plug-in

The vtfx file to be loaded in the plugin can be easily specified as follows:
4. Select the plug-in by clicking on it.
5. Click Load VTFx in the Add-in (tab GLview 3DPlugin).
6. Select the VTFx (or VTF) file you want to use in the resulting dialog and
click Open.
7. Now, if you view the slide show in presentation mode, the plug-in will open
the VTFx file immediately when the slide containing the plug-in appears.
An alternative way to steps 5 and 6 is to open the properties window of the
toolbar from the context menu and to edit the entries there. In this window,
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the property SWRENDERING can also be set to ON (default is OFF) in order to

turn on the software rendering (otherwise the hardware OpenGL acceleration
is used).
The VTFX file is loaded when the slide of the presentation is shown for the
first time. After that, returning to the slide from another one or even the restart
of the presentation (but not of Microsoft PowerPoint) does not cause the file
to be reloaded.
Remark:
If the Tab for Plugin inserton (GLvie 3D Plugin) does not appear in your Office
version, please check chapter 10.4.3 Add-Ins for Tosca Structure Report
Builder concerning the installation.
Using a simple VBA script, the user gains full control of the loading of a VTFX
file in the plug-in. As an example, a button in the presentation can be created
such that a certain file is loaded when the button is pressed. This behavior is
needed if the loading time of a VTFX file is large so that the user might wish
to skip it, or if different files are to be shown in the same plug-in (e.g., by clicking a button that corresponds to each file).
In order to create a button that opens a VTFX file, first insert the plug-in as
described in actions 1-3 above. Then, continue as follows:
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1. To add a button, select Command Button from the Control Toolbox in the
Developer tab, and drag a button into the slide. :
The button will look something like this:
2. Double click the button (or right click and select "View Code") to edit its
<button name>_Click method in Microsoft Visual Basic editor (the
code which handles the click of the button).
3. Add a codeline that calls the Open() method of the plug-in as follows
(replace the argument test.vtfx with your VTFX file name):
Private Sub CommandButton1_Click()
GLview3DPlugIn1.Open ("test.vtfx")
End Sub
4. Select the menu command File | Close and Return to

Microsoft PowerPoint.
5. Now, the VTFX file will be loaded once the presentation is started and the
button on the slide is clicked. Note that the file is loaded only once; it
unloads when Microsoft PowerPoint is exited.
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Remark:
Please note that advanced usage of the plug-in using VBA scripts requires
the use of Macros for this reason, PowerPoint presentations have to be
saved as PowerPoint Macro-Enabled presentation (*.pptm) files!
10.2.10 Integrating VTFX files in internet pages

The GLview 3D plug-in can be embedded in a HTML web page and then be
displayed in Microsoft Internet Explorer. Note that the plug-in is not compatible with other web browsers. The plug-in is defined using object tag, and
the VTFX file name as well as the information if the toolbar is to be shown
and the software rendering is to be used are supplied using param tags:

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Postprocessing with Tosca Extension for ANSYS/Workbench
<object
id="GLview3DPlugIn"
classid="clsid:D37577A1-960C-11D5-A482-006094EB12E8"
codebase="http://ceetron.com/plugins/
GLv3DPlugIn.cab#version=7,3,0"
type="application/x-oleobject"
width="900"
height="600" >
<param name="FileURL" value="model.vtfx">
<param name="TOOLBAR" value="ON">
<param name="SWRENDERING" value="OFF">
</object>
The plug-in is identified by classid. If the plug-in is not found locally on the
computer, it is loaded from the link given by codebase parameter. In this
manner, internet pages with embedded VTFX files can be made available for
interested external persons.
10.2.11 Limitations of the PlugIn

The plug-in offers no possibility to change the display mode of a part. Furthermore, no groups can be selected interactively. Therefore, in particular the
VTFX files containing topo_mat, shape_ctrl and bead_disp information
are recommended for integration in web pages and presentations.
Tosca Extension for ANSYS/WB provides multiple possibilites to regard a

completed optimization. Some are available in the Mechanical application
itself.
10.3.1 Optimization result view options

Topology optimization results
To display a topology optimization result correctly in the Mechanical application, make sure that the correct Geometry option in the upper toolbar is
activated.
Geometry view option
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10.3 Postprocessing with Tosca Extension for

ANSYS/Workbench
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With the option Capped IsoSurfaces it depends on the elements

density whether they are displayed or not. This limit density (elements
above or below are displayed) is adjustable.
With IsoSurfaces activated, no

result will be displayed.
To display the stress results of a shape optimization in the Mechanical

application, the created Controller Input has to be selected. This will
display the resulting stresses and optimized shape of the component.
Alternatively it is also possible to display the nodal displacement for each iteration in order to determine to what extent each node is moved during the optimization. Right click on Solution in the Tree Outline and then Insert
| Deformation | Total. Please note that this does NOT refer to the
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total deformation of the component subject to the different loadcases of the

static structural analysis..
Besides the total nodal displacement, the directional nodal displacement can
be visualized as well. Right click on Solution in the Tree Outline and
then Insert | Deformation | Directional if you wish to visualize the
directional results.

the optimization steps. Its either possible to have a look at each single iteration or to sow a little animation from the beginning until the end of the optimization run.
To display a single iteration step use the right mouse button on a certain point
of time on the graph; the corresponding model will be displayed. Use the right
mouse button and click Retrieve this result.
For an animation it is possible to use a Play and Stop button or regulate animation speed. All required buttons can be found in the Graph window.
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10.3.2 Iteration Animation
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For shape optimization, result animation can be started analogously.
10.3.3 Result files

A Tosca Structure optimization run saves a lot of data in either the saving
directory or a temporary directory.
Fig. 331 Open the solver files directoy
10.4
Tosca Structure Report Builder

Using Tosca Structure.view it is possible to combine optimization results consisting of animation sequences, tables and result graphs to reports in html,
text, MS powerpoint and word format. Please note: to use the full functionality
of the Tosca Structure Report Builder, MS Office 2007 and higher is required.
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To find the working directory easily, right click on the Solution item within
the Tree Outline and select Open Solver Files Directory.
There you find solution data files, the tosca.par-file, a vtfx-file for visualization
with Tosca Structure.view and much more information.
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10.4.1 Capturing Data for the Report

Starting with a vtfx archive generated by Tosca Structure.report, several data
can be captured to be included into a report file:
Fig. 332 Postprocessing file (vtfx archive) containing optimization results
Fig. 333 Capture active view (left), quick capture or capture all viewcases
(right)
Animation sequences can be captured either as image, i.e. a screenshot of
the actual view, or as 3D model which can be included into the report using a
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The capturing is done for either single (active) views or all available views,
thereby maintaining all actual settings (visualization settings, viewport,...)
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vtfx plugin or as film sequence. Graphs can be captured either as image or as

table of the values shown in the graph.
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Fig. 334 Situation type
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Fig. 335 3D view and table in Tosca Structure Report Builder
10.4.2 Report generation
Fig. 336 Create Report
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Once all relevant data is captured, the report can be generated.
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A template defining layout, distances between the several objects and other
general settings has to be chosen. Further, select the repository file for the
report generation and choose an output file. With the Tosca Structure installation, some standard templates are provided which can be found in the subdirectory report/templates of the installation directory.
Fig. 337 Settings for report generation

For each report the media type used for the report content can be chosen.
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3D plugin: animation sequences are shown using vtfx plugin

Video and image: animation sequences are shown as avi
Image only: only screenshots are included into the report (i.e. 3D content is
captured by a screenshot)
10.4.3 Add-Ins for Tosca Structure Report Builder

Addins for MS Word and MS Powerpoint that will make usage of the GLview
3D Plugin as well as creation of templates for GLview Report Builder easy for
the user is available from Ceetron. The addins are included with the GLview
Inova suite, the GLview 3D Plugin installers, and can be found in the Tosca
Structure installation directory for manual installation.
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10.4.3.1 Add-in for MS Word

The Report Builder Add-in for MS Word is provided in a macro-enabled MS
Word template file, named ReportBuilder.dotm. It is provided in the subdirectory bin\<os_winnt> of your Tosca Structure installation. Installation of this
Add-in consists of copying the file to the correct location on the hard-drive,
and making sure this location is a trusted location by MS Word.
The correct installation path for ReportBuilder.dotm is dependent on the version of MS Word that is used on the system on which the installation is done.
The required information can be found in the registry please note that the
internal version numbers are as follows:
Office 2007: "12.0"
Office 2010: "14.0"
Example
For example, for 32-bits MS Office 2007 installed on 64-bits Windows, check
the following key in the registry:
HKEY_LOCAL_MACHINE\SOFTWARE\Wow6432Node\Microsoft\
Office\12.0\Word\InstallRoot
To find:
C:\Program Files (x86)\Microsoft Office\Office12\
Installation
The MS Word Add-in for GLview Report Builder (ReportBuilder.dotm)
should be copied to the "STARTUP" directory found in the installation directory of MS Office i.e.:
C:\Program Files (x86)\Microsoft Office\Office12\STARTUP
All add-ins located in the "STARTUP" directory are automatically loaded
when MS Word is started.
To allow the features of the GLview Report Builder Add-in for MS Word to
work and to avoid security messages by MS Word, please make sure that the
location where ReportBuilder.dotm was installed is added to MS Word
Trusted Locations.
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MS Word Security settings
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This is done by accessing Word Options Trust Center Trust Center Settings Trusted Locations. When finished, your settings should look similar to
this:
10.4.3.2 Add-in for MS Powerpoint

The Report Builder Add-in for MS PowerPoint is provided in a macro-enabled
MS PowerPoint template file, named ReportBuilder.ppam. Installation of this
Add-in consists of copying the file to the correct location on the hard-drive,
and adding an entry in the registry to make PowerPoint load the Add-in at
startup.
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Installation path
The macro ReportBuilder.ppam file is located in the same folder as the executable file for GLview Report Builder (tosca_install_dir\bin\<os_platform>).
Registry settings
The add-in for MS PowerPoint (ReportBuilder.ppam) must be registered by
adding entries to the AddIns folder of the registry settings of Office.
A new key named GLview Report Builder PowerPoint Add-in must be added
to the AddIns folder, and two new entries have to be added to this new key
(one for autoload, and one containing the path to the ReportBuilder.ppam).
Note that the internal version numbers for MS Office versions are as follows:
Office 2003: "11.0"
Office 2007: "12.0"
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Office 2010: "14.0"

Example
For 32-bits MS Office 2007 installed on 64-bits Windows, use Regedit.exe (or
similar) to locate the following key in the registry:
HKEY_LOCAL_MACHINE\SOFTWARE\Wow6432Node\Microsoft\Office\
12.0\PowerPoint\AddIns\
Add a new key under AddIns, and name it GLview Report Builder PowerPoint Add-In you should now have the following registry entry:
HKEY_LOCAL_MACHINE\SOFTWARE\Wow6432Node\Microsoft\Office\
12.0\PowerPoint\AddIns\ GLview Report Builder PowerPoint Add-In
Under this registry entry;
add a key of type REG_DWORD named Autoload, with the value
0xffffffff, and
add a key of type REG_SZ called Path which is the path to the add-in, for
instance
C:\Program Files\Ceetron\GLview Report Builder\ReportBuilder.ppam.
MS PowerPoint security settings

The Add-in for MS PowerPoint does not require any changes to MS PowerPointsecurity settings.
10.4.3.3 Templates
Standard templates for report generation are provided with your Tosca Structure installation and can be found in the subdirectory report of the Tosca
Structure installation directory. Creation of user specific templates is no Tosca
Structure feature and is documented in the report generator documentation
which can be accessed directly in the report builder.
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When finished, your new registry entries should look similar to this:
SIMULIA
Tosca Structure
10.5 Toolbox for Postprocessing

Tosca Structure provides the user with a large variety of postprocessing capabilities. Sometimes the default settings are not sufficient for the experienced
user who may be interested in a specific design response (e.g., stress peak in
an area, relative displacements,...) and its progress during the optimization
run. To this end, a toolbox enabling more advanced output from the optimization task is available including the creation of variables, logical variables,
tables, complex stop conditions and user defined output files (containing text
or model and result information in a convertible neutral format (ONF)). In
Tosca ANSA environment this toolbox is in general available using Modules
Buttons toolbar. In Tosca Structure.gui, the commands for the advanced functionalities are found in the commands menu.
10.5.1 Numerical variables (VARIABLE)

Numerical variables are an important feature in Tosca Structure. In the simplest case, a numerical variable is used to write the contents of a database to
the screen or to a file. Some commands in Tosca Structure can only be
addressed with variables so that the numerical variables have to be defined
in advance. Other commands become more flexible when using variables.
Conditions for logical variables (LOGICAL) are set by numerical variables.
Numerical variables are defined with the VARIABLE command. They can be
assigned to constraint values or to data from the database.
DEF_TYPE = FIX
fixed value
DEF_TYPE = SYSTEM load case independent and load case dependent

value
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Version 8.1.0 Rev. 1 - 05.2014
The access to the database (i.e., to the analysis or optimization results) can
be precisely specified by:
Type of contents.
Definition of the selection area:
any node or element group.
Type of selection within the selection group:
minimum (MIN), average (AVERAGE) or maximum (MAX) value, sum
(SUM) or number of entries (COUNT) within the group.
Selection of the load case and type of the load case selection.
Besides direct database access, numerical variables can also be defined with
mathematical operators (DEF_TYPE = OPER) (ITEM VAR_OPER = ADD,
SUB, MULT, DIV, MIN, MAX, ABS or COMBINE) using 2 to 4 numerical variables (or up to 10 variables for COMBINE). Furthermore, the change for a
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Toolbox for Postprocessing
numerical variable in comparison to previous iterations can also be defined

as a variable (DELTA).
The following list represents a selection of the many possibilities to extract
results from a database, for a complete list refer to the definition of the VARIABLE command in the commands manual:
Load case dependent contents (determined for a specific load case or for
all load cases):
- Stress (principal stress or equivalent stress).
- Displacements (components or total displacement).
- Equivalent stress.
Load case independent contents:
- Number of iterations.
- Displacement values of the nodes through the material expansion or
material shrinkage (shape/bead optimization).
- Lengths of the free, fixed or total surface.
- Element volumes.
- Moments of inertia.
- Center of gravity.
Allowed values for the logical variables are TRUE, FALSE and UNSET. The
value is determined by the comparison of two numerical variables
(DEF_TYPE = BASE) or by combining several logical variables (DEF_TYPE
= BOOLEAN).
The permitted operators for two numerical variables are: GE (= greater or
equal than), LE, GT, LT and EQ. The comparison of the two numerical variables, Var1 > Var2, sets the status TRUE, FALSE or UNSET depending on
whether Var1 > Var2, Var1 < Var2 or one of the variables is not defined. The
status can also be determined with an AND or OR condition using 1 to 4 logical variables. In this way very simple as well as very complex logical variables
can be constructed.
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10.5.2 Logical variables (LOGICAL)
SIMULIA
Tosca Structure
Examples
(Var1 Var2)
Var1
= AND
Var2
= OR
True
True
True
True
True
False
False
True
False
False
False
False
True
Unset
Unset
True
False
Unset
Unset
False
Unset
Unset
Unset
Unset
Table 40
Status of variables in a logical "AND" or "OR" condition
In Table 40, the result of combination of two logical variables Var1 and Var2
using AND or OR operation is listed for all possible values of Var1 and Var2.
The logical variables are used in Tosca Structure, for example, for the definition of the stop conditions. It is also possible to control the dynamic model
modification (in OPT_PARAM) with logical variables.
Logical variables are defined with the LOGICAL command.
If one of the logical variables is UNSET, the second variable in AND operation
is ignored (see Table 40).
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10.5.3 Stop conditions (STOP)

The optimization is stopped when certain criteria are fulfilled. These criteria
are defined with the STOP command.
A stop condition is defined by assigning a logical variable (LOGICAL) to an
optimization task (OPTIMIZE). The stop condition can be specifically
addressed with its user defined name (ID_NAME).
STOP
ID_NAME
LOGICAL
OPTIMIZE
= stop_name
= logical_name
= opt_grp_name
END_
The stop condition ends the optimization for the selected optimization group
when the value for the assigned logical variable is TRUE. If several STOP
conditions have been defined for an optimization group, the optimization for
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Tosca Structure
this group is ended when one of the stop conditions is fulfilled (corresponds to
a logical OR condition).
The logical variable can vary significantly. Before using the STOP command,
numerical and logical variables must be defined with the VARIABLE and
LOGICAL commands.
The flexibility is achieved by using various logical variables as the stop criteria. Logical operations AND or OR can also be included in the STOP command by defining the logical variables.
For shape optimization, typical stop conditions can be defined more directly
by an enhanced stop command:
STOP
ID_NAME
MOD_NDGR
MOD_TYPE
MOD_OPER
MOD_REF
OPTIMIZE
END_
=
=
=
=
=
=
stop_command
all_nodes
MAX, CTRL_INP_SHAPE
LE
0.01, MULT, FIRST
run
In this case, the optimization task "run" should stop when the maximum
equivalent stress (CTRL_INP_SHAPE) of the node group all_nodes is
smaller than 1% of the maximum equivalent stress of the first iteration.
Using this enhanced stop command, the extraction of variables and their logical comparison is performed internally by Tosca Structure and need no longer be specified manually by the user. For a detailed description of the
several items, refer to the commands manual.
If desired, the global upper limit for the maximum number of iterations can be
set with a separate, brief command. In this case, a definition of logical variables is not required.
STOP
ID_NAME
ITER_MAX
= STOP_CONDITION
= <value>
A global stop condition is integrated in the system to limit the maximum number of iterations for safety reasons. This stop condition is always active. The
default value for the maximum number of iterations is set to 40. As an example, the command
STOP
ID_NAME
ITER_MAX
= STOP_CONDITION
= 55
END_
increases the maximum number of iterations.
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END_
SIMULIA
Tosca Structure
Remarks
1. When the optimization is halted due to a stop condition, it is possible that
the desired results are not achieved. This is especially true for topological
optimization when stipulating the global tensile stiffness.
10.5.4 User defined output files (USER_FILE)

In addition to the standard output files TOSCA.OUT, TOSCA.LOG and
optimization_report.csv (for more see volume 3: OPTIONS), the files in userdefined output can be generated.
For the evaluation or documentation of the optimization results, it is useful to
specifically write some information from the large amount of data to individual
files. With the USER_FILE command, the user can create customized output
files. These files contain specific information from selected groups in a special format.
These files can be used, for example, to evaluate the results in a spreadsheet
program (ASCII data) or convert geometric information (ONF format) into
data for viewer or postprocessor. To generate results files several settings
must be set for every output file created:
Name of the output file.
Output format (default: ASCII).
Type of result data.
Node or element group for which the results data should be written
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Version 8.1.0 Rev. 1 - 05.2014
Point in time when the file should be generated.

The most important property is the type of the results. Different types of data
are permitted depending on the output format set. More information concerning what kind of data is allowed for a certain output format can be found in the
Commands Manual (volume 3: USER_FILE). The node coordinates or the
properties of the nodes in the shape optimization (free or restricted) are
examples of useful output results. The values can be written at the end of the
optimization or for each optimization iteration.
Examples
The tension stress in a notch is homogenized using shape optimization. All
relevant nodes of the two-dimensional model are in the node group
nd_ground. The tension data should be written for all iterations in the ASCII
file, GROUND.INFO.
The necessary command sequence is the following:
USER_FILE
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ID_NAME
FILE_NAME
FORMAT
ND_GROUP
TYPE
WRITE
=
=
=
=
=
=
my_user_file
ground.info
ASCII
nd_ground
NODE_MOVE_PATH
EVER
END_
Remarks
1. Experience has shown that certain user-defined command sequences are
often used to generate result files. Therefore, it is recommended that the
user collects these commands in a macro and saves this macro in a directory. These macros can then be loaded with the command INCLUDE
during the optimization preprocessing.
10.5.4.1 Tabular output

Per default, Tosca Structure always writes a file optimization_report.csv containing the progress of the value(s) of the objective function and objective
function terms as well as the constraint terms. If other design responses or
variable values are required, these can be compiled to a table with the following command sequence:
USER_FILE
ID_NAME
FILE_NAME
FILE_OPTION
FORMAT
WRITE
TYPE
SEPARATOR
DATA_TAB
DATA_TAB
DATA_TAB
END_
=
=
=
=
=
=
=
=
=
=
tab1
my_table
ADD
ASCII
EVER
TABULAR
COMMA
ITER
DRESP_MAX_MISES
...
10.5.4.2 Modification file for CATIA RSO module

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DRESP
... (several DRESP definitions, e.g. DRESP_MAX_MISES)
VARIABLE
... (several variable definitions for later reference)
SIMULIA
Tosca Structure
macro uf_shape_catia_rso.mac already contains the necessary output

request.
USER_FILE
ID_NAME
FILE_NAME
FILE_OPTION
FORMAT
ND_GROUP
TYPE
WRITE
SEPARATOR
=
=
=
=
=
=
=
=
UF_RSO
RSO_OUTPUT.TXT
VAR
ASCII
TITLE_1
= x(mm) # y(mm) # z(mm) #

C1(mm) # C2(mm) # C3(mm)
all_nodes
CATIA_RSO
EVER
TAB
END_
10.5.4.3 Modification file for NX

macro uf_shape_nx_deform.mac already contains the necessary output
request.
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Version 8.1.0 Rev. 1 - 05.2014
USER_FILE
ID_NAME
FORMAT
ND_GROUP
TYPE
FILE_NAME
FILE_OPTION
WRITE
SEPARATOR
=
=
=
=
=
=
=
=
NX_DEFORM_ORG
ASCII
ALL_NODES
NX_DEFORM_ORG
NX_DEFORM_ORGINAL.DAT
FIX
NOW
COMMA
=
=
=
=
=
=
=
=
NX_DEFORM_MOD
ASCII
ALL_NODES
NX_DEFORM_MOD
NX_DEFORM_MODIFIED_MESH.DAT
VAR
EVER
COMMA
END_
USER_FILE
ID_NAME
FORMAT
ND_GROUP
TYPE
FILE_NAME
FILE_OPTION
WRITE
SEPARATOR
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END_
10.5.4.4 ONF output
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The output of optimization results and model information is required in ONF

format (Optimization Neutral Format) when other postprocessing possibilities
are needed. Model and result information in ONF format form the basis for
the calculation of isosurfaces with Tosca Structure.smooth (see vol.2 chapter
9.1, Tosca Structure.smooth). ONF data is also needed for the preparation of
the optimization results for FE postprocessing (see vol.2 chapter 10, Postprocessing of Optimization Results).
In general, ONF data is written per default. If the user requires specific information (e.g., only part of the model) this can be requested with the user file
command, parameter FORMAT=ONF. The node and element information can
be written using TYPE=FINITE_MODEL (for an example, see the macro
uf_model_onf.mac). The macro uf_topo_onf.mac defines the output of the
results of the topological optimization in ONF format.
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Solver Specific Features
This chapter describes the formats and functionalities of the different solvers
The topological and physical properties of the analysis model (finite element
input deck) are required for the optimization of an FE model. Normally, not all
information contained in the analysis model is necessary for an optimization.
The optimization module returns the modified model data to the FE solver.
The node coordinates are changed during shape and bead optimization. New
materials and element properties are generated during topology optimization
and the assignments of the elements to the material definitions and material
properties are changed. Therefore, there are very few restrictions to the FE
modeling (finite element input deck).
The FE input file (finite element input deck) is processed in two ways during
the optimization procedure. Initially, the optimization preprocessing step
reads the FE input file and all necessary information is written into the optimization database. Afterwards, in each optimization iteration only the properties
changing during the optimization will be modified in of FE input file.
The flow diagram shown in Fig. 338 is identical for all FE solvers. The optimization preprocessor TOSCA_PREP executes the program fem2onf. This program converts the FE-input-deck into a neutral file format (ONF). The
essential information regarding the FE-model is written in the neutral file. The
first file called <jobname>_req.onf contains the result requests. These are the
FE-results needed for the optimization module. The second file contains FEmodel (<jobname>_fem.onf) information, i.e. grid points, elements and etc.
The last file contains the group definitions (<jobname>_grp.onf).
The optimization iterations begin when the preprocessor is finished. No previous optimization iterations exist for the first optimization iteration. However,
fem_modif modifies the FE-input deck(s) (model1.<input>, model2.<input>,
...) which ensures that requested results are present after FE-analysis.
The chosen FE solver calculates the requested results (model1.<output>, ...).
The specific results required for the optimization are read by res2vtm and the
results are stored in the database (tosca_memory). Using these results the
optimizer TOSCA_OPT generates a modification file (<jobname>_mod.onf).
Afterwards, fem_modif once again modifies the original FE-input deck using
the modification file. The standard configuration ensures that the FE-input
decks will be stored for each optimization iteration in the directory
SAVE.<input>. The directory SAVE.<input> also contains the original input
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11 Solver Specific Features
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Tosca Structure
deck having the name model_org.<input>. The first and last FE results files
are stored in the directory SAVE.<output>.
Flow diagram for Tosca Structure

model.par
model1.<input>,
model2.<input>,...
TOSCA_PREP
fem2onf
model_req.onf
model_fem.onf
model_grp.onf
FEM_MODIF
SAVE<input>
model1.<input>,
model2.<input>,...
SOLVER
model1_<iter>.<input>
model2_<iter>.<input>
...
SAVE<output>
model1.<output>,
model2.<output>,...
RES2VTM
model1_<iter>.<output>
model2_<iter>.<output>
...
tosca_memory.idx
tosca_memory.vtm
model_mod.onf
Fig. 338 Detailed flow diagram for Tosca Structure. "input" and "output" is
the FE input deck extension and result output extension, respectively. The extension names correspond to the extensions given
by the FE solver. See supported file formats and extensions in
Table 41.
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TOSCA_OPT
SIMULIA
Tosca Structure
Tosca Structure
supported input
Solver type
Abaqus
*.inp
Tosca Structure
supported output
*.fil or *.sim (see below)
*.odb
ANSYS
*.cdb
*.rst
*.dat
*.inp
Marc
*.dat
*.t16
MSC Nastran
*.bdf
*.op2
(*.dat)
PERMAS
*.uci
*.post
*.dat
Table 41
Tosca Structure supported file formats for the different solvers. See also flow diagram Fig. 338
Some Features in Tosca Structure are not available for all solver interfaces.
Sensitivity based
Optimizations
with contact
Frequency
Response
Optimizations
Use of internal
Forces
Abaqus
ANSYS
Marc
MSC Nastran
PERMAS
Table 42
Supported Features for different solver interfaces
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Solver
User Manual 2 - 621
SIMULIA
Tosca Structure
Abaqus
11.1 Abaqus
Solver type
Abaqus
Tosca Structure
supported input
.inp
Tosca Structure
supported output
.fil or .sim (see below)
.odb
Table 43
Tosca Structure supported file formats for Abaqus. See also

flow diagram Fig. 338.
All FE input models (.inp) and FE results (.odb, .fil or .sim) are moved into
their corresponding SAVE directory, see flow diagram Fig. 338.
11.1.1 Files and formats

The optimization preprocessor can only read Abaqus input files in free format
corresponding to the correct syntax for Abaqus 6.1 and higher. The so-called
fixed format (allowed for Abaqus 5.8) is not supported and leads to errors.
Integrating external files in an Abaqus input file by using the option
*INCLUDE is permitted. This allows several input files to be used. Note, that
the *INCLUDE statement cannot be used in other Abaqus commands like for
example *NODE. The use of the INPUT parameter is also permitted. The referenced filenames must not contain any blanks.
Currently, the use of parts and assemblies in the Abaqus input file is not supported by Tosca Structure. If the input deck is not flat, Tosca Structure uses
an Abaqus data check run to convert the model data. This may influence the
details in the input deck, especially the element and node IDs, although the
structure stays the same.
When the input file is converted to the flat format using the data check run,
the names of the element and node groups change: for a certain instance in
an assembly, the groups dealing with its elements or nodes are named
<assembly name>_<instance name>_<group_name>.
These new names should be referenced in Tosca Structure parameter file if
needed.
If the input file references an external file with the use of the *INCLUDE keyword, the flattened input file will contain this included file(s). That is, the flattened version will contain the data in the external files, so that only one input
file is generated. If an optimization should consider several parts, it is recommended to configure Abaqus/CAE so that no parts and assemblies are writ-
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Input files and formats
SIMULIA
Tosca Structure
ten. To achieve this, the following parameter must be set in the configuration
file abaqus_v6.env:
cae_no_parts_input_file=ON
Alternatively, the format my be switched during a Abaqus/CAE session:
MDB.MODELS[MODELNAME].SETVALUES(NOPARTSINPUTFILE=ON)
Result Files and Formats

By default Tosca Structure reads the results of the Abaqus FE-Analysis from
the binary result file (*.fil file) and the result database (*.odb). The standard
result file format is the *.odb format. If the optimization task requires additional information from the fil file which is not contained in the odb fie (e.g.
stiffness matrices), the request is made automatically.
Further results, e.g. stresses at integration points, can be requested by the
user without any impact on the optimization. Tosca Structure needs only the
results at the end of each step. Therefore, we also recommend requesting
other results at the end of the steps to minimize the size of the result file.
However, in Tosca 8.1.0 in combination with Abaqus 6.14-1 the user can
change default so the results for the optimization are read from the ODB-file
and SIM-file.
The novel, high-performance data format SIM can be used by the Tosca interface to transfer stiffness matrices from the solver to the optimization system.
Since this format undergoes intensive further development, the compatibility
of Tosca 8.1.0 with respect to SIM is guaranteed only towards Abaqus 6.14-1.
The SIM-files from any earlier Abaqus versions are not compatible with Tosca
8.1.0.
Changing the default from FIL-file to SIM-file is done adding the following
command in the parameter file or generally, adding the command in the
tosca_ctrl.cfg:
www.3ds.com/tosca
Version 8.1.0 Rev. 1 - 05.2014
CONFIG
$fe_modif_add_call = "$fe_modif_add_call -format_matrices
sim";
$res2vtm_add_call = "$res2vtm_add_call -format_matrices
sim";
END_
If Abaqus versions older than 6.14-1 should be used, the additional command
line options --format_matrices sim should be removed from the settings
fem_modif_add_call and res2vtm_add_call.
Remarks:
1. The SIM-file can not be used for Tosca Structure 8.1.0 when using Abaqus
versions older than 6.14-1.
2. It is recommended to use the SIM-file due to significant lower CPU-time for
sizing optimization and for sensitivity based shape and bead optimization.
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Tosca Structure
Abaqus
3. The SIM-file is platform compatible opposite to the FIL-file, e.g. when

copying from a Linux cluster to a local Windows workstation.
4. Higher order shell elements often write wrong results in the FIL-file contrary
to SIM-file having correct results for higher order shell elements.
5. In special cases the user may require all results in fil-file format, e.g. when
coupling the optimization with user fatigue codes.
The following command CONFIG in the Tosca Structure parameter file may
be used to switch to the *.fil interface. The necessary result requests for the
optimization are inserted automatically into the analysis input deck.
${fem_modif_add_call} = "--format fil";
${res2vtm_add_call} = "--format fil";
11.1.2 Supported element types

The analysis model can contain arbitrary element types, but not all element
types can be used in the design area. Also for the definition of restriction
areas only certain element types are permitted.
All other elements in the analysis model are considered as dummy elements
in the optimization, e.g. the elements not changed during the optimization
process. Some further restrictions may apply regarding specific design
responses. Please check remarks for this.
PLANE_QUAD_4
Abaqus-element
type
CAX4
CAX4H
CAX4HT
CAX4I
CAX4IH
CAX4R
CAX4RH
CAX4RHT
CAX4RT
CAX4T
Design element
(see below)
C, S, F
C, S
C, S
C, S
C, S
C, S, F
C, S
C, S
C, S
C, S
C=allowed for controller-based optimization (bead, shape and topology);

S=allowed for sensitivity based topology optimization;
F=allowed for the design responses that use the element based reaction
and internal forces and for frequency response
Z=allowed for sizing optimization
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Tosca Structure-element
type
SIMULIA
Tosca Structure
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Version 8.1.0 Rev. 1 - 05.2014
type
Abaqus-element
type
Design element
(see below)
PLANE_QUAD_4
CGAX4
CGAX4H
CGAX4HT
CGAX4R
CGAX4RH
CGAX4RHT
CGAX4RT
CGAX4T
C, S
C, S
C, S
C, S
C, S
C, S
C, S
C, S
PLANE_QUAD_4
CPE4
CPE4H
CPE4HT
CPE4I
CPE4IH
CPE4R
CPE4RH
CPE4RHT
CPE4RT
CPE4T
C, S, F
C, S
C, S
C, S
C, S
C, S, F
C, S
C, S
C, S
C, S
PLANE_QUAD_4
CPEG4
CPEG4H
CPEG4HT
CPEG4I
CPEG4IH
CPEG4R
CPEG4RH
CPEG4RHT
CPEG4RT
CPEG4T
C, S
C, S
C, S
C, S
C, S
C, S
C, S
C, S
C, S
C, S
PLANE_QUAD_4
CPS4
CPS4I
CPS4R
CPS4RT
CPS4T
C, S, F
C, S
C, S, F
C, S
C, S

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Abaqus
Abaqus-element
type
Design element
(see below)
PLANE_QUAD_8
CPE8RT
CPE8T
CPEG8
CPEG8H
CPEG8HT
CPEG8R
CPEG8RH
CPEG8RHT
CPEG8T
C, S
C, S
C, S
C, S
C, S
C, S
C, S
C, S
C, S
PLANE_QUAD_8
CPS8
CPS8R
CPS8RT
CPS8T
C, S, F
C, S, F
C, S
C, S
PLANE_QUAD_8
CAX8
CAX8H
CAX8HT
CAX8R
CAX8RH
CAX8RHT
CAX8RT
CAX8T
C, S, F
C, S
C, S
C, S, F
C, S
C, S
C, S
C, S
PLANE_QUAD_8
CGAX8
CGAX8H
CGAX8HT
CGAX8R
CGAX8RH
CGAX8RHT
CGAX8RT
CGAX8T
C, S
C, S
C, S
C, S
C, S
C, S
C, S
C, S
PLANE_QUAD_8
CPE8
CPE8H
CPE8HT
CPE8R
CPE8RH
CPE8RHT
C, S, F
C, S
C, S
C, S, F
C, S
C, S

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type
SIMULIA
Tosca Structure
www.3ds.com/tosca
Version 8.1.0 Rev. 1 - 05.2014
type
Abaqus-element
type
Design element
(see below)
PLANE_TRIANG_3
CAX3
CAX3H
CAX3T
C, S, F
C, S
C, S
PLANE_TRIANG_3
CGAX3
CGAX3H
CGAX3HT
CGAX3T
C, S
C, S
C, S
C, S
PLANE_TRIANG_3
CPE3
CPE3H
CPE3T
CPEG3
CPEG3H
CPEG3HT
CPEG3T
C, S, F
C, S
C, S
C, S
C, S
C, S
C, S
PLANE_TRIANG_3
CPS3
CPS3T
C, S, F
C, S
PLANE_TRIANG_6
CPE6H
CPE6M
CPE6MH
CPE6MHT
CPE6MT
C, S
C, S
C, S
C, S
C, S
PLANE_TRIANG_6
CPEG6
CPEG6H
CPEG6M
CPEG6MH
CPEG6MHT
CPEG6MT
C, S
C, S
C, S
C, S
C, S
C, S
PLANE_TRIANG_6
CPS6
CPS6M
CPS6MT
C, S, F
C, S
C, S

User Manual 2 - 627
SIMULIA
Tosca Structure
Abaqus
Abaqus-element
type
Design element
(see below)
SOLID_BRICK_8
C3D8
C3D8H
C3D8HT
C3D8I
C3D8IH
C3D8R
C3D8RH
C3D8RHT
C3D8RT
C3D8T
SC8R
C, S, F
C, S
C, S
C, S
C, S
C, S, F
C, S
C, S
C, S
C, S
C, S
SOLID_BRICK_20
C3D20
C3D20H
C3D20HT
C3D20R
C3D20RH
C3D20RHT
C3D20RT
C3D20T
C, S, F
C, S
C, S
C, S, F
C, S
C, S
C, S
C, S
SOLID_TETRA_4
C3D4
C3D4H
C3D4T
C, S, F
C, S
C, S
SOLID_TETRA_10
C3D10
C3D10H
C3D10M
C3D10MH
C3D10MHT
C3D10MT
C, S, F
C, S
C, S
C, S
C, S
C, S
SOLID_PENTA_6
C3D6
C3D6H
C3D6T
SC6R
C, S, F
C, S
C, S
C, S
SOLID_PENTA_15
C3D15
C3D15H
C, S, F
C, S

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type
SIMULIA
Tosca Structure
Abaqus-element
type
Design element
(see below)
SHELL_QUAD_4
M3D4
M3D4R
S4
S4R
S4R5
C, S, F
C, S, F
C, S, F, Z
C, S, F, Z
C
SHELL_QUAD_8
M3D8
M3D8R
S8R
S8R5
S8RT
C, S, F
C, S, F
C, S, F, Z
C
C, S
SHELL_TRIANG_3
M3D3
S3
S3R
STRI3
C, S, F
C, S, F, Z
C, S, F, Z
C, S, F
SHELL_TRIANG_6
M3D6
STRI65
C, S, F
C, Z (only supported
if user ensures, that
rotational DOFs are
written to ODB-file)
BEAM_2D
B21
B21H
R2D2
RAX2
RB2D2
T2D2
T2D2H
T2D2T
F
F
Beam elements are
only allowed as
restriction elements in
shape optimization

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Version 8.1.0 Rev. 1 - 05.2014
type
User Manual 2 - 629
SIMULIA
Tosca Structure
Abaqus
type
BEAM_3D
Abaqus-element
type
B31
B31H
RB3D2
T3D2
T3D2H
T3D2T
SPRINGA
SPRING2(S)
MASS_1
MASS
DUMMY_ELEM_TYPE
all not supported

element types
Design element
(see below)
F
F
Beam elements are
only allowed as
restriction elements in
shape optimization
F
F

For shape and bead optimization, only nodes belonging to elements supported by Tosca Structure can be used as design nodes. More solver specific
information about Sensitivity based algorithm is found in vol.2 chapter 11.1.8,
Remarks for sensitivity based optimizations. For sensitivity based bead optimization, see vol.2 chapter 7.11, Special Remarks Using Sensitivity Based
Algorithm.
Remarks
2. For frequency response the geometrical nonlinearities and the incompatible, modified and hybrid elements are not supported.
3. Shell elements are not admitted for stresses in topology optimization.

Node and element groups are defined in the ABQAQUS input file as following:
*NSET, NSET
= <setname>
*NODE, NSET
= <setname>
*ELSET, ELSET
= <setname>
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1. It is important to note that in shape optimization the form of the shell structure is optimized and not its thickness. This means that the shell edges are
modified and that modifications on the shell level are not carried out.
SIMULIA
Tosca Structure
*ELEMENT, ELSET
= <setname>
These groups are loaded from the Abaqus input file during the preprocessing
of the optimization execution. These groups and their group names are available for the definitions applied in the parameter file along with the groups
ALL_NODES and ALL_ELEMENTS. If node and element groups with identical names are defined in the Abaqus input file, the extensions "_NODE" and
"_ELEM" are added to the distinguish group names during importation. This
guarantees that each group is identically identified by Tosca Structure.
Blanks in the group name are ignored during the import in Tosca Structure.
Generally, groups that are required for definition of the optimization area
should already be defined in the Abaqus input file and be used in the parameter file without using a redefinition.
Example:
File ex1.inp (group definition in FE input deck):
...
*ELSET, ELSET=DESIGN_ELEM, GENERATE
1, 10000, 1
15000, 20000, 1
...
File ex1.par (apply group in parameter file):

...
DV_TOPO
ID_NAME
EL_GROUP
= dv_design_elements
= design_elem
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Version 8.1.0 Rev. 1 - 05.2014
END_
Selection of properties and materials

It is not possible to do material or property selection when using Tosca Structure in connection with Abaqus as properties in Abaqus do not have independent names or IDs and these are always assigned to a particular element
group. Therefore, it is recommended that a selection is based upon the
assigned element group and not on the selection of a property.
Abaqus assigns material definitions with own names. Tosca Structure allocates an ID for the material definition that runs sequential starting with the
number 1. Tosca Structure can either select material by name or by ID. However, it is recommended that selection is done using a name in order to avoid
any dependency on the position of the definition within the input file.
User Manual 2 - 631
SIMULIA
Tosca Structure
Abaqus
In Abaqus different coordinate systems can be defined using the commands

*SYSTEM, *TRANSFORM and *ORIENTATION.
The *SYSTEM option is used to determine the axes of the nodes in the local
coordinate system. The coordinate systems (rectangular Cartesian, cylindrical or spherical) are each set with the keyword *NODE via the parameter
SYSTEM during the node definition.
The *TRANSFORM option is used to define a local displacement coordinate
system of a node group. E.g. this can be used to define boundary conditions.
The *ORIENTATION command is used to define a local coordinate system for
the definition of material or element properties.
Tosca Structure requires that coordinate systems are applied for selecting
and defining restrictions. As the same coordinate system is usually used both
in the definition of the model and in definition of the optimization task, the
coordinate systems defined as *SYSTEM or *TRANSFORM are loaded from
the optimization preprocessor and are available in the parameter definition.
Coordinate systems defined with the option *ORIENTATION or cylindrical
coordinate systems defined using *TRANSFORM can not be used in the definition of an optimization task.
No ID or name is assigned to coordinate systems in Abaqus. Therefore,
Tosca Structure numbers them consecutively according to their order of
appearance and labels them as "CS_<nr>". The numeration begins with 1 as
the name CS_0 is reserved for the standard global cartesian coordinate system provided by Tosca Structure. Therefore, the first coordinate system from
the input file has the name CS_1. All defined coordinate systems (with the
command *SYSTEM) are first considered in the numeration and afterwards
the displacement coordinate systems (with the command *TRANSFORM) are
considered.
The importance of the name allocation of the coordinate systems must be
considered when defining a separate coordinate system in the parameter file.
The numbered prefix "CS_" should not be used at the start of the separate
coordinate system in order to prevent the redefinition (and therefore invalid
definition) of a name.
Remark
1. Cylindrical coordinate systems defined with *TRANSFORM are not

Materials allowed in Topology optimizations:
All linear, some non-linear constitutive and anisotropic material laws for
Abaqus are supported as design elements:
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SIMULIA
Tosca Structure
Linear-elastic, isotropic material

*ELASTIC, TYPE=ISOTROPIC
Linear-elastic, anisotropic material
*ELASTIC, TYPE=ENGINEERING CONSTANTS
*ELASTIC, TYPE=LAMINA
*ELASTIC, TYPE=ORTHOTROPIC
*ELASTIC, TYPE=ANISOTROPIC
not supported as design element:
*ELASTIC, TYPE=TRACTION
*ELASTIC, TYPE=COUPLED TRACTION
The material card *PLASTIC is supported as design element, see also Fig.
339.
Supported for the type HARDENING=ISOTROPIC (default).
A main limitation is that each material point (gauss point) is only allowed to
be unloaded once and it should not be elastoplastic again. Meaning that
cyclic loading is not supported.
*CONCRETE is supported for design elements
www.3ds.com/tosca
Version 8.1.0 Rev. 1 - 05.2014
Hyperelastic:
Some material cards of *HYPERELASTIC are supported as design elements, see also figure Fig. 339.
ARRUDA-BOYCE
MOONEY-RIVLIN
NEO HOOKE
OGDEN
POLYNOMIAL
REDUCED POLYNOMIAL
VAN DER WAALS
YEOH
Not supported as design elements:
MARLOW
USER
Using TEST DATA INPUT parameter in *HYPERELASTIC (that is usually
followed by *UNIAXIAL TEST DATA or other test data) is not allowed.
User Manual 2 - 633
SIMULIA
Tosca Structure
Abaqus
The material card *HYPOELASTIC is support as design element, see also

figure Fig. 339. .
Fig. 339 Some of the *PLASTIC (a), *HYPOELASTIC (b) and *HYPERELASTIC (c) cards in Abaqus are supported for design elements.
Dependency of temperature or other field variables (Parameter DEPENDENCIES).
Materials allowed in shape optimization:
All linear and non-linear elastic materials:
*ELASTIC
*HYPERELASTIC
*HYPERFOAM
*HYPOELASTIC
*POROUS ELASTIC
Plasticity
Remark
The use of nonlinear materials in an optimization is only permitted for users of
the Tosca Structure.nonlinear license. This applies for the commands and
parameters below:
*CONCRETE
*HYPERELASTIC
*HYPERFOAM
*HYPOELASTIC
*PLASTIC
*POROUSELASTIC
*VISCOELASTIC
If no license is held for this mode, the optimization stops once the parameters
or commands listed above are used.
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Rev. 1Rev.
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Dependency of temperature or other field variables (Parameter DEPENDENCIES).
SIMULIA
Tosca Structure

Geometric Nonlinear Analysis
Geometric nonlinear analysis (parameter NLGEOM) can be used in both
topology and shape optimization. An excessive deformation of soft elements
can occur during topology optimization. This does not occur for a linear analysis. However, in the case of a geometric nonlinear analysis this leads to an
adverse effect on the convergence which eventually leads to the termination
of the analysis. This has to be considered when applying topology optimization using hyperelastic material.
Optimizing using Abaqus/Explicit
The use of Abaqus/Explicit is permitted for shape optimization of quasi static
problems. The ODB result interface must be activated (see vol.2 chapter
11.1.1) which is also default. The result of one explicit analysis step is divided
into 20 increments which are interpreted as 20 single sub-steps in Tosca
Structure. A step in the finite element input deck has to be divided into several
steps if the results of more than 20 substeps should be included in the optimization.
Topology and bead optimization in combination with Abaqus/Explicit is not
supported.
Allowed analysis types for sensitivity based optimizations
In Abaqus responses from the two following analysis types are allowed:
*STEP
*STATIC
...
*END STEP
and
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Version 8.1.0 Rev. 1 - 05.2014
*STEP, PERTURBATION
*STATIC
...
*END STEP
and
*STEP
*FREQUENCY
...
*END STEP
Remarks
1. If PERTURBATION is added then the step command *STEP will be recognized as a linear static solution in Tosca Structure. If PERTURBATION is
User Manual 2 - 635
SIMULIA
Tosca Structure
Abaqus
not added then the analysis is non-linear. The sensitivity based algorithm
supports geometrical nonlinearities (NLGEOM) and contact for Abaqus.
2. Abaqus has no predefined numbers for the load cases. Therefore, the first
defined load case in the INP file is recognized as load case one, the
second defined load case in the INP file is recognized as load case two and
etc.
3. Computationally, it is recommended that the user defines the static load
cases in Abaqus using the load case command *LOAD CASE in one
*STEP and not be defining more steps using *STEP several times. Hence,
using the load case command *LOAD CASE will keep the CPU-time significant lower, e.g.
*STEP, PERTURBATION
*STATIC
*LOAD CASE
...
*END LOAD CASE
*LOAD CASE
...
*END LOAD CASE
...
*END STEP
4. The results of the finite element analysis can only be read from the ODB
file when the command *LOAD CASE is activated (default) and not the FIL
file.
READING FROM THE FIL FILE INSTEAD OF ODB FILE IS ACTIVATED

WITH THE FOLLOWING COMMAND IS ADDED IN THE CONFIG COMMAND:
CONFIG
....
${res_ext} = "fil";
...
END_
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5. The user can decide to write to the FIL file only when *STEPS are defined
in the Abaqus input deck.
SIMULIA
Tosca Structure

Node Restrictions for Shape Optimization
Node restrictions in the Abaqus input file (command *BOUNDARY) are
imported during the Tosca Structure preprocessing step if the following command is defined:
OPTIONS
READ_BC
= ALL
END_
By default, this command is already included in the configuration file command.ini. Therefore it must not be defined explicitly in the parameter file.
Node restrictions defined in the FE-analysis (and maybe not used in the FE
analysis) can be used as restrictions for design variables for shape and bead
optimization (see command DVCON_SHAPE, DVCON_BEAD) to avoid optimization nodal displacements in specified places.
www.3ds.com/tosca
Version 8.1.0 Rev. 1 - 05.2014
Contact Boundary Conditions

This behavior may be avoided by the definition of different restrictions in the
optimization task (casting or minimum member size restrictions)
Sometimes the exact boundary conditions can not be specified before
designing the components. Often the exact boundary conditions are unknown
early in the design phase. Furthermore, also non-linear boundary conditions
such as contact definitions can change during designing. Linearized models
often require several re-calculations and re-optimizations with respect to the
linearized boundary conditions and are therefore time-consuming. Thus, it is
more efficient if the contact conditions are directly specified in the finite element input deck applied for the optimization.
Tosca Structure is easy to operate for the familiar user of Abaqus. The user
creates an analysis model for Abaqus with the relevant contact definitions.
Furthermore, one also defines the design area for the optimization and the
optimization task. Information for Tosca Structure regarding the actual contact
problem is not required because Tosca Structure is a modular system. The
contact problem becomes a part of the optimization through the forces of the
nodes and the stresses. As a result, the user can make full use of the capabilities in Abaqus for the contact calculations.
Contact conditions are permitted in the analysis model for topology and
shape optimization. Defining a contact surface directly on the edge of the
design space is allowed in topology optimization. The shape optimization
algorithm has to be inverted (see command OPT_PARAM, Parameter
SCALE) if the design edge belongs to a contact surface in shape optimization. Convergence difficulties in the FE analysis may arise in cases of complex contact problems due to large changes in the model during optimization.
User Manual 2 - 637
SIMULIA
Tosca Structure
Abaqus

Prescribed accelerations for sensitivity based topology optimization
Prescribed acceleration loading are often caused by gravity fields, centrifugal
loading and rotary acceleration loads. This chapter defines which kind of
acceleration types for the Abaqus solvers is feasible for sensitivity based
The following commands are supported for acceleration loading:
1. GRAV: Gravity loading.
2. CENTRIF: Centrifugal load
3. ROTA: Rotary acceleration load
The following are not supported:
1. CENT: Centrifugal load is can not supported.
2. CORIO: Coriolis force loading is not supported.
Several CPU-processors in combination with sensitivity based topology
optimization
Abaqus fails to deliver all results requested by Tosca Structure sensitivity
based topology optimization when an Abaqus analysis is executed using
more than one CPU-processor in combination with Tosca Structure sensitivity
based topology optimization. Abaqus failing to deliver all results requested by
Tosca Structure sensitivity based topology optimization is solved by adding
the following in the OPT_PARAM command,
Remarks
1. Default is PROCESSORS = SINGLE.
2. Design responses for reaction forces and internal forces can not be applied
when PROCESSORS = MULTI is activated.
Temperature loading
The following commands are supported for temperature loading in sensitivity
based topology optimization: *TEMPERATURE.
Remarks
1. When reading temperatures from the results or output database file (FILE)
then the temperature (FILE) should be the same in each optimization iteration.
2 - 638 User Manual
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OPT_PARAM
....
PROCESSORS = MULTI
....
END_
SIMULIA
Tosca Structure
11.1.9 Nonsupported Features (Cards/Keywords...)

*ELCOPY
*ELGEN
*NCOPY
*NFILL
*NGEN
*NMAP
Individual nodes and elements are changed during the optimization. Thus,
the commands used in Abaqus to define nodes and elements of transformations are invalid. The appearance of these keywords in the finite element
input deck leads to a termination of the optimization. Therefore, these definitions should be executed in a preprocessor so an explicit definition of the
nodes and elements are created.
When input files already exist then a data check should be carried out with
Abaqus. In this data check the nodes and elements are generated and written
in the output file (*.dat). The node and element definitions can then be copied
from the output file and inserted into a new input file.
*PARAMETER
*PARAMETER DEPENDENCE
*PARAMETER SHAPE VARIATION
Parametric inputs in the Abaqus input deck can not be used with Tosca Structure. A parameter check should be executed when parametric inputs exist.
This parameter check causes an evaluation and substitution of only the parametric inputs:
abaqus job=job-name parametercheck
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Version 8.1.0 Rev. 1 - 05.2014
Then a modified input file containing no parameter and parameter dependence table definitions and <parameter> instances is produced. Use the generated file named job-name.pes for optimization with Tosca Structure.
11.2
ANSYS
Solver type
ANSYS
Table 44
Tosca Structure
supported input
*.cdb, *.dat, *.inp
Tosca Structure
supported output
*.rst
Tosca Structure supported file formats for ANSYS. See flow

diagram Fig. 338
User Manual 2 - 639
SIMULIA
Tosca Structure
ANSYS

The Tosca Structure preprocessor can read ANSYS input files of arbitrary format, however, the ANSYS input files must be able to be process in batch
mode. The ANSYS input file can be created by an arbitrary FE-Preprocessor.
In ANSYS, the CDB file is created with the following command:
CDWRITE, OPTION, FNAME, EXT, DIR, FNAMEI, EXTI, FMAT
At least one Solve-Command has always to be specified: solve or

lssolve.
To check, if the input file is executable in batch mode, one analysis should be
performed in batch mode from the command line before starting the complete
optimization. The corresponding batch call of ANSYS version 14.0 on Windows is as following:
Ansys140 -b -i<input file> -o<output file> -p<productvar>
Error messages and warnings can be found in the *.err file. The input file
must be corrected if an error occurs.
As input file for the optimization loop TOSCA_PREP generates an ANSYS
CDB file from the ANSYS input file. Compared to a complete ANSYS input
file this file contains no solution strategy (/SOLU).
During the optimization procedure the analysis results are read from the *.rst
file.
Remarks
2. For a topology optimization with the controller algorithm using static finite
element analysis, which contains only solid elements, the iterative PCG
Solver of ANSYS should be used due to performance reasons. The solver
may be activated by adding the following command in the solution block of
the corresponding CDB file:
eqsl, pcg, 1.e-5
3. The iterative solver is not recommended for sensitivity based optimizations.
4. It is not allowed to define new nodes or elements after the first /SOLU
statement. (The solution part is cut off the .cdb file before the ANSYS
Preprocessing-run.)
5. In Tosca Structure configuration file tosca_ctrl.cfg (see also CONFIG) the
environment variable ANSWAIT=1 will be set, to let ANSYS wait for a free
license.
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1. The ANSYS interface will stop reading element and node definitions when
the first /SOLU definition in the input file occurs. Elements that are defined
after the first /SOLU (usually elements and nodes generated by macros)
are not known in Tosca Structure. In return this allows for more possibilities
of using macros and /PREP7 sections after a /SOLU definition. Most definitions after /SOLU are not modified by the interface.
SIMULIA
Tosca Structure
6. In earlier versions of the ANSYS interface, for shape and bead optimization
the positions of nodes used to be modified using the special command
"NMODIF", which is unsupported by Tosca ANSA environment. This
prevented the user from visually inspecting the modified state of the model.
The interface now modifies directly the coordinates of the nodes, thus all
intermediate steps of the shape or bead optimization can be visualized with
Tosca ANSA environment.
ANSYS Files generated during a Tosca Structure optimization
During the optimization preprocessing the ANSYS model will be imported
to ANSYS and exported again to generate a standard blocked CDB file.
During this import/export step all macros in the ANSYS input file will be
executed in ANSYS and can no longer be found as macros in the input files
used during the Tosca Structure optimization.
The input file (model.cdb) is split into multiple files during the optimization
preprocessing (TOSCA_PREP):
- model_ans.cdb
Input file without solution /SOLU
- model_ans.head
File containing the ANSYS Header
- model_ans.solu
File containing the ANSYS Solution /SOLU. Eventually, existing load
case files *.s0X are copied into the optimization working directory. These
remain unchanged during the optimization process.
- model_ans.tosca
temporary file which is used for the generation of the model_ans.cdb file
www.3ds.com/tosca
Version 8.1.0 Rev. 1 - 05.2014
Two files are generated during the fem_modif call:

- model_<iter>.ans
- model_<iter>.cdb
The CDB file is included in the ans file using a CDREAD
The model<iter>.ans file is renamed into model.ans before the finite element analysis is executed. The CDB file is not renamed - it is referenced
with the iteration extension in the ans file.
Two files are moved in the corresponding SAVE directory:
- model.ans: is copied (copy_solver_info_list) into the corresponding SAVE
directory and gets an iteration counter number before the finite element
analysis is executed.
model_<iter>.cdb: is moved (move_per_iter_xxx_list) into the corresponding SAVE directory at the end of the design cycle.
User Manual 2 - 641
SIMULIA
Tosca Structure
ANSYS
The newly created CDB file in blocked format is detected and analyzed
automatically by the optimization preprocessor. Thus, the FE model is
imported into Tosca Structure. The data of the ANSYS model (coordinates
of nodes, materials, properties and assignment of elements) in the CDB file
can be modified during the optimization. The load files contain the boundary restrictions which provide information about boundary movements for
shape optimization.
The solve section contains the solution strategy of the original input file,
checks and the definition of which kind of results must be written to the *.rst
files for shape and topology optimization, respectively. Thus, during the
ANSYS analysis only the results necessary for the optimization are written
to the result file.
During the optimization the data in the CDB file is modified. Afterwards the
three parts are merged and a new ANSYS analysis is performed. The load
files are not changed during the optimization.

In topology optimization only the type of elements that are supported can be
used in the design area. All other element types in the analysis model are
regarded as dummy elements, i.e. the elements are not modified during the
optimization. Some further restrictions may apply regarding specific design
responses. Please check remarks for this.
BEAM_2D
ANSYS-element
type
BEAM23
LINK1
LINK10
LINK11
LINK180
LINK8
BEAM3
Design element
only allowed as
restriction element for
shape optimizations

F=allowed for the design responses that use the element-based reaction
and internal forces
* = shell elements admitted for sizing optimization
2 - 642 User Manual
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Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
type
SIMULIA
Tosca Structure
www.3ds.com/tosca
Version 8.1.0 Rev. 1 - 05.2014
type
ANSYS-element
type
Design element
BEAM_3D
BEAM24
BEAM4
BEAM188
only allowed as
shape optimizations
MASS_1
MATRIX27
PLANE_QUAD_4
PLANE182
C, S, F
PLANE42
C, S, F
PLANE_TRIANG_6
PLANE146
C, S, F
PLANE_QUAD_8
PLANE145
PLANE183
PLANE82
C, S, F
SHELL_QUAD_4
SHELL143
SHELL181*
SHELL41
SHELL43
SHELL63
C, S, F
SHELL_QUAD_8
SHELL150
SHELL93
SHELL281*
C, S, F
SOLID_BRICK_8
SOLID185
SOLID45
C, S, F
SOLID_TETRA_4
SOLID285
C,S,F
SOLID_TETRA_10
SOLID148
SOLID187
SOLID92
C, S, F
SOLID_BRICK_20
SOLID147
SOLID186
SOLID95
C, S, F
SOLID_PYRAM_5
SOLID185
SOLID45

and internal forces
User Manual 2 - 643
SIMULIA
Tosca Structure
ANSYS
type
ANSYS-element
type
SOLID_PYRAM_13
SOLID147
SOLID186
SOLID95
DUMMY_ELEM_TYPE
all not supported

element types
Design element
C

and internal forces
For shape and bead optimization only nodes belonging to elements supported by Tosca Structure can be used as design nodes. More solver specific
information about the sensitivity based algorithm is found in vol.2 chapter
11.2.8, Remarks for sensitivity based optimizations. For sensitivity based
bead optimization, see vol.2 chapter 7.11, Special Remarks Using Sensitivity
Based Algorithm.
Remarks
1. It is important to note that in shape optimization the form of the shell structure is optimized and not its thickness. This means that the shell edges are
modified and that modifications on shell level are not carried out.
Node and element components or assemblies from components in ANSYS

are defined as follows:
CM, Cname, Entity
CMGRP, Aname, Cnam1, Cnam2, Cnam3, Cnam4, Cnam5, Cnam6,
Cnam7, Cnam8
CMBLOCK,Cname,Entity,NUMITEMS
These components or assemblies are treated in Tosca Structure as node or

element groups. These groups are loaded from the ANSYS input file during
the optimization preprocessing and these groups are available for further definition in the parameter file along with the groups ALL_NODES and
ALL_ELEMENTS. If components containing nodes and elements have identical names in the ANSYS input file, the endings "_NODE" and "_ELEM" are
added to the specified group name during importation. This guarantees that
the group can be identically identified by Tosca Structure.
2 - 644 User Manual
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Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure

Tosca Structure will read the coordinate systems that are defined with the
ANSYS command LOCAL
LOCAL, R5.0, TYPE, NSCY, CSTYP, VAL1, VAL2, VAL3
The coordinate systems can be referenced in Tosca Structure as CS_* where

* is the id number NSCY of the coordinate system.

Tosca Structure supports linear elastic, isotropic material for static and modal
analysis.
Also non-linear materials are supported for shape optimization. Therefore,
the material models Mooney and Ogden can be used in shape optimization.
The interface to ANSYS recognizes and supports a wider range of materialrelated features, including:
All properties specified for a material in the original model are assigned
(and modified, if necessary) to the materials created by Tosca Structure
during topology optimization.
Anisotropic materials get scaled for all material-directions.
Temperature-dependent properties are supported for both MPxxx and
TBxxx-types of commands.
The following TB-command variants are supported by the interface for
modification:
www.3ds.com/tosca
Version 8.1.0 Rev. 1 - 05.2014
TB
Anisotropic Elastic Material
ANEL
Anisotropic Constants
ANISO
Bilinear Isotropic Hardening Constants
BISO
Bilinear Kinematic Hardening Constants
BKIN
Cast Iron Plasticity Material Constants
CAST
Drucker-Prager Constants
DP
TBOPT
ISOTROPIC (*)
(*) TBOPT is optional
User Manual 2 - 645
SIMULIA
Tosca Structure
ANSYS
TB
TBOPT
Hyperelastic Material Models
HYPER
BOYCE,
BLATZ,
FOAM,
GENT,
MOONEY,
NEO,
OGDEN,
POLY,
YEOH
Kinematic Hardening Constants
KINH
PLASTIC (*)
MKIN
Multilinear Elastic Constants
MELAS
Multilinear Isotropic Hardening Constants
MISO
Nonlinear Isotropic Hardening Constants
NLISO
VOCE (*),
POWER (*)
Plastic Strain
PLASTIC
MISO (*),
KINH (*)
Uniaxial Behaviour
UNIAXIAL
TENSION,
COMPRESSION
(*) TBOPT is optional

Remarks
2. Tosca Structure needs different properties for different element types. For
example it is not allowed that a solid element and a shell element share the
same element property.
3. Geometrical non-linear modeling might cause convergence issues in the
FE-solver for the void elements (in topology optimization) because the void
elements might have semi definite or negative definite elemental matrices.
Especially, for geometrical non-linear modeling combined with nonlinear
material convergence issues emerge in the FE-solver. No unique solution
exists if convergence issues occur for the void elements. However, a
potential candidate for a solution could be to use SOFT_DELETE (see
chapter 5.8.1.4 Relation between relative density and stiffness or
OPT_PARAM) or increasing the relative minimum density (parameter
DENSITY_LOWER in OPT_PARAM). Additional, the user should check if
2 - 646 User Manual
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Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
1. The use of nonlinear Materials requires a Tosca Structure.nonlinear

license.
SIMULIA
Tosca Structure
the most favorable settings for solving the non-linear equilibrium are
applied in the FE-solver.
4. With Tosca Structure 8.0 "SECBLOCK"-sections for shell elements are
supported in both sizing and topology optimization.
5. Shell properties for elements used for sizing must be defined using the
"SECBLOCK" keyword. Elements using only the RLBLOCK definition are
not admitted for sizing optimization with Tosca Structure. This implies that
only shell elements of type SHELL181 and SHELL281 are admitted for
sizing optimization.

Geometric Nonlinear Analysis
Geometric nonlinear analysis (parameter NLGEOM) can be used in topology,
bead and shape optimization.
Allowed analysis types for sensitivity based optimizations
The responses from the two following analysis types in ANSYS are allowed
for sensitivity based topology optimization:
ANTYPE,0
www.3ds.com/tosca
Version 8.1.0 Rev. 1 - 05.2014
ANTYPE,2
Only one set of the command LSSOLVE is allowed in each finite element file
(CDB). Furthermore, the load cases should be specified in an order starting
from 1 and then the numbering should be chronologically increasing. The
load cases are referred in the parameter file using the number of the load
case.
E.g. if two static load cases (LSSOLVE,1,2,1 and ANTYPE,0 in
file_fe_static.s01 and file_fe_static.s02) are defined in the file
file_fe_static_1.cdb and two eigenfrequency load cases (LSSOLVE,1,2,1 and
ANTYPE,2 in file_fe_dynamic.s01 and file_fe_dynamic.s02) are defined in
the file_fe_dynamic_1.cdb, they are defined in parameter file like:
FEM_INPUT
ID_NAME
FILE
FILE
= Two_files
= file_fe_static.cdb
= file_fe_dynamic.cdb
END_
and the two static responses can be referred to like:

DRESP
...
User Manual 2 - 647
SIMULIA
Tosca Structure
ANSYS
LC_SET
...
= STATIC,1,
END_
and
DRESP
...
LC_SET
...
= STATIC,2,
END_
and the two modal frequency responses can be referred to like:

DRESP
...
LC_SET
...
= MODAL,10001,...
END_
and
DRESP
...
LC_SET
...
= MODAL,10002,.....
END_
1. Significant improvement in the CPU-time is obtained using the following

command in each load case:
OUTPR,ALL,NONE ! No output in ASCII format
This ensures that no ASCII information is written as output. Therefore,
adding this command in each load case is strongly recommended.
2. When two or more finite element input files (CDB) are referred in the
command FEM_INPUT command then the ANSYS command /FILNAME,
<name>, 1 has to be added in all finite element input files (CDB) for
uniquely defining the load cases for each finite element input file (CDB).
3. When only one finite element input file (CDB) is referred in the command
FEM_INPUT, the ANSYS command /FILNAME, <name>, 1 does not have
to be added in the finite element input file (CDB). However, then the load
case files have to be named file.s01, file.s02, file.s03, etc.
2 - 648 User Manual
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Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Remarks
SIMULIA
Tosca Structure

algorithm has to be inverted (see command OPT_PARAM, parameter
The use of contact boundary condition requires a Tosca Structure.nonlinear license
Node fixations are not loaded during the loading of the analysis model. The
boundary conditions (SPC = NR1 and SPC = NR2) are transferred to the optimization model by entering the command
OPTION
READ_BC
= ALL
END_
Node fixations are created in ANSYS in the load files (*.sxx) of the analysis
model with the command:
D, NODE, LAB, VALUE, VALUE2, NEND, NINC, LAB2, LAB3, LAB4,
LAB5, LAB6
We recommend considering all fixed node during the reading of the model
with the command
www.3ds.com/tosca
Version 8.1.0 Rev. 1 - 05.2014
READ_OPTION, SPC, ON

acceleration types for the ANSYS are feasible for sensitivity based topology
optimization.
The following commands are supported (In global Cartesian directions):
1. ACEL specifies the linear acceleration of the structure.
2. OMEGA specifies the rotational velocity of the structure.
3. DOMEGA specifies the rotational acceleration of the structure.
User Manual 2 - 649
SIMULIA
Tosca Structure
ANSYS
The following commands are supported (About another reference coordinate

system):
1. CGLOC specifies the origin location of the acceleration coordinate system.
2. CGOMEGA specifies the rotational velocity of the global origin.
3. DCGOMG specifies the rotational acceleration of the global origin.
The following commands are supported (For element components):
1. CMDOMEGA specifies the rotational acceleration of an element component about a user-defined rotational axis.
2. CMOMEGA specifies the rotational velocity of an element component
about a user-defined rotational axis.
Remarks
1. Applying lumped mass matrices can be enforced using LUMPM,OFF
Applying consistent mass matrices can be enforced using LUMPM,ON
Nonlinear Sensitivity based Optimizations (ANSYS 14 required)
Displacements, internal and reaction forces and stress values (i.e. all design
responses except of compliance) extracted from nonlinear static analysis
require information (pseudoloads) from ANSYS perturbation steps for sensitivity based optimization. These perturbation analyses are only available in
ANSYS 14 or newer and allow for the elements enlisted in the table below.
Category
Element Name
Spars
LINK180
Beams
BEAM188
BEAM189
Pipes
PIPE288
PIPE289
2-D Solids
PLANE182
PLANE183
(*) support of this element type will be added in ANSYS 14.5
2 - 650 User Manual
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Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Remark:
Nonlinear optimizations using pseudoloads with ANSYS versions < 14 are no
longer supported! If you want to use this kind of optimizations please make
sure you are using at least ANSYS 14.
Linear perturbations in ANSYS currently only allow the following element
types:
SIMULIA
Tosca Structure
www.3ds.com/tosca
Version 8.1.0 Rev. 1 - 05.2014
Category
Element Name
3-D Solids
SOLID185
SOLID186
SOLID187
SOLID285
Shells
SHELL181
SHELL208
SHELL209
SHELL281
Solid-Shell
SOLSH190
Interface
INTER192
INTER193
INTER194
INTER195
Contact
TARGE169
TARGE170
CONTA171
CONTA172
CONTA173
CONTA174
CONTA175
CONTA176
CONTA177
CONTA178
Specialty
COMBIN14
MASS21
MATRIX27
COMBIN39 (*)
SURF153
SURF154
SURF156
PRETS179
MPC184
MESH200
FOLLOW201
COMBI214
HSFLD241
HSFLD242
(*) support of this element type will be added in ANSYS 14.5

Other element types are not allowed in the model for nonlinear optimizations
using pseudoloads in Tosca Structure.
User Manual 2 - 651
SIMULIA
Tosca Structure
Marc
11.3 Marc
Solver type
Marc
Table 45
Tosca Structure
supported input
*.dat
Tosca Structure
supported output
*.t16
Tosca Structure supported file formats for Marc. See flow diagram Fig. 338
Please Note:
For subsequent versions of Tosca Structure the Marc interface will be frozen
with functionality of Tosca Structure 7.0.1. The interface will be available in
the current version as as-is interface. No further developments and enhancements will be made for this interface.

Input Format
The optimization preprocessor reads the ASCII input files *.dat from Marc.
Tosca Structure can read both the Free Field and Fixed Field formats but
preference should be given to the Free Format.
Tosca Structure reads the results of the Marc FE calculation from the binary
result file modelname.t16. The optimization preprocessor automatically
enters the post codes necessary for the optimization (result requests) in the
input file (modelname.dat).
For stress evaluations Tosca Structure reads components of tensor 411 referenced in the binary result file modelname.t16.
For analysis with geometric nonlinearities the user has to ensure that this tensor is assigned with components of the CAUCHY STRESS TENSOR. It is
recommended to use the updated Lagrange approach for equilibrium conditions:
The Plasticity parameter with options 3,4 and 5 utilizes the updated
Lagrange procedure for elastic-plastic analysis.
The Elasticity parameter with option 2 utilizes the updated Lagrange procedure for large strain elasticity (Mooney, Ogden, etc.).
2 - 652 User Manual
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Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Result Format
SIMULIA
Tosca Structure
Tosca Structure element

type
Marc element type
PLANE_QUAD_4
C, S
10
C, S, F
11
C, S, F
20
C, S
95
C, S
114
C, S, F
115
C, S, F
116
C, S
118
C, S
119
C, S
Design element

and internal forces
www.3ds.com/tosca
Version 8.1.0 Rev. 1 - 05.2014
The analysis model can contain any kind of element types.

Only design nodes that are allocated to certain element types can be used in
shape optimization. Elements of other element types are not modified during
optimization. Additionally, only certain element types are permitted for the
definition of restriction areas.
Only elements that have a supported element type in the optimization area
can be used in topology optimization. All other elements in the analysis model
are taken to be dummy-elements during optimization, i.e. the elements are
not modified during optimization. Some further restrictions may apply regarding specific design responses. Please check remarks for this.
User Manual 2 - 653
SIMULIA
Tosca Structure
Marc

type
Marc element type
PLANE_QUAD_8
26
C, S, F
27
C, S, F
28
C, S
32
C, S
33
C, S
34
C, S
53
C, S, F
54
C, S, F
55
C, S
56
C, S
58
C, S
59
C, S
60
C, S
63
C, S
66
C, S
67
C, S
73
C, S
74
C, S
96
C, S
C, S
C, S, F
155
C, S
156
C, S

and internal forces
2 - 654 User Manual
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Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
PLANE_TRIANG_3
Design element
SIMULIA
Tosca Structure

type
Marc element type
PLANE_TRIANG_6
124
C, S, F
125
C, S, F
126
C, S
128
C, S
129
C, S
18
C, S, F
22
C, S
68
C, S
75
C, S
80
C, S
81
C, S
82
C, S
83
C, S
139
C, S, F
140
C, S, F
30
C, S, F
72
C, S, F
SHELL_TRIANG_3
138
C, S, F
SOLID_BRICK_20
21
C, S, F
35
C, S
57
C, S, F
61
C, S
SHELL_QUAD_4
www.3ds.com/tosca
Version 8.1.0 Rev. 1 - 05.2014
SHELL_QUAD_8
Design element

and internal forces
User Manual 2 - 655
SIMULIA
Tosca Structure
Marc

type
Marc element type
SOLID_BRICK_8
C, S, F
84
C, S
117
C, S, F
120
C, S
127
C, S, F
130
134
C, S, F
157
C, S
can be used as
shape optimizations
can be used as
shape optimizations
can be used as
shape optimizations
52
can be used as
shape optimizations
SOLID_TETRA_4
BEAM_2D
DUMMY
all not supported

element types

and internal forces
More solver specific information about the sensitivity based algorithm is found
in chapter vol.2 chapter 11.3.7, Remarks for sensitivity based optimizations.
For sensitivity based bead optimization, see vol.2 chapter 7.11, Special
Remarks Using Sensitivity Based Algorithm.
Node and element groups can be defined using the commands DEFINE,
ELEMENT, SET, and DEFINE, NODE, SET in the Marc model file.
These groups can be used in Tosca Structure to define the optimization task.
When a node group and an element group have the same name, Tosca
Structure attaches the endings _NODE and _ELEM to the groups for unique
definition.
2 - 656 User Manual
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Version
Version
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Rev. 1Rev.
- 05.2014
1 - 05.2014
SOLID_TETRA_10
Design element
SIMULIA
Tosca Structure

The coordinate systems defined in Marc are imported in Tosca Structure and
can be used in the parameter file. Coordinate systems can be defined in Marc
using the commands TRANSFORMATION and CYLINDRICAL.
As the coordinate systems in Marc are not allocated an ID or name, they are
numbered in sequence of their appearance in the input file. They receive the
name "CS_<nr>" from Tosca Structure. The numbering begins with 1, as
Tosca Structure contains the default coordinate systems CS_0. The first coordinate system from the input file has the name CS_1. The coordinate systems are numbered in the order of their appearence in the input file.
The implicit allocation of names for the coordinate systems is to be considered when defining ones own coordinate system in the parameter file. User
defined coordinate systems should not begin with the prefix "CS_" in order to
avoid an invalid definition of a name.

Topology optimization:
Tosca Structure supports linear-elastic, isotropic materials for static calculation.
Shape optimization:
www.3ds.com/tosca
Version 8.1.0 Rev. 1 - 05.2014
The following Marc material models are supported in shape optimization:

ISOTROPIC
MOONEY
ARRUDBOYCE
GENT
OGDEN
The use of nonlinear materials requires an Tosca Structure.nonlinear
license

In Marc the responses from the two following analysis types are allowed:
Marc finite element files (*.dat) should include the command "ELASTIC" for
linear static analysis.
Marc finite element files (*.dat)) should include the command "DYNAMIC"
for linear dynamic analysis.
User Manual 2 - 657
SIMULIA
Tosca Structure
Marc
Remarks
1. Marc has no predefined numbers for the load cases. Therefore, the first
defined load case in a specified DAT file is recognized as load case one,
the second defined load case in the specified DAT file is recognized as load
case two and etc.
2. One finite element files (*.dat)) is only allowed to contain a static analysis or
a dynamic analysis. Not both simulation types are allowed simultaneously
in the same finite element file (*.dat)).
3. Finite element models having nodes in local degree of freedom (DOF)
defined in a local coordinate system using the Marc command TRANSFORMATION is not supported for sensitivity based topology optimization.

Contact definitions
Contact conditions are permitted in the analysis model for controller based
topology and shape optimizations. Defining a contact surface directly on the
edge of the design space is allowed in topology optimization. The shape optimization algorithm has to be inverted (see command OPT_PARAM, Parameter SCALE) if the design edge belongs to a contact surface in shape
optimization. Convergence difficulties in the FE analysis may arise in cases of
complex contact problems due to large changes in the model during optimization.
Currently contact definitions in input files for sensitivity based optimizations are not supported
Node fixations in the Marc input file are imported during optimization preprocessing if the following command is set:
This command is set by default in the configuration file command.ini. Therefore, it must not be specified explicitly in the parameter file.
Node restrictions defined in the FE-analysis (and maybe not used in the FE
analysis) can be used as restrictions for design variables for shape optimization (see command DVCON_SH

Currently contact definitions in input files for sensitivity based optimizations
are not supported
2 - 658 User Manual
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Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Temperature loading
The following commands are supported for temperature loading in sensitivity
based topology optimization:
1. THERMAL_LOADS
2. POINT_TEMP
11.3.8 Frequency spectrum

Frequency Response analyses are not supported in the Marc interface.
11.4 MSC Nastran

Tosca Structure
supported input
Solver type
MSC Nastran
*.bdf
Tosca Structure
supported output
*.op2
(*.dat)
Table 46
Tosca Structure supported file formats for MSC Nastran. See

flow diagram Fig. 338.
www.3ds.com/tosca
Version 8.1.0 Rev. 1 - 05.2014
Input Files and Formats

The optimization preprocessor reads the ASCII input files *.bdf. The Bulk
entries must be in fixed format and in either small or large field format.
Parameter statements (PARAM) may be set as free format.
Result Files and Formats
Tosca Structure uses MSC Nastran output OP2. The following parameters
are automatically generated or changed by Tosca Structure:
PARAM,POST,-1
PARAM,POSTEXT,YES
PARAM,TINY,0.0
PARAM,DBALL,SCRATCH
PARAM,OUGCORD,BASIC
For sensitivity based topology optimization PARAM, POST, -4 is set in the first
iteration.
User Manual 2 - 659
SIMULIA
Tosca Structure
MSC Nastran
Tosca Structure 8.1.0 adds any output (DISPLACEMENTS, STRESS, etc.)

required by the optimization if no outputs are given.
Remarks
1. Please let Tosca Structure add the output request for obtaining the lowest
possible CPU-time of the optimization. In many cases output writing is the
most CPU-time consuming task for MSC Nastran and thus Tosca Structure
adds only those output requests that are necessary for the optimization.
Therefore, the user should set as few output requests as possible, if any.
2. Please note: the validation input file is created based on the original input
deck. Thus for an automatic validation all required outputs have to be
added in the beginning to the original input deck or the validation input file
has to be changed manually after generation before starting the validation
run.
3. When using mode=i8 for MSC Nastran you must set
fem_modif_add_call = "mode=i8"in your configuration.
MSC Nastran does not write the stifffness matrix using mode=i8. For a
workaround "ASSIGN OUTPUT2=LTLEND.OP2 UNIT=12 FORM=UNFORMATTED" must be added in the model file. The solver now creates the file
LTLEND.OP2 which must be used for result extraction by Tosca Structure
for res2vtm not to fail. With Tosca Structure 8.0 this is automatically
managed by the control shell. The only thing you need to do is to set
fem_modif_add_call = "mode=i8". The control shell will append "-mode i8" to the call of res2vtm also.
PARAM,MAXRATIO,10.E10

The analysis model can contain arbitrary element types and supplementary
options.
Only design nodes that are attached to certain element types can be used in
shape and bead optimization (see table below). All other element types are
allowed if they are not modified during the optimization. Only certain element
types for defining the restriction areas of elements are permitted.
2 - 660 User Manual
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Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
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4. In topology optimization large changes are applied to the elements' density

and thus Young's modulus. This may result in problems with the pivot ratio
of the stiffness matrices during a Nastran run. This could be overcome by
changing the MAXRATIO parameter in the bulk data section like, e.g.:
SIMULIA
Tosca Structure
Some further restrictions may apply regarding specific design responses.

Please check remarks for this.
www.3ds.com/tosca
Version 8.1.0 Rev. 1 - 05.2014
Tosca Structure Element

type
MSC Nastran Element

type
Design
element
SOLID_BRICK_8
CHEXA
C, S, F
SOLID_BRICK_20
CHEXA
C, S, F
SOLID_TETRA_4
CTETRA
C, S, F
SOLID_TETRA_10
CTETRA
C, S, F
SOLID_PENTA_6
CPENTA
C, S, F
SOLID_PENTA_15
CPENTA
C, S, F
SHELL_QUAD_4
CQUAD4
CQUAD8
CQUAD
CQUADR
CSHEAR
CQUADX
C, S, F
C, S, F
C
C, S, F
C, S, F
SHELL_QUAD_8
CQUAD8
CQUAD
CQUADX
C, S, F
C
SHELL_TRIANG_3
CTRIA3
CTRIA6
CTRIAR
CTRIAX
CTRIAX6
C, S, F
C, S
C, S, F
C
SHELL_TRIANG_6
CTRIA6
CTRIAX
CTRIAX6
C, S, F
C
BEAM_3D
CBAR
CBEAM
CBEND
CBUSH
can be used
as restriction
element for
shape optimizations
GAP_2_ND
CGAP

and internal forces
User Manual 2 - 661
SIMULIA
Tosca Structure
MSC Nastran
Tosca Structure Element

type
MSC Nastran Element

type
MASS_1
CONM1
CMASS1
DUMMY_ELEM_TYPE
all not supported element

types
Design
element

and internal forces
Table 47
Supported MSC Nastran Element Types
in vol.2 chapter 11.4.7, Remarks for sensitivity based optimizations. For sensitivity based bead optimization, see vol.2 chapter 7.11, Special Remarks
Using Sensitivity Based Algorithm.
Remarks
1. Elements with linear or quadratic element formulations are supported.
Mixed elements types are not permitted. A model can contain linear as well
as quadratic elements.
2. It is important to note that shell structures are optimized in form and not in
thickness in shape optimization. This means that the "shell edges" need to
be modified and not the shell layers.

Supported Coordinate Systems
CORDiC, CORDiR, CORDiS
Remark
1. Coordinate systems may be referenced in the Tosca Structuree parameter
file as:
CS_REF
= CS_1
The above references the coordinate system id = 1 in the input deck. CS_0
is always the global rectangular coordinate system even if it is not defined in
the input deck.
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Tosca Structure

Supported Materials
MAT1, MAT2, MAT3, MAT4, MAT5, MAT8, MAT9, MAT10, MATHE, MATHED,
MATHP, MATORT, MATS1, MATTEP, MATTG, MATTHE, MATTi
Remarks
For topology optimization are only MAT1, MAT2, MAT8 and MAT9 allowed for
the design elements. The full constitutive matrix for MAT2, MAT8 and MAT9 is
scaled in topology optimization.
Supported Properties
PBAR, PBCOMB, PBEAM, PBEAML, PBEND, PBMSECT, PBRSECT,
PBUSH, PBUSH1D, PCOMP, PDAMP, PDAMP5, PDUMi, PELAS, PGAP,
PSHEAR, PSHELL
Remarks
1. In topology optimization the PSHELL cards assigned to the design
elements are duplicated and modified. If the original PSHELL card contains
the property definitions MAT2, MAT3, and MAT4 in addition to the essential
number MAT1, these will be ignored if they are different from MAT1. All
materials will be allocated the same number as the required MAT1 in a
duplicated PSHELL card.
2. PCOMP may only be used with one material for topology optimization - the
directions of this single material may of course vary.
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Following solution types are allowed with MSC Nastran:
SOL 101, 103, 106, 108, 111, 114 and 115.
Contact definitions in 101 (BCONTACT) are also allowed.
Allowed analysis types for Sensitivity based optimizations
In Nastran the responses from the two following analysis types are allowed:
SOL 101
SOL 103
SOL 101 and SOL 103 represent the linear static and linear eigenvalue analysis, respectively. Therefore, one has to define a finite element file (e.g. bdf)
containing the SOL 101 and another finite element file (e.g. bdf) containing
the SOL 103 when both the responses from the static and frequency analysis
are applied in the optimization formulation (e.g. minimizing the compliance
but still ensuring that the first eigenfrequency is higher than a given value).
User Manual 2 - 663
SIMULIA
Tosca Structure
MSC Nastran
However, a workaround exists for reducing the finite element analysis CPUtime for Nastran when having responses consisting of both static and modal
responses. Only the SOL 103 solution can be used when both the responses
from the static and frequency analysis are applied in the optimization formulation. This is done by adding static load cases in the SOL 103 solution. However, the eigenfrequency solutions of the structure are not allowed to be
prestressed (then convergence is not guaranteed). Thus, the user should
define a dummy load case which has no stresses and this dummy load case
is referenced in the eigenfrequency analysis. An example of combining several frequency analyses and several static analyses in SOL 103 is given the
following example:
SOL 103
...
SUBCASE 1
$ DYNAMIC LOADCASE 1
METHOD=....
SPC = ....
$
THE STRUCTURE IS PRESTRESSED.
THE REFEERED SUBCASE (20) HAS NO STRESSES !

STATSUB = 20
SUBCASE 2
$
DYNAMIC LOADCASE 2
METHOD=....
THE STRUCTURE IS PRESTRESSED.
THE REFEERED SUBCASE (20) HAS NO STRESSES !

STATSUB = 20
.......
SUBCASE 13
$
STATIC LOADCASE 1
SPC = ....
LOAD = ....
SUBCASE 14
$
STATIC LOADCASE 2
SPC = ...
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SPC = .....
SIMULIA
Tosca Structure
LOAD = ...
..
SUBCASE 20
$
DUMMY STATIC LOADCASE, WHICH IS STRESS FREE !
THE COMMAND LOAD SHOULD NOT BE PRESENT HERE !
BOUNDARY CONDITIONS ARE ADDED FOR ENSURING
NO SINGULARITIES OF THE GLOBAL STIFFNESS AND MASS MATRIX

SPC = 3
BEGIN BULK
..
ENDDATA
Remarks
1. Remember when defining the command DRESP in the parameter file to
distinguish between the different type of load cases (STATIC - MODAL)
and the number of eigenfrequencies.
2. Generally, laminate materials can not be designed in topology optimization.
However, laminate materials as design elements are allowed for MAT2,
MAT8 and MAT9 in Nastran.
Temperature loading
TEMPERATURE(LOAD) or TEMPERATURE(BOTH) in sub cases referring
the following types are supported for temperature loading using Tosca Structure:
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1. TEMP
2. TEMPD
3. TEMPP1
4. TEMPRB
TEMPAX
Remarks
1. Note, that different sub case can have different temperature loading and
also some sub cases without temperature loading.
2. STRAIN_ENERGY as DRESP when having temperature loading is not
allowed for Nastran because Nastran is calculating the strain energy using
a wrong principle.
User Manual 2 - 665
SIMULIA
Tosca Structure
MSC Nastran
3. Shell elements are not supported in design domain:CTRIA3, CTRIA6,

CTRIARCQUAD4, CQUAD8, CQUADR for temperature loading. However,
the elements can still be included in the model they are just not allowed to
be a part of the design domain!!!!
4. The material parameters are not allowed to be a function of the temperature. Thus, TEMPERATURE(MATERIAL) and TEMPERATURE(INITIAL)
are not supported.
5. TEMPBC and TEMPF are not supported.

Load cases
SUBCASE is the default load case statement for Tosca Structure. SUBCOM
allowed only for controller based algorithms.
The iterative solver should be avoided for sensitivity based algorithms
because of additional pseudo loads usually
Supported Boundary Conditions
Linear contact conditions (SOL 101) are permitted in the analysis model for
controller based topology, shape and bead optimization. Contact definitions
with BCPROP can be used for shape and bead optimization, but are not
allowed for topology optimization (as element properties are changed).
Defining a contact surface directly on the edge of the design space is allowed
in topology optimization. The shape optimization algorithm has to be inverted
(see command OPT_PARAM, parameter SCALE) if the design edge belongs
to a contact surface in shape optimization. Convergence difficulties in the FE
analysis may arise in cases of complex contact problems due to large
changes in the model during optimization.
Node Restrictions for Shape Optimizations
Node fixations are not loaded when loading the analysis model. The boundary conditions (SPC = NR1 and SPC = NR2) are transferred to the optimization model by entering the command
OPTIONS
READ_BC
= ID, NR1, NR2 (or ALL)
END_
When the optimization boundary conditions have been written into a separate
sub case then the "Main SPC" number can be specified which has been
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SIMULIA
Tosca Structure
entered in the CASE CONTROL SECTION of the analysis bulk data file. All
SPC commands that are linked in the MSC Nastran input file with SPCADD
are also transferred to the optimization model. Specification of the sub case
number itself is not permitted.

loading and rotary acceleration loads. This chapter defines which kinds of
acceleration types for the MSC Nastran are feasible for sensitivity based
1. GRAV: Defines acceleration vectors for gravity or other acceleration
loading.
2. RFORCE: Defines a static loading condition due to an angular velocity and/
or acceleration.
3. ACCEL1: Defines static acceleration loads at individual GRID points.
1. ACCEL: Defines static acceleration loads, which may vary over a region of
the structural model. The load variation is based upon the tabular input
defined on this Bulk Data entry.
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2. DMIG,UACCEL: Defines rigid body accelerations in the basic coordinate

system.
Remarks
1. ACCEL and ACCEL1 may not be available in all versions of MSC Nastran.
2. Default in Nastran is to apply lumped mass matrices.
3. Applying lumped mass matrices can be enforced using PARAM,COUPMASS,-1
4. Applying consistent mass matrices can be enforced using PARAM,COUPMASS,1
5. Tosca Structure only reads PARAM,COUPMASS for indicating if lumped
mass matrices or consistent mass matrices are applied. Consequently, if
User Manual 2 - 667
SIMULIA
Tosca Structure
PERMAS
the METHOD card for RFORCE is applied then the METHOD card should
correspond to the mass element type chosen in PARAM,COUPMASS.

The SOL108 (direct frequency response) and SOL111 (modal frequency
response) are supported for Nastran. Gravity loading and temperature loading are not allowed in finite element modeling.
Solution excitation frequencies defined using FREQ, FREQ1 and FREQ2 are
allowed in the finite element input deck. The solution excitation frequencies
defined using FREQ3, FREQ4 and FREQ5 should be used with care
because the eigenvalues usually change a lot during optimization.
In frequency response, structural damping PARAM,G and GE on the MATi
are allowed for all design elements. Note, that the structural damping should
be the same for all design elements and that the structural damping for the
design elements should also be defined using OPT_PARAM yielding
OPT_PARAM
...
DAMP_STRUCTURAL_STIFF = G or GE
...
END_
where G or GE is the structural damping of the design elements.
1. All kind of discrete damping elements and other kind of damping are
allowed outside the design domain as long as they are not of function of the
eigenfrequencies or eigenmodes. Meaning that modal damping e.g.
defined using SDAMPING is prohibited.
11.5 PERMAS
Solver type
PERMAS
Tosca Structure
supported input
*.uci
Tosca Structure
supported output
*.post
*.dat
Table 48
2 - 668 User Manual
Tosca Structure supported file formats for PERMAS. See flow
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Remarks:
SIMULIA
Tosca Structure
diagram Fig. 338

Please Note:
For subsequent versions of Tosca Structure the PERMAS interface will be frozen with functionality of Tosca Structure 7.0.1. The interface will be available
in the current version (7.1.x) as as-is interface. No further developments and
enhancements will be made for this interface.

The User Control Interface (modellname.uci) must be specified with the
command FEM_INPUT in the parameter file and not the PERMAS input file
modelname.dat.
PERMAS Input Files
The optimization preprocessor reads the ASCII input files *.uci and *.dat from
PERMAS.
A .uci file must be created that converts the model for generating a PERMAS
model from a Medina file.
Example file that can be used to convert a Nastran file in a PERMAS model:
NEW
INPUT
READ NASTRAN FILE = MODELL.BDF
RETURN
EXPORT
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MODEL DESCRIPTION FILE=MODELL

STOP
Include statements are allowed in the PERMAS input. The include file will be
changed by Tosca Structure if node or element definitions are located in an
include file.
The main model file (*.dat) and the control file (*.uci) must have the same
base name.
Subcomponents as they are defined in PERMAS are not supported by Tosca
Structure as node and element numbers could be repeated several times.
System variants (e.g. variants with different materials) may not be defined in
the optimization model.
User Manual 2 - 669
SIMULIA
Tosca Structure
PERMAS
PERMAS Result Files

Tosca Structure reads the results of the FE calculation from PERMAS from
the ASCII result file .post.
Tosca Structure will add the necessary result requests that are needed for the
optimization automatically.
For complex .uci files it is possible that Tosca Structure can not add the correct statements. In this case the automatic modification can be deactivated by
defining an environment variable "fem_modif_keep_uci=yes". The results
then have to be added manually.
For topology optimization, the following results have to be requested in addition to the primary results:
GEN EL Stress
GEN N P STRAIN
GEN STRAIN EN DEN
For shape optimization:

GEN EL Stress
The FE results have to be written as a PERMAS-Ascii-Result file. Exporting

the results is done using the command GO PERMAS ASCII in the .uci file.
When several situations are calculated, Tosca Structure reads the *.post files
for all situations.

Elements in PERMAS which can be applied in the design area are shown
below:
PERMAS
element
type
Element
description
Design
element(*)
SOLID_TETRA_4
TET4
4 node solid tetrahedron
C, S, F
SOLID_TETRA_10
TET10
10 node solid tetrahedron
C, S, F
SOLID_BRICK_8
HEXE8
8 node solid hexahedron
C, S, F
SOLID_BRICK_20
HEXE20
20 node solid hexahedron
C, S, FX & S

forces
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Tosca Structure
element type
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Version 8.1.0 Rev. 1 - 05.2014
Tosca Structure
element type
PERMAS
element
type
Element
description
Design
element(*)
SOLID_PENTA_6
PENTA6
6 node solid pentahedron
C, S, F & S
SOLID_PENTA_15
PENTA15
15 node solid pentahedron
C, S, F
PLANE_TRIANG_3
TRIA3
3 node triangular
shell element
C, S, F
PLANE_TRIANG_3
TRIA3K
3 node triangular thin

shell element
C, S, F
PLANE_TRIANG_3
TRIM3
3 node triangular
plane membrane
element
C, S, F
PLANE_TRIANG_3
TRIMS3
3 node triangular
solid shell element
PLANE_TRIANG_6
TRIM6
6 node triangular
plane membrane
element
C, S, F
PLANE_TRIANG_6
TRIMS6
6 node triangular
solid shell element
PLANE_QUAD_4
QUAD4
4 node quadrilateral
shell element
C, S, F
PLANE_QUAD_4
QUAM4
plane membrane
element
C, S, F
PLANE_QUAD_4
QUAMS4
solid shell element
PLANE_QUAD_4
SHEAR4
plane shear panel
element
C, S, F

forces
User Manual 2 - 671
SIMULIA
Tosca Structure
PERMAS
PERMAS
element
type
Element
description
Design
element(*)
PLANE_QUAD_8
QUAM8
plane membrane
element
C, S, F
PLANE_QUAD_8
QUAMS8
solid shell element
PLANE_TRIANG_3
TRIAX3
3 node triangular
axis-symmetric solid
element
PLANE_TRIANG_6
TRIAX6
6 node triangular
element
PLANE_QUAD_4
QUAX4
element
PLANE_QUAD_8
QUAX8
element
BEAM_2D
BEAM2
2 node straight general beam
BEAM_2D
BEAM2W
2 node straight general beam
BEAM_2D
BECOC
2 node straight thinwalled tube
BEAM_2D
BECOP
2 node straight thinwalled open beam
BEAM_2D
BECOS
2 node straight solid

beam
BEAM_2D
BETAC
2 node straight
tapered thin-walled
tube

forces
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Tosca Structure
element type
SIMULIA
Tosca Structure
PERMAS
element
type
Tosca Structure
element type
Element
description
Design
element(*)
BEAM_2D
BETOP
2 node straight
tapered thin-walled
beam
BEAM_2D
FLA2
2 node straight
flange (rod)
BEAM_2D
FLAX2
2 node axis-symmetric membrane element
MASS_1
MASS3
Point mass
DUMMY_ELEM_TY
PE
all element types that

are not supported for
the optimization

forces
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in vol.2 chapter 11.5.8, Remarks for sensitivity based optimizations. For sensitivity based bead optimization, see vol.2 chapter 7.11, Special Remarks
Using Sensitivity Based Algorithm.
All other PERMAS element types are allowed in the PERMAS input deck but
are not considered in the optimization.

Node and element groups can be defined in the PERMAS model file using
the commands for node sets:
$NSET NAME=name
and
$COOR NSET=name
and using the commands for element sets

$ESET
NAME=name
and
$ELEMENT ESET=name
User Manual 2 - 673
SIMULIA
Tosca Structure
PERMAS
The groups can be used in Tosca Structure to define the optimization task. If a
node and an element set are defined with the same name then _ELEM is
attached to the element set name and _NODE is attached to the node set
name, respectively. This is done automatically by Tosca Structure and thus
the extensions should also be used when using the groups in the parameter
file.

The defined coordinate systems in PERMAS are read by Tosca Structure and
can be used in the parameter file. Coordinate systems are defined in PERMAS using the command $RSYS.
The coordinate system RSYS=0 is the default system and can not be overwritten. No reference is possible to another coordinate system in the definition of the coordinate system using $RSYS.
The coordinate systems in Tosca Structure have the names CS_<id>, in
which <id> is the ID of the coordinate system in PERMAS. Only numbers >=
1 should be used, as the coordinate systems CS_0 is the default coordinate
system in Tosca Structure.

In PERMAS the responses from the two following analysis types are allowed:
"STATIC" in the UCI file
"VIBration ANalysis" (Modalanalyse) in the UCI file
Remark
1. PERMAS has no predefined numbers for the load cases. PERMAS is referring to situation (boundary condition changes) and loadcase (changes
in loads). The load case number which should be used in Tosca Structure
is determined using: (situation-1)*100 + loadcase. Furthermore, the
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Tosca Structure supports linear-elastic isotropic materials for static calculation

and natural frequency analyze. In the block $MATERIAL (found under
$ENTER MATERIAL) only the key words $ELASTIC, $DENSITY and
$THERMEXP are permitted.
Temperature dependant material definitions are not allowed inside the design
area of a topology optimization. Only material parameters of the type
"INPUT=DATA" are supported.
SIMULIA
Tosca Structure
load case should be differentiated according to the order in command

FEM_INPUT.

Load case Numbering
The solution task is defined in a so-called SITUATION in PERMAS. This
defines the combination of the following variations:
Constraint Variant:
contains the boundary conditions (e.g. constraint and prescribed degrees of freedom).
System Variant:
used for e.g. in the allocation of properties to

Elements
Loading Variant:
contains all loads (with many random LPAT)
Modification Variant:
contains the definition of design restrictions
Result Variant:
used for referencing existing calculated

results for further calculations
If a component is to be calculated for different situations, each solution task

(SITUATION) is defined in PERMAS. The single load cases (LPAT) can be
referenced in Tosca Structure as load case number SITUATION-Nr.*100 +
load case.
The first load case in the first situation will have the load case number "1" in
Tosca Structure. The first loadcase in the second iteration has the loadcase
number "101" in Tosca Structure...
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Contact definitions
algorithm has to be inverted (see command OPT_PARAM, Parameter
Node Restrictions for Shape Optimizations
Node fixations in the PERMAS input file are imported during optimization preprocessing when the following command is set:
User Manual 2 - 675
SIMULIA
Tosca Structure
PERMAS
This command is set by default in the configuration file named command.ini.

Thus, the command must not be specified explicitly in the parameter file.
Node fixations can be used as restrictions of design variables in shape optimization (see command DVCON_SHAPE). However, a nodal displacement
contrary to a fixation of the model is to be avoided.

acceleration types for the PERMAS are feasible for sensitivity based topology
optimization.
Generally, the definition of inertia forces (accelerations) in PERMAS is
$INERTIA. For axis-symmetric structures the commands are $INERTIAX.
1. ACCELERATION in $INERTIA.
2. GRAVITY in $INERTIA.
3. ROTATION in $INERTIA.
4. ACCELERATION in $INERTIAX.
5. GRAVITY in $INERTIAX.
6. ROTATION in $INERTIAX.
CORIOLIS in $INERTIA.
In Unix, the databases generated by PERMAS are not deleted after a PERMAS run using standard settings. The standard settings must be changed in
either the file PERMAS.DFT or in a current .uci file in order to use the Tosca
Structure-PERMAS interface. The line SET DATABASE=DELETE must be
inserted.
11.5.10 Nonsupported Features (Cards/Keywords...)

NLLOAD
Currently the command $NLLOAD is not supported in PERMAS input decks
used in Tosca Structure optimizations.
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11.5.9 PERMAS Configuration for use with Tosca Structure
SIMULIA
Tosca Structure
Input of MPCs
The ID in the definition of MPCs must be smaller than 10000.
Further Restrictions
The key words GSYS, ROTB, RSYSAX are in general allowed but are usually
not checked by Tosca Structure.
Only one single block $ENTER COMPONENT and $SYSTEM can exist in the
PERMAS input file

Frequency Response analyses are not supported in the PERMAS interface.
11.6 Shape Optimization Based on a Durability

Analysis
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The homogenization of the stresses on a components surface often indirectly

leads to a reduction of the maximum damage in these areas.
In Tosca Structure a durability analysis can be included in the optimization
loop. The direct use of damage results for the homogenization strategy leads
to a minimization of the maximum damage in the critical areas. In Tosca
Structure the damage values have to be provided as equivalent stress values.
The coupling of a durability analysis enables the consideration of the loadtime histories.
The notions fatigue, durability and life analysis will all be used in the following
as the same thing.
11.6.1 Supported durability solvers

The only "out of the box" supported durability solver is:
Femfat
fe-safe
The following list of durability solvers are known to work with Tosca Structure
using some customizing:
DesignLife
FALANCS
User Manual 2 - 677
SIMULIA
Tosca Structure
Shape Optimization Based on a Durability Analysis
FE-fatigue
FEMSite
MSC.fatigue
LMS Virtual.Lab Durability
For more information about using the above durability programs with Tosca
Structure please contact your Tosca Structure sales representative.
It is also possible to use in-house durability codes with Tosca Structure, see
chapter 11.6.5 ONF.
11.6.2 Workflow
For the consideration of damage data during optimization, a durability analysis is performed after each finite element solver run in the optimization loop.
The results of the finite element analysis are directly read in the durability
solver and a damage calculation is performed. The results of the damage
analysis are provided in a special result block. Then Tosca Structure modifies
the components surface based on the damage distribution.
11.6.2.1 Preprocessing
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The preprocessing of the durability analysis has to be performed additionally

to the finite element and the optimization preprocessing. All control files have
to be generated before starting the optimization procedure. A damage calculation run should be performed in advance to check if all necessary data is
available and the durability analysis runs in batch mode without any errors.
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Tosca Structure
11.6.2.2 Optimization loop

After the solver call, a damage solver call is added.
PREPROCESSING
FE Preprocessor
Analysis model
Durability
Preprocessor
Control file
OptimizationPreprocessor
Optimization model
OPTIMIZATION LOOP
FE SOLVER
DAMAGE SOLVER
Tosca
Structure.shape
POSTPROCESSING
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Fig. 340 Flowchart of the optimization with Tosca Structure, FE and Damage Solver

Adding life file to FEM_INPUT
Tosca Structure needs information about the used input file(s) for the life
solver. This is added in the FEM_INPUT command:
FEM_INPUT
ID_NAME
FILE
LIFE_FILE
END_
= FILE_INFO
= static_analysis.ext
= life_input.ext
User Manual 2 - 679
SIMULIA
Tosca Structure
Remarks
1. The name of LIFE_FILE may have any name.
2. The LIFE_FILE command may be repeated more times for life solvers that
support the ONF 601-format (DRESP TYPE = DAMAGE_LC).
For some life solvers it is often needed to add some extra files in working
directory - files that Tosca Structure not always recognizes as default files.
The easiest way to copy these files into the optimization working directory is
by using the COPY_FILE command.
FEM_INPUT
ID_NAME
FILE
LIFE_FILE
COPY_FILE
COPY_FILE
END_
=
=
=
=
=
FILE_INFO
static_analysis.ext
life_input.ext
some_extra_file.ext
some_other_extra_file.ext
In the example above the two files "some_extra_file.ext" and

"some_other_extra_file.ext" are copied in to the working directory at the start
of the optimization. See also configuration possibility "add_files_to_work_dir".
DRESP
ID_NAME
DEF_TYPE
ND_GROUP
TYPE
GROUP_OPER
UPDATE
END_
=
=
=
=
=
=
OBJ_FUNC
ID_NAME
DRESP
TARGET
END_
= MINIMIZE_DAMAGE
= DRESP_DAMAGE
= MIN
DRESP_DAMAGE
SYSTEM
DESIGN_NODES
DAMAGE
MAX
EVER
11.6.2.4 Start of the optimization

Start in Tosca ANSA environment
1. START_OPTIMIZATION | Run | Edit
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The design response that is referenced in the OBJ_FUNC command must

have the type = DAMAGE. The objective function is formulated as a minimization of the maximum damage.
SIMULIA
Tosca Structure
2. Choose your life solver
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Fig. 341 Starting Tosca Structure with life solver using Tosca ANSA environment
User Manual 2 - 681
SIMULIA
Tosca Structure
Start in Tosca Structure.gui

The damage solver has to be specified. The solver can be selected in the
LIFE SOLVER list box in the additional parameters.
Fig. 342 Start of Tosca Structure with a durability analysis (Tosca Structure.gui)
Start on the command line
The damage solver must be specified using the --life flag on the command
line. Example with femfat:
tosca810 hole_damage --solver mscnastran --life femfat
After the optimization is finished, all Tosca Structure postprocessing capabilities are available (see vol.2 chapter 10, Postprocessing of Optimization
Results and vol.2 chapter 9, Result Transfer and Validation Run). Additionally,
the damage results may be used for postprocessing. The corresponding
result files are stored in the SAVE directories of the optimization system.
11.6.3 FEMFAT
11.6.3.1 General
For a shape optimization with Tosca Structure in combination with FEMFAT,
special results have to be requested in the FEMFAT preprocessing. The
requested result files may be read by Tosca Structure and allow the correct
interfacing of the two software packages.
The following result formats for Tosca Structure may be requested in FEMFAT:
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11.6.2.5 Postprocessing
SIMULIA
Tosca Structure
ONF 600
Tosca Structure optimization neutral file
This data block contains a node list and a damage value for each node.
ONF 601
Tosca Structure optimization neutral file with loadcase information.
This additionally data block contains load case information. This allows
several FEMFAT Basic calculations which may later be combined in Tosca
Structure.
Remark:
1. The type of DRESP determines the result format! Use:
TYPE = DAMAGE
! For ONF 600
TYPE = DAMAGE_LC
! For ONF 601
It is important that the result from the life analysis has the same name as the
life-solver input deck except for the file extension. I.e.:
<life_input_file>.ffj
Must produce a result file called:

<life_input_file>_600.onf
(or <life_input_file>_601.onf)
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If the latter file does not exist in the working directory of the Tosca Structure
Job, the optimization will stop due to missing results. A corresponding error
message will be output to the user.
Fig. 343 ONF result request in FEMFAT
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For all design nodes that are used for shape optimization a damage value
has to be provided. So the area for damage calculation may be reduced to
the design area in order to save calculation time.
Changes in the FEMFAT FFJ file
During the fatigue life simulation preprocessing, the user selects the finite element solver result file interactively in FEMFAT. While exporting the ffj file, the
absolute path settings for the stress input file(s) are stored to the control file.
setValue {0 {{setValue {} {} StressFileDatasetNumber 0}}} {0
ok} StressInputFile C:\scratch\holeplate_dam.op2
If FEMFAT is called inside the Tosca Structure optimization loop, it has to be

ensured, that FEMFAT is reading the modified stress data in each design
cycle. The new result file(s) are always generated in the Tosca Structure optimization working directory. So Tosca Structure is automatically modifying the
ffj file and adapting the path of the stress input(s) to a relative path into the
actual working directory. This is admissible as during the optimization procedure, FEMFAT is always running in the Tosca Structure working directory.
setValue {0 {{setValue {} {} StressFileDatasetNumber 0}}} {0
ok} StressInputFile ./holeplate_dam.op2
One has to be careful, if a FEMFAT analysis should be executed outside

Tosca Structure based upon a Tosca Structure-modified FEMFAT input file. If
FEMFAT is not running in the directory where the ffj file is located, the stress
result files may not be found and FEMFAT will stop with an appropriate error
message.
Start of FEMFAT in BATCH mode
For the optimization, FEMFAT has to run in batch mode. The following files
must exist
FEMFAT Jobfile *.ffj

The FEMFAT jobfile name and the FE-input deck name are not required to
be the same.
At the end of the job file, the FEMFAT calculation must be started. The following entry must exist in the jobfile:
SETVALUE {} {} STARTANALYSISLOOP
This can be realized easily by exporting the ffj file from the FEMFAT application after the execution of the analysis.
The FEMFAT batch run should be tested before the complete optimization is
started. The command line for a FEMFAT batch run is the following:
Windows
<femfat_install>\lib\dll\femfat4exe
<femfat_install>\bin\bin\femfat.tbc -job=<jobname>.ffj
Unix
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Solver Input file(s) (*.bdf, *.inp, *.cdb, ...)
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<femfat_install>\bin\bin\femfat4 -job=<jobname>.ffj
PERMAS specific settings

FEMFAT cannot read the *.uci and *.dat files, that are used for the optimization with Tosca Structure in combination with PERMAS. The MEDINA interface may be used to make an optimization. In PERMAS, the following
command is used to generate a *.bif file in each iteration:
EXPORT
GO MEDINA
RETURN
The resulting *.bifo file may then be used as input file in FEMFAT.
11.6.4 fe-safe
General
For a shape optimization with Tosca Structure in combination with fe-safe you
must be able to run your job as a batch job. This is done by setting up an fesafe analysis interactively and then exporting the necessary files or copying
the files from the fesafe project directory. For in depth information please see
the fe-safe documentation (fe-safe User Guide) about Saving analysis configuration settings and Running fe-safe from the command line.
The following assumes that the user understands the different files and command line arguments for fe-safe.
Exporting setup files from the fe-safe GUI
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In a typical setup you need to export a .stlx and the .ldf files to a directory
from which you will start Tosca Structure and thus already have an FE-input
file there, e.g. Abaqus .inp file. You can typically find the necessary files after
having run fesafe interactively in the specified fesafe project directory.
Generating results
fe-safe writes life results per default. The user specifies the fe-safe output format in combination with Tosca Structure. Actually output format is set to .csv
format which is converted automatically to .onf format by Tosca Structure. As
Tosca Structure expects a "damage like" format the life results n are automatically inverted by csv_2_onf to 1/n.
Running fe-safe on command line
Test that fe-safe runs correctly on the command line by executing the fe-safe
job. Change to the directory where your .stlx file is saved and execute fesafe_cl. Example:
e:\Safe_Technology\fe-safe\version.6.4\exe\fe-safe_cl.exe -p
b=holeplate_dam.stlx o=.\holeplate_dam.csv j=refresh
mode=surface
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Check that the .csv file is generated and has correct values (life values).
Configuration of fe-safe for Tosca Structure
The default setup by the installer is to use the .csv output of fe-safe which is
then converted to an ONF600 format by the executable csv_2_onf. Please
note that an additional inversion step is included which transfers the life
results (n) to damage results (1/n) automatically.
The standard configuration should then include these lines in the fe-safe configuration section:
if ($life_solver eq fesafe) {
...
$life_solver_cmdline = "-p ./SAVE.fesafe b=${__LIFE_FILE__}
LOGLIVES=0 mode=surface j=refresh o=./
${__LIFE_MODEL__}.csv";
# generate _600.onf file from csv file:
$pre_life2vtm = "$tosca/bin/csv_2_onf";
$pre_life2vtm_add_call = "${__LIFE_MODEL__}.csv";
The command line option -p ./SAVE.fesafe forces fe-safe to run in the

directory ./SAVE.fesafe. This directory is overwritten in each iteration.
If you want to use the pre-scan option in batch or other advanced options,
you must use a configuration with fe-safe macro-file. The use of a macro-file
instead of a .stlx file is supported, but not recommended and you must note
the following:
Only stlx file referenced from macro file is scanned by Tosca Structure
macro and all included files (.stlx, .ldf, ) must be available in start directory of Tosca Structure.
macro file must write out a csv file with the same name as the macro, e.g.
result file holeplate_dam.csv
Macro-support is experimental. Please use .stlx for standard work flows.
Change in configuration to use macro file:
$life_solver_cmdline = "-p ./SAVE.fesafe
macro=${__LIFE_FILE__}";
# generate _600.onf file from csv file:
$pre_life2vtm = "$tosca/bin/csv_2_onf";
$pre_life2vtm_add_call = "${__LIFE_MODEL__}.csv";
Legacy .kwd files may also be used, but in that case the user is resposible for
copying the right files into the working directory and that command line is cor-
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LIFE_FILE must be set to point to macro file, e.g. LIFE_FILE =

holeplate_dam.macro
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Tosca Structure
rect. The copying of files can be done using COPY_FILE in the FEM_INPUT
command.
Changes done by Tosca Structure in .stlx file
Tosca Structure runs in the working directory, therefore are all absolute paths
in the .stlx file substituted with a relative path to ensure that the current FEinput deck and results are used in the durability analysis. E.g. the following
files are assumed to be in current directory:
source file(s) (odb or fil)
ldf file and files referenced herein
kt file
msc file
11.6.5 ONF
11.6.5.1 General
This life option is for the users who may want to use their own fatigue program. The only requirement is that the program writes in ONF-format. This
format can be acquired by contacting FE-DESIGN GmbH.
The following variables must also be set in your Tosca Structure configuration:
The optimization run starts like the other fatigue codes with the solver run,
which results are first read into the Tosca Structure database. Then the
defined life-solver is called, and the ONF-results are then read by Tosca
Structure.
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${life_solver_exe} = "<name_of_life_executable>";
${life_solver_cmdline}= "<parameters_for_program>";
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Tosca Structure Control
12 Tosca Structure Control

Tosca Structure consists of many individual software modules that load the
FE input and result data or modify the input decks when required. The complete optimization process is controlled from one principal module named
Tosca Structure Control. It controls the calling sequence of the individual software modules and the relevant solver.
12.1 Program Sequence and Data Flow of Tosca

Structure
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The program sequence of an optimization is the same independent of how

Tosca Structure is started. You can either use Tosca ANSA environment (see
vol.2 chapter 2.1) or Tosca Structure.gui (see vol.2 chapter 2.2) or start Tosca
Structure even in batch modus on the command line (see vol.2 chapter 2.4).
In order for the program to work, it is essential that the correct path specification is entered during installation.
The startup of Tosca Structure first launches a process to check out and handle the necessary licenses and load the configuration information. This process launches the main control program.
This program is responsible for controlling the complete data flow and calling
the individual modules and programs.
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Program Sequence and Data Flow of Tosca Structure
The flow of optimization process is the same for all solver interfaces, only the
solver specific data and file formats are different (see vol.2 chapter 11, Solver
Specific Features).
Options for call

tosca_ctrl.cfg
License file and
server
jobname.par
Loading TOSCA
Configuration
Licensing
tosca_server.err
tosca_server.log
Controlling the
optimization
Directory jobname
Analysis model
FEM2ONF
Model specification in
ONF-format
Parameter file
TOSCA_PREP
optimization_data
base.vtm
Result requests
Start model
Modified analysis model
FE-Analysis
modell_xxx.res
RES2VTM
FE-Results
TOSCA_OPT
END
Fig. 344 Detailed optimization process with Tosca Structure and data flow
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Specification for
modifications
FEM_MODIF
SIMULIA
Tosca Structure
12.2 Starting Tosca Structure

The program call in the command line is:
tosca810 --input_1 option_1 ... [--input_n option_n]
The user interfaces are started as follows:

Tosca ANSA environment:
tosca_ansa_env
Tosca Structure.gui:
tosca_gui
The start script can be found in <install_dir>\bin\tosca_ansa_env

or in <install_dir>\bin\tosca_gui.
12.2.1 List of command line options

The following command line options are most common used in Tosca Structure:
Input
Option
--job
jobname
Jobname of the optimization job
--opt
parfilename
Name of the parameter file (if not

<jobname>.par)
--help
Short command line help
--loglevel
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NOTICE
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Comment
INFO (default)
DEBUG
TRACE
--loglevel
_stdout
NOTICE (default)
INFO
DEBUG
TRACE
Loglevel in logfile TOSCA.OUT

NOTICE - Least verbose general
information
INFO - Important information about
running optimization
DEBUG - more verbose output.
TRACE - Extremely verbose output.
Do not use with large models!
Change loglevel to command shell.
Loglevels are the same as above.
--loglevel_stdout <value> must be
higher or equal to --loglevel <value>
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Starting Tosca Structure
Option
Comment
--stderr
separates the stderr from the stdout.

If used and the stderr is still output
to stdout there will be doubled output for message with levels
ERROR, FATAL and CRITICAL.
--ow
Overwrite existing jobname directory. If this flag is not specified,

Tosca Structure will move the existing job directory to a directory with a
counter extension.
When running in -report or -smooth
mode all files will be overwritten if
possible.
--restart
Restart of a Tosca Structure optimization job. The restarted optimization job starts with the finite element
analysis.
--solver
Specification of the finite element

solver
Abaqus
ANSYS
Marc
MSC Nastran
PERMAS
abaqus
ansys
marc
mscnastran
permas
--fe_solver_
version
fe solver version
--life
femfat
onf
Specification of the finite element

solver version (optional)
Specification of the durability solver
Femfat
Any life-solver which delivers results
in ONF-format
--life_solver_
version
life solver version
Specification of the life solver version (optional)
--type
test1
test2
test3
test4
Several test levels to check the optimization run

for detailed description see chapter
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Input
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Input
Option
Comment
--smooth
Tosca Structure control runs only

Tosca Structure.smoothand executes the SMOOTH commands in
the given parameter file.
Requires completed optimization job!
--report
Tosca Structure control will run only

Tosca Structure.report and executes
the REPORT commands in the
given parameter file.
--view
Tosca Structure control will run only

Tosca Structure.view and tries to
find last generated optimization
result file (vtfx-file)
--cpus
<number cpus>
The number of CPUs Tosca Structure should use. Tosca Structure is

mainly a single tread program so
large speed ups should NOT be
expected.
--logfile
<filename>
Will change the log file name to

filename in job directory.
--loglevels
_exes
<loglevel>:
<executable>,
<loglevel>:
<executable>
To set loglevels for certain executables directly. See also configuration

%loglevels. To set more loglevel
use comma separated list without
spaces.
--print_
tosca_
includes
no (default)
yes
only
Prints include files necessary for

Tosca Structure to run. If option
"only" is used, file with include files
is printed and Tosca Structure stops.
--reuse
Advanced option!
Reuse work directory with ONFfiles. Only changes in parameter file
are regarded. For testing purposes
only.
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Input
Option
Comment
--restart2
Advanced option!
Restart assuming solver run was
successful.
--restart3
Advanced option!
Restart assuming life-solver run was
successful.
--docu
Start the Tosca Structure documentation with Acrobat reader.
--run
nohup
Run Tosca Structure in No Hangup

Mode.
--cdb2classic
--modification
_file
Convert FEM_INPUT file to ANSYS

classic format using Tosca Structure interfaces.
<modificytion>.onf
file
Use Tosca Structure interfaces to

apply modifications to FEM_INPUT
files.
The --job name is mandatory, all other parameters are optional. A default
solver can be entered in the configuration file. Otherwise, --solver must be
set.
If only the jobname is given, the name of the parameter file is derived automatically (jobname.par) and the name of the analysis file is extracted from
the FEM_INPUT command in the parameter file.
Remark:
For backwards compatibility commandline parameters may be given with a
single minus, e.g.
12.2.1.1 Deprecated command line options
--post
Use REPORT command in parameter file instead
--temp
Use FEM_INPUT command instead
--restart2
--restart3
--aio
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$ tosca810 -input_1 option_1 ... [-input_n option_n]
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--out
Use --loglevel instead
12.2.2 General
The minimal Tosca Structure call is
tosca810 <jobname>
The name of the parameter file can be derived directly from the jobname. The
file <jobname>.par is loaded in this case.
If it is needed that the jobname directory has a name different from the
parameter file name, use the command line option --opt as follows:
tosca810 <jobname> --opt <parameterfilename>
In this instance, the name of the working directory is specified by the jobname.
The file name for the input file of the FE analysis is entered in the parameter file using the command FEM_INPUT.
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12.2.3 Logging
Logging is always done to the command shell and to the file <jobname>/
TOSCA.OUT-file. The following levels can be used.
- WARNING (not recommended) Only WARNINGs and ERRORs are
printed
- NOTICE Default output to STDOUT. Only the most important logging
- INFO
Default output to logfile TOSCA.OUT
- DEBUG
Very verbose output, mostly for support
- TRACE
(not recommended) Extremely verbose,
major performance los, only for developers
Using the command line option --stderr the errors are written on STDERR as
well. This concerns the output for messages with the following log-levels:
ERROR
FATAL
CRITICAL.
If this option is used and the stderr is written to stdout there will be double output for these messages.
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12.2.3.1 TOSCA.OUT
The logfile TOSCA.OUT is the main logfile of Tosca Structure. The logfile is at
best viewed in a text editor that uses a fixed width font, e.g. Courier New.
The structure of the logging lines is:
(<log tag>) [<time stamp> | <executable>] <message>
Where:
<log tag>
=CRITICAL
=ERROR
=WARNING
=NOTICE
=DEBUG
=TRACE
<time stamp>
Current time in format HH:MM:SS (Hours, Minutes, Seconds)
<executable>
Name of the executable that wrote the logging

message
Interpretation
CRITICAL
A critical error has occurred within the program.

Please contact support and explain
ERROR
An error has occurred in execution of optimization

system and the user should be able to make
changes in optimization definition or finite element model to correct the problem. Please also
take note of previous warnings
WARNING
A warning alerts the user that a problem has been

identified, but the optimization system continuous.
NOTICE
Very general, important information, e.g.

"Starting Tosca Structure optimization module - design cycle 6"
INFO
Information for the user.
DEBUG
Very verbose output, mostly for support. Debug

messages are not printed to TOSCA.OUT using
default settings. To enable debug output in
TOSCA.OUT add --loglevel debug to commandline.
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Log-tags
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TRACE
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Table 49
Extremely verbose output where a major performance los is to be expected. Only for developers
Description of loglevels
Fig. 345 Example of TOSCA.OUT using Tosca ANSA environment

TOSCA.OUT logfile viewer. See also Fig. 346.
12.2.3.2 Special logfiles

Beside TOSCA.OUT a few other logfiles can be useful for trouble shooting
special problems:
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authorization.log
Logging from Tosca Structures authorization module tosca_server is written
to this file. In case of licensing/authorization problems please look into this file
for details.
signal.log
This logfile will only have a content if the user interrupts the optimization process with a SIGNAL, typically by pressing Ctrl-C in the command prompt.
Tosca Structure will then kill the running subprocess, optionally using a script
defined by the setting $killscripts. See CONFIG for details.
TOSCA_post.OUT
This logfile is generated when using the commandline flags --smooth or -report. This enables the user to generate SMOOTH or REPORT results during a running optimization.
12.2.3.3 Viewing TOSCA.OUT using Tosca ANSA environment
Fig. 346 Adding a TOSCA.OUT item in Tosca ANSA environment.

Request DEBUG output level to TOSCA.OUT is possible at the following
Items:
CHECK_INPUTS -> TEST_SHAPE_CHECK -> TEST_SHAPE_1
START_OPTIMIZATION -> RUN
POST_PROCESSING -> GENERATE_REPORT_FILE
SMOOTH -> SMOOTH_INSTANCE -> RUN_SMOOTH
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In Tosca ANSA environment you see the logging to the so-called STDOUT
which means the same as when you would have started Tosca Structure in a
command shell.
SIMULIA
Tosca Structure
Right click the item and select Edit and change the LOGLEVEL to either
INFO or DEBUG.
12.2.3.4 Viewing TOSCA.OUT using Tosca Structure.gui

Viewing TOSCA.OUT in Tosca Structure.gui is done from the Start Tosca
Structure Module by pressing the button "View TOSCA.OUT", see Fig. 347.
Fig. 347 Viewing the TOSCA.OUT logfile from Tosca Structure.gui. Also
highlighted how to request logging on debug level.
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To add debugging output in TOSCA.OUT simply activate the check-box

"Debug Output".
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12.2.3.5 Viewing TOSCA.OUT using Tosca Extension for ANSYS/WB

Viewing TOSCA.OUT in Tosca Extension for ANSYS/Workbench is possible
in two ways. The output can be displayed live during the optimization by
selecting Solution Information in the Outline Tree, see Fig. 348.
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Fig. 348 Viewing the TOSCA.OUT logfile from Tosca Extension for
ANSYS/WB.
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Alternatively, its possible to open the TOSCA.out file itself. Right click on
Toscas Solution in the Outline Tree and choose Open Solver Files
Directory, see Fig. 349. The logfile is located in \tosca\TOSCA.out.
Fig. 349 Opening the Solver Files Directory in Tosca Extension for
ANSYS/WB.
The loglevel can be changed in the Analysis Settings.
12.2.3.6 Changing logging using the command shell

To change loglevel to logfile TOSCA.OUT use the commandline parameter:
tosca810
--loglevel <new_level> ...
To increase the amount of output to the command shell set the parameter:
tosca810 --loglevel_stdout <new_loglevel>
Note that --loglevel must be equal or more verbose than --loglevel_stdout.

To separate stderr from stdout:
tosca810 --stderr
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Example:
1. Increase loglevel to INFO on the command shell and DEBUG output into
the logfile TOSCA.OUT
tosca810 --loglevel_stdout INFO --loglevel DEBUG ...
12.2.3.7 Tips and tricks viewing TOSCA.OUT

Finding errors
Search for the word "(ERROR" and make sure your editor has not activated
regular expressions. This search should always be done from the beginning
of the logfile because the first printed error message is usually of greatest
importance.
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Runtime
You can view the runtime or elapsed time of each executable in a Tosca
Structure run by searching for the keyword "Elapsed":
(INFO ) [13:20:22|tosca_perl] Elapsed time of fem_include
: 00:00:00 - Actual time: 13:20:22
(INFO ) [13:20:24|tosca_perl] Elapsed time of fem2onf
: 00:00:02 - Actual time: 13:20:24
(INFO ) [13:20:29|tosca_perl] Elapsed time of tosca_prep
: 00:00:05 - Actual time: 13:20:29
(INFO ) [13:20:31|tosca_perl] Elapsed time of fem_modif
: 00:00:02 - Actual time: 13:20:31
(INFO ) [13:21:57|tosca_perl] Elapsed time of abaqus
: 00:01:26 - Actual time: 13:21:57
(INFO ) [13:21:59|tosca_perl] Elapsed time of odb2vtm
: 00:00:02 - Actual time: 13:21:59
(INFO ) [13:22:03|tosca_perl] Elapsed time of tosca_opt
: 00:00:04 - Actual time: 13:22:03
The time format is in HH:MM:SS. In this case we see that Abaqus has run 1
minute and 26 seconds, whereas the optimization module, tosca_opt, only
spent 4 seconds.
How is my FE-solver called?
All calls of executables are written in the logfile TOSCA.OUT. To see how a
certain executable (e.g. your FE-solver) is called, search the file for
"Calling". In the search results you will also see the FE-solver call, e.g.:
(INFO
) [13:29:59|tosca_perl] Calling(17048): "/store2/
app/bin/abaqus" job=shapeV2 analysis interactive --version
6.10-3
Debug output from only one executable

Using loglevel debug is very verbose and this might be annoying if only logging from one single executable is of interest. There are two ways of getting
debugging information from a single executable:
Use the commandline flag --loglevels_exes <exe>:<loglevel>. If you want
only debugging output from Tosca Structure preprocessor and optimization
module (tosca_prep and tosca_opt), use:
$ tosca
...
--loglevels_exes tosca_prep:debug,tosca_opt:debug
Second option is to use the configuration, see also CONFIG. To get the
same result as the commandline above write in the parameter file:
CONFIG
$loglevels{tosca_prep} = "debug";
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The number in parenthesis Calling(<pid>) is the process identification

number, PID.
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$loglevels{tosca_opt} = "debug";
END_
12.2.4 Solver interface

Entering the type of solver to be used (--solver <solvername>) automatically activates the interface according to the type of solver. If no solver interface is specified in the command line, the default solver is used which is
already set in the Tosca Structure configuration (see vol.2 chapter 12.3).
The typical Tosca Structure call with a specific solver interface is:
tosca810 <jobname> --solver <solvername>
Remark
1. Only licensed interfaces can be activated.
12.2.5 Durability interface

Using the parameter --life <life_solver_name> the durability interface is specified. No damage calculation is carried out by default.
The typical Tosca Structure call with a specific life-solver interface is:
tosca810 <jobname> --solver <solvername> --life <lifesolvername>
Remark
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1. Durability can only be used with an Tosca Structure.durability license.

Please contact FE-DESIGN GmbH for more information.
12.2.6 Tosca Structure.report run

Tosca Structure.report is run automatically at the end of your optimization but
you can also run it manually after optimization. Use command line parameter
--report to (re)run Tosca Structure.report.
tosca810 <jobname> --report
The above command runs only the Tosca Structure.report command hence
an optimization job must have run prior to this call. See chapter 12.2.1 List of
command line options for details on this command. The resulting files are
generated in the subdirectory TOSCA_POST of the job directory.
Each time Tosca Structure.report is called a new post-file is created (<jobname>_report_<nnn>.par). To avoid this behaviour use overwrite (--ow):
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tosca810 <jobname> --report --ow
in which case the post-file (<jobname>_post.par) is overwritten for each call.

Remark
1. Note that using --ow and --report together will not overwrite the jobdirectory.
12.2.6.1 Configuring default Tosca Structure.report run

In case no REPORT-command is defined in the input files Tosca Structure
looks for the default REPORT-macros which are found in the installation
directory <tosca> in the directory marcos
<tosca>/macros/report_template_bead.mac
<tosca>/macros/report_template_shape.mac
<tosca>/macros/report_template_topo.mac
More information about macro-files are found in the documentation of the
CONFIG-command. The default templates are listed in vol.2 chapter 10.1.5,
Standard Reports.
12.2.7 Automatic Tosca Structure.smooth run

Tosca Structure will automatically call Tosca Structure.smooth (see chapter
9.1 Tosca Structure.smooth) if the parameter file contains a SMOOTH command. Moreover, Tosca Structure control will add the following lines (in bold)
to the SMOOTH command if missing:
= <some_id_name>
=
=
=
=
SAVE.onf/<fe-input-file>_fem.onf
SAVE.onf/<last_result>.onf
SAVE.onf/groups.onf
TOSCA_POST/<smooth-id_name>.ext
The modified SMOOTH command is written to a file "<jobname>_post_000.par" in the working directory. After the optimization, Tosca
Structure.smooth is called by Tosca Structure control with this parameter file.
After optimization, a user may want to generate a Tosca Structure.smooth
result with different parameters. This is done by changing the parameters in
the parameter file (<jobname>.par) and calling Tosca Structure as follows:
tosca810 <jobname> --smooth
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SMOOTH
ID_NAME
...
MODEL
RESULT
GROUP_FILE
OUTPUT_FILE
END_
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A new smooth file will be generated (<jobname>_post_<nnn>.par) and Tosca

Structure.smooth will be called with the modified parameters using the optimization results from last optimization.
Each time Tosca Structure.smooth is called a new post-file is created (<jobname>_post_<nnn>.par). To avoid this behaviour use overwrite (--ow):
tosca810 <jobname> --smooth --ow
in which case the post-file (<jobname>_post.par) is overwritten for each call.
Remark
Note that using --ow and --smooth together will not overwrite the jobdirectory.
12.2.7.1 Configuring default Tosca Structure.smooth run

In case no SMOOTH-command is defined in the input files you can configure
Tosca Structure to look for a default SMOOTH-macro by uncommenting the
line in tosca_ctrl.cfg:
$smooth_default_file = "smooth_template";
Templates are found in the installation directory <tosca> in the directory marcos
<tosca>/macros/smooth_template_bead.mac
<tosca>/macros/smooth_template_shape.mac
<tosca>/macros/smooth_template_topo.mac
More information about macro-files are found in the documentation of the
CONFIG-command.
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Usually, an optimization requires several iterations. Wrong or incomplete definitions can be seen very early in the internal preprocessing of the optimization process. There are four different types of test levels available for
controlling the optimization process.
Remarks
Test levels 2-4 are not available for sensitivity based topology optimization.

Test level 1 is called using the command
tosca810 job_name --type test1
For the first test level, it is required that the following files exist:
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a complete file with the commands for the optimization preprocessor

(*.par).
a FE model (*.ext), that can be loaded in the optimization preprocessor
using the command FEM_INPUT.
The optimization is stopped after the optimization preprocessing is finished
and the database for the optimization has been created. The directory jobname is created containing all files needed for loading of the input files and
creating the Tosca Structure database.
If the test run has been finished correctly (output "TOSCA job finished"), it
means that they syntax of all necessary parameters is correct. If some
parameter is not defined correctly, this is logged as "ERROR" in TOSCA.OUT
file located in TOSCA_POST directory; the relevant comments be found
there. The optimization will be stopped because of this and a summary of all
failed commands will be available at the end of the file TOSCA.OUT.
In shape optimization, all restrictions can be checked using the
TEST_SHAPE command, which applies a virtual optimization displacement
to the design area.
In bead optimization, all restrictions as well as the direction of the resulting
beads can be checked using the TEST_BEAD command.
*.par
*.ext
FE-Analysis
Optimization Module

Test level 2 requires not only the files *.par and *.ext (as in test level 1), but
also the result file from a separate analysis produced by the relevant solver.
This file is saved in the start directory of the optimization job. The result file
must contain all the results needed for the optimization. Please note: this test
level is not available for sensitivity based topology optimization.
In this test level, the first optimization step is carried out without a FE analysis. The existing result file is copied to the working directory from the start
directory.
The optimization is stopped after the optimization module has been called
once and a modified analysis model for the relevant solver has been created.
The first optimized model, derived from the optimization model and the analysis of the initial design, is generated with low CPU time. As no FE analysis is
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carried out at this test level, a saving of 70% to 90% in CPU time is achieved
compared with the time needed for a single optimization loop including a FE
analysis of large models.
*.par
*.ext
Test level 2
*.ext_res
FE-Analysis
Optimization Module
In this way, several variations can be tested effectively (e.g. different parameter files such as file1.par and file2.par) using an analysis model with the
respective result file before the real optimization is started:
tosca810 job_name --type test2 --opt file1.par
tosca810 job_name --type test2 --opt file2.par
*.par
*.ext
Test level 3
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No finite element analysis has to be completed previously in test level 3. After

the evaluation of the parameter file (*.par) and the finite element model by the
optimization preprocessor, the analysis file is calculated by the FE solver.
When a modified analysis model has been generated from one evaluation of
the preprocessing results and the FE results, the optimization is stopped. The
modified analysis model is not analyzed by the finite element solver at this
test level.
FE-Analysis
*.ext
Optimization Module
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Example:
Remarks
1. If the same analysis model is to be used several times for test level 3, it is
better to switch to test level 2. To do this, the result file of the FE analysis
has to be copied into the start directory of the optimization from the
SAVE.<res_ext> directory and renamed as <modelname>.<res_ext>.
(During saving in the optimization process, the result files are automatically
given an iteration number this extension must be deleted from the file
name)
2. This test level is not available for sensitivity based topology optimization!

Test level 4 is an extension of test level 2. A result file must exist in the start
directory of the optimization job. This result file must contain all results
needed for the optimization.
In test level 4 and during the first iteration, the present result file is copied to
the working directory. The optimization continues as normal until convergence has been achieved or a stop condition has been met.
Using this test level, the finite element analysis performed in the first iteration
of an optimization can be reused for a completely different optimization performed on the same model. Because the results of the initial model are
always the same, the same result file can always be used and does not need
to be re-calculated each time.
Example:
*.par
*.ext
Test level 4
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12.2.9 Restart modes

An optimization is an iterative process that can run several hours or days
depending on the size of the model. Different problems can arise during this
process that can lead to a termination of the optimization task.
Tosca Structure has an in-built restart possibility that can be used in order to
avoid starting the complete optimization task again after a stop due to external factors. Optimization starts at the iteration where the interruption
occurred.
Remark:
Please note: Restart of an interrupted optimization should not be confounded
with starting the (sensitivity based topology) optimization newly with an
already existing material distributation (see chapter 5.3.1.1 Results from previous runs as initial material distribution). In general this initial material distribution is derived from a previous optimization run and defined using the
parameter INITIAL_DV_FIELD in the command DV_TOPO.
12.2.9.1 Requirements for a restart

It is not always possible to resume the optimization after an interruption. Certain requirements have to be fulfilled to be able to restart a Tosca Structure
optimization.
A restart of an externally interrupted Tosca Structure job can be carried out
when the following problems occur:
Stop of the FE analysis due to a licensing problem;
Stop of the FE analysis due to insufficient hard disk space;
Stop of the optimization module due to a lack of licenses;
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User stop of the task (e.g. by pressing Ctrl-C in command line).

When a task interruption occurs due to problems with the optimization task
formulation or due to convergence problems, a restart will not help. For example, when the finite element analysis stops because of distorted elements
during shape optimization, the same problem will occur when a restart is executed.
12.2.9.2 Restart process

During a restart, all settings of the original task are used to resume the optimization. There is no possibility of modifying the settings for a restart because
the parameter file cannot be loaded again. But you may change the "-logevel"-parameters in the command line.
The start directory of the optimization task can be moved to any location.
However, it is important that the relative location of the files in the job directory remains unchanged. For example, if the task was interrupted due to
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insufficient hard disk space and there is no possibility to create more space
on the hard disk, the complete job directory can be transferred to another
hard disk and a restart can be made from there.
After optimization has been stopped, the files that were created during the
optimization can be found either in the directory jobname/DB_ERROR or
(when the control job has been interrupted) in the working directory
(jobname).
At the beginning of a restart, all data is copied into the working directory
(jobname).
Various methods are available for a restart:
Mode: -restart (recommended)
This is the standard restart mode.
Program call:
tosca810 <jobname> -restart
The standard restart is always started with a finite element analysis. This
means, after the required data has been copied, the finite element analysis is
started using the analysis model that was modified last and the optimization
task is then carried out.
Mode: -restart2 (not recommended)
Restart2 is used when the finite element analysis sequence has been completed without any errors but an interruption occurred in the optimization module. The computing time needed for the FE analysis can be saved in this case
and the last result file is used by Tosca Structure for the optimization.
Program call:
Mode: -restart3 (not recommended)

Restart3 is used when an optimization with an integrated durability analysis is
carried out. If all results of the durability analysis are available, the revised
damage calculation is skipped.
12.2.10 Online help

The parameter --docu can be used to start the PDF documentation from the
command line.
With the parameter --help are the commandline options listed.
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Remark
1. In order to use the parameter --docu, Adobe Acrobat Reader must be
installed. When installing Tosca Structure, the path for Adobe Acrobat
Reader has to be specified.
12.2.11 Sequential temperature analysis

A sequentially coupled temperature analysis can be carried out during optimization when using Abaqus as finite element solver. A temperature calculation
is carried out first, then its results are used as boundary conditions for the following finite element calculation.
The input file used for the temperature calculation is specified using
FEM_INPUT command as shown below (the command line parameter -temp
is obsolete). All model changes due to the optimization are also reflected in
the temperature model.
FEM_INPUT
TEMPERATURE_FILE = temperature_analysis.inp
FILE
= static_analysis.inp
END_
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12.2.12 Arbitrary analysis sequence

Multiple analysis may be made using the FEM_INPUT command in Tosca
Structure parameter file. The results of all finite element calculations are summarized in one Tosca Structure result file with each finite element calculation
being interpreted as a single load case.
In FEM_INPUT command, multiple finite element input files may be specified
using the parameter FILE.
Example:
FEM_INPUT
FILE = static_analysis.dat
FILE = modal_analysis.dat
END_
Instead of performing only one finite element analysis, Tosca Structureautomatically runs multiple finite element analyses in the order of FILE = ...
parameters in FEM_INPUT. In the example above, first the static analysis and
then the modal analysis are performed.
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Configuration
Remarks
1. The model information of the different input files (nodes, elements, groups)
has to be identical. The loads may be different for the different input files.
2. The modifications of the geometry that occur during the optimization are
applied to all input files at once.
12.3 Configuration
The complete program is controlled by a system of variables. To allow user
and model-specific variations, the necessary variables are loaded from several configuration files. The different configuration commands are described
in volume 3: CONFIG.
12.3.1 Configuration files

The configuration files are loaded in the following sequence:
1. System settings (lowest priority)
2. User-specified settings
3. Model-specific settings
System Configuration (tosca_ctrl.cfg))
Model Configuration (jobname.cfg)

Commandline
tosca jobname -type all
Remarks
1. The current settings of the environment variables can be checked using the
command
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User Configuration (tosca_ctrl.cfg)
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tosca -help
and then choosing the heading Information about the Tosca Structure
configuration.
Before starting the program, the system settings are loaded. During installation of the optimization program system, the settings for the variables
used to control the optimization call are made and saved in the file
$tosca/bin/tosca_ctrl.cfg
The system configuration file tosca_ctrl.cfg must contain all necessary
environment variables.
2. The configuration file is written completely in Perl syntax. If you change the
configuration file, take care to follow Perl syntax.
Each user has the possibility to create a user-specific configuration file in
his home directory. Usually user-specific details (e.g. the scope of type of
data back-up during optimization and search paths for macros) are set. The
file is automatically loaded by Tosca Structure before the control program is
called in case that the file
$HOME/tosca_ctrl.cfg
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exists. Definitions of job-specific parameters in Tosca Structure parameter

file (CONFIG command) are extracted automatically to the file
<jobname>.par_cfg in the start directory.
Options set with the call of the control program have the highest priority.
Usually, the job name and job type are determined here.
3. The file tosca_ctrl.cfg in the $tosca/bin directory of Tosca Structure installation should not be modified. If a modification should be necessary, a
backup of the original configuration file should be kept.
4. A user configuration file may easily be generated by copying the configuration of the Tosca Structure installation into the users home directory and
modifying the file.
5. The environment variable $HOME must exist if Tosca Structure is going to
use user defined configuration settings.
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Configuration
12.3.2 Environment variables

Tosca Structure uses and sets several environment variables during the optimization. Some can be configured by the user (either in the installation process, directly using standard operating system procedures or via Tosca
Structure configuration files (see chapter 12.3.1 Configuration files). Internal
variables cannot (should not) be set or changed manually.
Configurable environment
variables
Description
tosca
Installation directory of Tosca
FED_LICENSE_SERVER_TYPE
FLEX - Legacy FlexLM License Server

(FED vendor daemon)
DSLS - Dassault Systemes License
Server
FED_LICENSE_FILE
FLEX: License path of the used legacy

license server
FED_DSLS_LICENSE_CONFIG
DSLS: Path of the license server config

file for DSLS
FED_DSFLEX_LICENSE_CONFIG
DSFLEX: License path of the used

Abaqus FlexLM License server
FED_TOSCA_SERVER_OPTIONS
Command line options for tosca_server
ANSA_SRV
License server for Tosca ANSA

environment
ANSWAIT
Set to 1 for Ansys to wait for license,

see documentation
home
User configuration directory
vtm_cache_size
Cache in MB (default size:1024 MB)
Internal variables
FED_PRODUCT
COMMON_ENV__
TOSCA_OSDIR
ORIG_DEFAULT_LIB
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Server (ABAQUSLM vendor daemon)
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Internal variables
Description
LD_LIBRARY_PATH
COMMON_ENV_REPLACE__
fem2onf
tosca_interface
life_interface
tosca_size
FED_ASSERT_DEBUG
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12.4 Script Entry Points

In Tosca Structure, scripts may be specified at several positions in the Tosca
Structure optimization workflow (see also Fig. 350).
pre_prep
Execution of a script before starting the Tosca Structure preprocessor
TOSCA_PREP
post_fem2onf
Execution of a script after the conversion of FE input to ONF (Optimization
Neutral Format) file (fem2onf)
post_prep
Execution of a script after Tosca Structure preprocessor TOSCA_PREP
pre_fem_modif
Execution of a script before starting modification of finite element input file
pre_fem_modif_matrix
Execution of a script before starting modification of finite element input file in
matrix step
post_fem_modif
Execution of a script after finishing modification of finite element input file
post_fem_modif_matrix
Execution of a script after finishing modification of finite element input file in
matrix step
pre_solver
Execution of a script before each finite element solver run
pre_solver_matrix
Execution of a script before each finite element solver matrix run
post_solver
Execution of a script after each finite element solver run
post_solver_matrix
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Execution of a script after each finite element solver matrix run

pre_res2vtm
Execution of a script before starting Tosca Structure result interface
pre_res2vtm_matrix
Execution of a script before starting the Tosca Structure result interface in
matrix step
post_res2vtm
Execution of a script after finishing Tosca Structure result interface
post_res2vtm_matrix
Execution of a script after finishing the Tosca Structure result interface in
matrix step
pre_life
Execution of a script before each durability solver run
post_life
Execution of a script after each durability solver run
pre_opt
Execution of a script before starting the Tosca Structure optimization
TOSCA_OPT
pre_matrix
Execution of a script before starting the TOSCA_OPT matrix step
post_opt
Execution of a script after the Tosca Structure optimization TOSCA_OPT
post_matrix
Execution of a script in the end of a matrix step, after TOSCA_OPT
post_eval
Execution of a script after Tosca Structure optimization (before deleting
unused files)
pre_report
Execution of a script before Tosca Structure.report
post_report
Execution of a script after Tosca Structure.report
pre_smooth
Execution of a script before Tosca Structure.report
post_smooth
Execution of a script after Tosca Structure.report
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Script Entry Points
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Configuration
pre_prep
FEM2ONF
post_fem2onf
TOSCA_PREP
post_prep
pre_fem_modif
pre_fem_modif_matrix
FEM_MODIF
post_fem_modif
post_fem_modif_matrix
pre_solver
pre_solver_matrix
FE-Analysis
RES2VTM
post_solver
post_solver_matrix
pre_res2vtm
pre_res2vtm_matrix
post_res2vtm
post_res2vtm_matrix
pre_life
Life-Analysis
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post_life
LIFE2VTM
pre_opt
pre_matrix
TOSCA_OPT
post_opt
post_matrix
post_eval
END
Fig. 350 Scripting entry points in Tosca Structure
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Script Entry Points
The user may specify an absolute or relative path to a script that is located in
the network. Note that, if relative paths are used, the execution directory is
always the working directory of Tosca Structure.
All user scripts hooks like pre_prep accept _add_call after the hook name.
This means the scripts should contain only the script name with or without
leading path. Parameters submitted to the user script are added in the
_add_call definition:
$pre_prep = "pre_prep_script.pl";
$pre_prep_add_call = "1 2 argument3";
The user may also specify command line calls directly using Perl variables in
scripts. On UNIX systems, one has to be careful to set the command in
quotes in order to avoid problems with the blanks in the command line definition. As the script entry variables are defined in the Perl command syntax of
the configuration, the command line has to be additionally set between \"
signs:
Example:
${pre_prep} = "\" echo just before TOSCA_PREP \"";
Remarks
1. It is not possible anymore to have in the definition of the hook the script
name and the parameters, what was possible in versions prior 7.2. If the
old behaviour is used an ERROR message is thrown informing that the
format has changed.
Multiple command in one single command line on UNIX platforms:

separate commands with semicolon
Example:
echo contents of actual directory ; ls -la
Multiple command in one single command line on Microsoft Windows

platforms:
separate commands with ampersand
Example:
e: & cd work\tosca & dir
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2. If multiple commands have to be specified in command line, they all have

to be set in one script definition. This is realized differently on UNIX and
Microsoft Windows systems.
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12.4.1 Adding files to the working directory

An often needed functionality is to have the script files or other files copied
into the working directory.
The most simple way is to use the FEM_INPUT command COPY_FILE:
FEM_INPUT
ID_NAME
FILE
COPY_FILE
COPY_FILE
END_
=
=
=
=
fem_input
my_solver_file.ext
file1.ext
file2.ext
The same can be done directly in your configuration using

add_files_to_work_dir("file1.ext","file2.txt");
In both cases "file1.ext" and "file2.ext" must exist in the starting directory and
both files are copied into the working directory right after starting Tosca Structure.
12.5 Optimization Preprocessing (TOSCA_PREP)
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12.5.1 TOSCA_PREP
In optimization preprocessing (TOSCA_PREP), the analysis model and the
commands used to define the optimization problem (see vol.2 chapter 3.1
and vol.3 Commands Manual) are loaded in order to create the optimization
model.
The analysis model exists as a solver input model and is converted before
loading into ONF format using FEM2ONF module.
The optimization problem is defined by either using Tosca ANSA environment, Tosca Structure.pre or an editor.
After the data has been loaded, an internal check run is carried out to ensure
that the optimization model is complete. If the check run is completed successfully, an optimization database is created which is always referred to during the optimization.
When the optimization preprocessor starts, the control program loads the file
$tosca/command.ini automatically. This file contains the pre-settings for the
optimization.
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Solver Run
Dynamic memory management

Tosca Structure offers a dynamic memory management, i.e. the necessary
memory requirement depends on the size of the model and is read from the
configuration file when the program is started. The required disk space
depends on the size of the finite element model, or more accurately, on the
number of elements or nodes in the analysis model. In case of larger numbers of elements or nodes, an automatic reallocation of required memory is
performed. The applied default settings for the memory allocation should be
sufficient in order to avoid this reallocation for most models.
12.5.2 Files after preprocessing (TOSCA_PREP)

After completion of the optimization preprocessing, the following files exist in
the directory jobname:
TOSCA.OUT
Output protocol file of the optimization in the directory TOSCA_POST (see vol.2 chapter 12.5)
jobname_org.ext
Initial analysis model in the directory SAVE.ext;

user-specified files in the directory SAVE.ext (if
required)
TOSCA_DB
The directory with Tosca Structure database
The FE-solver selected using the option --solver in Tosca Structure command line is started after the optimization preprocessing has been successfully completed. The correct paths must be set in order for the program to
start. The paths are set during installation. If the program does not start,
please ask the system administrator for advice or look in the protocol file of
the solver in order to search for possible errors.
12.7 Optimization Module (TOSCA_OPT)

The optimization loop runs in batch mode. After preprocessing, the solver,
RES2VTM module, the optimization module (TOSCA_OPT) and
FEM_MODIF module are started successively.
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12.6 Solver Run
SIMULIA
Tosca Structure
12.7.1 RES2VTM
The program RES2VTM loads the results generated by the solver into the
VTM (Virtual TOSCA Memory) database file.
12.7.2 TOSCA_OPT
The optimization module requires not only the result file from the previous
calculation in ONF format, but also the loads as well as the necessary model
and control information found in the optimization database. The optimization
module is responsible for specifying the model modifications in ONF format.
The optimization loop is completed when the optimization target is achieved
or when a stop condition (e.g., the maximum number of iterations) is fulfilled.
12.7.3 FEM_MODIF
FEM_MODIF module generates the modified analysis model by combining
the initial model with the instructions from TOSCA_OPT. The optimization
database is updated in each iteration.
12.8 Completion of the Optimization Process
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After the optimization loop has been completed, the directory jobname is
cleaned up. First, all unnecessary files are deleted. The configuration files
determine which files and in what scope (NEVER, FIRST_LAST or EVER)
files are saved or deleted. (see vol.2 chapter 12.3). Different decisions for
wildcards can be made in the configuration files (copy, delete etc.). Further
details can be found in the specification of the CONFIG command.
12.8.1 Directories and files after the completion of optimization

The user has a wide range of files for evaluation after optimization has been
completed, including the complete model of the initial design and a complete
model of the optimized design. Files with additional information are created
that serve for the quick evaluation of the optimization.
Following subdirectories of jobname directory are created:
TOSCA_DB: contains the database of the optimization program. It is only
needed if a restart is required in topology optimization.
User Manual 2 - 721
SIMULIA
Tosca Structure
Completion of the Optimization Process
SAVE.ext: contains the files of the single iterations, with ext being a file
extension. In addition to solver-specific data (input files, protocol files,
result files etc.), solver-independent files (VRML, STL, ONF, etc.) can also
be saved.
TOSCA_POST: Contains the files for postprocessing the optimization
results. In addition, the protocol file TOSCA.OUT can be found in this directory (see vol.2 chapter 12.5). The results of Tosca Structure.smooth are
normally saved in this directory as well.
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The protocol file TOSCA.OUT is copied to the directory TOSCA_POST after

the optimization has been successfully completed. If the optimization stopped
due to an error, the logfile is copied into the directory DB_ERROR.
2 - 722 User Manual
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Tosca Structure
Troubleshooting
13 Troubleshooting
This section describes methods of identifying and correcting errors that occur
when the program aborts during optimization.
The search of error messages is depending upon when the program stopped
(see Fig. 352) which can be easily identified using the main logfile
TOSCA.OUT in the job-directory (see also vol.2 chapter 12.2.3, Logging). If a
licensing problem is detected the log file authorization.log may be of
interest (see also chapter 12.2.3.2 Special logfiles). In case that the FE-solver
has not completed the analysis one has to look into the respective FE-solvers
log-files.
When the program aborts, all files required for the error search are moved to
the subdirectory DB_ERROR in the jobname directory (see vol.2 chapter
12.8.1). The most frequent sources of errors and the methods for correction
are described in the following sections.
13.1 Errors During Optimization

General
During the optimization, different modules (the optimization preprocessor, FE
solver, the optimization module) generate the control files (log files). The control program checks the existence and contents of these control files and consequently determines if the optimization has to be continued or stopped.
www.3ds.com/tosca
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DB_ERROR directory
When the program cancels an optimization, a directory named DB_ERROR
is created in the jobname directory in order to facilitate the error search. This
directory contains all files that are necessary to find the error. These include
the protocol file TOSCA.OUT of the optimization and the protocol files of the
FE solver. In addition, the initial model, parameter file and all files and macros
are present in this directory.
Log files
The most important files used to search for error messages are the log files
(see vol.2 chapter 12.5):
TOSCA.OUT of the optimization: All errors that occur in TOSCA_PREP or
TOSCA_OPT are documented in this file; search it for entries containing
the words CRITICAL, ERROR or WARNING.
authorization.log (see also vol.2 chapter 12.2.3.2, Special logfiles) of the
authorization process (located in the start directory of the optimization):
configuration and licensing information is written to this file.
User Manual 2 - 723
SIMULIA
Tosca Structure
Determining the Point of Program Termination
Solver-specific protocol files (moved to DB_ERROR directory) created by

the solver. The file names depend on the used solver. For more information, please refer to the FE-solver documentation.
Result control file
When the result file created by the solver does not contain any useful results,
the optimization module generates an empty file. The control program checks
the existence of this file and stops the optimization if the file is found.
Some solver results sometimes do not allow the optimization to proceed due
to following reasons: a result request in the input file is incorrect (e.g., no
node stresses were written in the result file); the solver cannot perform the
finite element analysis due to numerical problems; element twisting, rigid
body displacements due to missing boundary conditions or too large displacements occur.
A check of the previous optimization iteration and the modification of the
model can be used to find the reason for a termination that affects the optimization (e.g. element twisting or too large displacements).
Screen information
When Tosca Structure is started, the output that is being made during the
optimization process appears on the screen and in the window of Tosca
ANSA environment or Tosca Structure.gui. The amount of information in the
logfile TOSCA.OUT and on screen can be controlled by requesting a certain
loglevel. For more information, please see vol.2 chapter 12.2.3, Logging.
13.2 Determining the Point of Program

Termination
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Version
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An indication of where the program terminated can easily be found

TOSCA.OUT.
2 - 724 User Manual
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Tosca Structure
Troubleshooting
(INFO
) [20:28:44|tosca_perl] Modifying solver input files
(INFO
) [20:28:44|tosca_perl] Calling(21480): "/store2/develop/tosca/
7.1.0/bin/fem_modif" --loglevel INFO --cycle 004 --solver ansys clip.ans
(INFO
) [20:28:44|fem_modif] TOSCA Structure.fem_modif "
(INFO
) [20:28:44|fem_modif] Reading ONF Mod file clip_mod.onf
(INFO
) [20:28:44|fem_modif] TOSCA Structure.fem_modif successfully
finished
(INFO
) [20:28:44|tosca_perl] Elapsed time of fem_modif
:
00:00:00 - Actual time: 20:28:44
(NOTICE ) [20:28:44|tosca_perl] Starting Ansys analysis - design cycle 4
(INFO
) [20:28:44|tosca_perl] Calling(21496): "/store2/app/bin/ansys"
b -i clip.ans -o clip.erg -s noread -p ansys --version 13.0
(INFO
) [20:28:47|tosca_perl] Elapsed time of ansys
:
00:00:03 - Actual time: 20:28:47
(INFO
) [20:28:47|tosca_perl] Reading results
(INFO
) [20:28:47|tosca_perl] Calling(21604): "/store2/develop/tosca/
7.1.0/bin/res2vtm" --loglevel INFO --cycle 4 --solver ansys clip
(INFO
) [20:28:47|res2vtm] TOSCA Structure.res2vtm - version 7.1.0"
(WARNING ) [20:28:47|res2vtm]
no rst file with basename clip found
(ERROR
) [20:28:47|res2vtm] **** TOSCA Structure ERROR ****
(ERROR
) [20:28:47|res2vtm] emat file clip.emat not found
(ERROR
) [20:28:47|res2vtm] TOSCA Structure.res2onf finished with exit
code 128
Executable with problem
www.3ds.com/tosca
Version 8.1.0 Rev. 1 - 05.2014
Fig. 351 Trouble shooting in TOSCA.OUT. Here, the result reader res2vtm
stop because of missing result files. This reason for this error
should be found in the logfiles of the FE_solver (this case ANSYS)
which has terminated incorrectly.
The following four points of optimization system are known to be the most frequent in which an error may occur:
1. Stop at the start of the program (configuration, licensing and control start).
2. Stop in a preprocessing step (TOSCA_PREP).
3. Stop during a FE analysis.
4. Stop in an optimization step (RES2VTM, TOSCA_OPT, FEM_MODIF).
For a more detailed description of the program sequence please see Fig.
344. When the program is started, the configuration is first loaded and the
licenses are checked. Information regarding this can be found in the protocol
file authorization.log (see also Special logfiles).
Afterwards, the Tosca Structure control program will be started. Protocol information will be printed to the display and to the file TOSCA.OUT.
User Manual 2 - 725
SIMULIA
Tosca Structure
Determining the Point of Program Termination
The sequence of configuration files that are read in the beginning of the optimization will be logged to TOSCA.OUT:
2 - 726 User Manual
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.
------------------------------------------------------------------------|
_______
____
_____
_____
|
|__
__| / __ \ / ____| / ____|
/\
|
| |
| | | || (___ | |
/ \
|
| |
| | | | \___ \ | |
/ /\ \
|
| |
| |__| | ____) || |____ / ____ \
|
|_|
\____/ |_____/ \_____|/_/
\_\
|
|
_____ _
_
|
/ ____| |
| |
|
| (___ | |_ _ __ _
_ ___| |_ _
_ _ __ ___
|
\___ \| __| '__| | | |/ __| __| | | | '__/ _ \
|
____) | |_| | | |_| | (__| |_| |_| | | | __/
|
|_____/ \__|_|
\__,_|\___|\__|\__,_|_| \___|
|
------------------------------------------------------------------------|
|
Starting: OPTIMIZATION CONTROL TOSCA Structure.control
|
TOSCA Structure by FE-DESIGN GmbH
|
TOSCA Structure.topo, TOSCA Structure.shape and
|
TOSCA Structure.bead are registered trademarks and service
|
marks of the FE-DESIGN GmbH
|
|
Copyright(c) 2011 by FE-DESIGN GmbH, all rights reserved
|
------------------------------------------------------------------------|
PERL execution control
|
|
Version 8.1.0
|
|
FE-DESIGN GmbH, Karlsruhe, Germany
|
http:://www.fe-design.de
|
------------------------------------------------------------------------Logging to STDOUT at loglevel NOTICE
Logging appended to log-file "clip/TOSCA.OUT" at loglevel INFO
Generating working directory "clip"
The directory "clip" exists and will be deleted
Logfile: clip/TOSCA.OUT
SIMULIA
Tosca Structure
Troubleshooting
------------------------------------------------------------------------READING TOSCA Structure CONFIGURATION

------------------------------------------------------------------------Reading Configuration file: /store2/develop/tosca/7.1.0/bin/tosca_ctrl.cfg
Reading Configuration file: /users/clausen/tosca_ctrl.cfg
For each module that is started by the control program and finishes, an entry
with information concerning the running time of the module can be found. For
example, in TOSCA_OPT in the fourth iteration:
(NOTICE
) Starting TOSCA Structure optimization module - design cycle 4
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Version 8.1.0 Rev. 1 - 05.2014
The course of the individual processes and cycles can be seen in Fig. 352
and can be followed in the protocol file TOSCA.OUT.
Several points should be checked depending on where the program stop
occurred. These are illustrated in the diagram below (Fig. 352) together with
the protocol files where the error messages are saved. Different error messages, their causes and possible ways of correcting these errors are also
User Manual 2 - 727
SIMULIA
Tosca Structure
Program Abort at the Start of the Optimization
described in the following section. A description of which files contain error

messages is also given.
1. Program start
2. Preprocessing
3. FE analysis
4. Optimization
Installation correct?
Settings correct?
License available?
File names and
command line
parameters correct?
(vol.2 chapter
13.3.1)
authorization.
log
Parameter file:
Syntax correct?
Task completely
defined?
TOSCA.OUT
Error in analysis
model?
License found?
Path settings correct?
Solver
protocol file
TOSCA.OUT
Results available?
Is there enough
storage space?
License available?
TOSCA.OUT
End
Fig. 352 Search for errors when a program is aborted
13.3.1 Check of program installation and paths

Care must be taken to ensure that all programs are properly installed as various programs work interdependently in an optimization run (see the Installation Manual). It only makes sense to search for the error in a different place
when it is certain that all individual programs can be started correctly.
If Tosca Structure cannot be found then a check must be made to see if the
program was properly installed.
Only then the program starts and the system specific configuration is loaded.
In order for the user specific configuration (tosca_ctrl.cfg) to be found, the
environment variable "$HOME" must be set.
The name of the model to be optimized is called "jobname". Path settings,
default names and default extensions can easily be checked in TOSCA.OUT.
2 - 728 User Manual
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13.3 Program Abort at the Start of the Optimization
SIMULIA
Tosca Structure
Troubleshooting
www.3ds.com/tosca
Version 8.1.0 Rev. 1 - 05.2014
--------------------------------------------------------------environment TOSCA
: T:\Tosca810
environment HOME
: h:\user
--------------------------------------------------------------jobname
: hole
fe-input File
: hole.bdf
parameter file
: hole.par
fe_solver
: nastran
fe_solver_exe
: "c:/Programme/msc/msc2001/i386/nastran.ex
fe_solver_cmdline
: hole.bdf notify=no old=no
opt_type
: test1
--------------------------------------------------------------Prep-module: "C:/Programme/Tosca810/bin/tosca_prep"
Opt -module: "C:/Programme/Tosca810/bin/tosca_opt"
--------------------------------------------------------------Act Directory : C:/scratch/work/test
jobname
: hole
Workdir
: C:/scratch/work/test/hole
Generate working directory "C:/scratch/work/test/hole"
The directory "C:/scratch/work/test/hole" exists and will be del
-------------------------------------------------------------Actual settings for optimization job :

-------------------------------------------------------------actual working dir
: C:/scratch/work/test
-------------------------------------------------------------environment TOSCA
: T:\Tosca810
environment HOME
: h:\user
-------------------------------------------------------------jobname
:
fe-input File
: <modelname>.<inp_ext>
parameter file
: <parname>.<opt_ext>
fe_solver
: nastran
fe_solver_exe
: "c:/Programme/msc/msc2001/i386/nastran.
fe_solver_cmdline
: <modelname>.<inp_ext> notify=no old=no
opt_type
: all
-------------------------------------------------------------Prep-module: "C:/Programme/Tosca810/bin/tosca_prep"
Opt -module: "C:/Programme/Tosca810/bin/tosca_opt"
--------------------------------------------------------------
User Manual 2 - 729
SIMULIA
Tosca Structure
Program Abort at the Start of the Optimization
13.3.2 Analysis files not found

All necessary files are copied into the directory jobname at the beginning of
the program loading. The files that are to be loaded should be specified in the
commands INCLUDE or FEM_INPUT of the parameter file. If one of the files
is not specified (or cannot be found in the current directory or in the specified
path directory), then the optimization is immediately stopped.
-----------------------------------------------------------------|
TOSCA COMMAND_SHELL ERROR
-----------------------------------------------------------------Error while copying necessary files for optimization into working
directory
File could not be found:
hole.bdf
-----------------------------------------------------------------Causes:
Files do not exist
Incorrect Jobname or file name in command line arguments
To locate the error:
Check the Jobname and file name in command line arguments

Check the file extension
Correction:
Enter the correct file and Jobname
Define the path to the files or copy them to the current directory
Any deviations from the standard extensions must be specified explicitly in
the control program command line
2 - 730 User Manual
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Check for the existence of the necessary files (also the INCLUDE files) in
the local directory or in a directory with the path specified in the parameter
file
SIMULIA
Tosca Structure
Troubleshooting
13.4 Program Abort in TOSCA_PREP

The optimization preprocessing results in the creation of a Tosca Structure
database file. This file is not created in case that some incorrect or inapplicable commands are entered during preprocessing, or the optimization task has
not been completely defined. More information can be found in the protocol
file TOSCA.OUT in the messages containing the words "WARNING", "ERROR",
and "CRITICAL".
Fig. 353 Open TOSCA.OUT with the graphical user interface

The TOSCA.OUT log file can easily be accessed from the "Start Tosca Structure" page of Tosca Structure.gui.
Tosca Structure.gui opens the file TOSCA.OUT that is located in the working
directory of the current job.
A basic search functionality is included in the text viewer to find warning or
error messages.
www.3ds.com/tosca
Version 8.1.0 Rev. 1 - 05.2014
Messages in TOSCA.OUT
User Manual 2 - 731
SIMULIA
Tosca Structure
Program Abort in TOSCA_PREP
Summary of errors and warnings in TOSCA.OUT file:

------------------------------------------------------------------------|
EEEEEEEEE RRRRRRR
RRRRRRR
OOOO
RRRRRRR
|
E
R
R
R
R
O
O
R
R
|
E
R
R R
R
O
O
R
R
|
E
R
R R
R O
O R
R
|
E
R
R R
R O
O R
R
|
EEEEEEEE
R
R
R
R
O
O R
R
|
E
RRRRRRR
RRRRRRR
O
O RRRRRRR
|
E
R
R
R
R
O
O R
R
|
E
R
R
R
R
O
O R
R
|
E
R
R
R
R
O
O
R
R
|
E
R
R
R
R
O
O
R
R
|
EEEEEEEEE R
R R
R
OOOO
R
R
-----------------------------------------------------------------------********* TOSCA ERROR *********
Definition of the optimization task was not
sucessful because there are/is a command defintion
which returned an error or a serious warning.
Please check the listed command(s) in the table
below and check the TOSCA.OUT file
for detailed information about the error(s).
At the end of TOSCA.OUT file, the list of commands that failed during the
optimization preprocessing is written. Usually the first command in the list has
caused the error. The following commands fail because they reference the
first command.
Causes (as follows from TOSCA.OUT file):
Incorrect or missing definitions in the parameter file (syntax error):
Item CONSTRAINT = VOL_CONST is not admitted.

Please ensure that the referenced entry is defined
correctly.
2 - 732 User Manual
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To ensure that the optimization problem

found in the database is identical to the problem
intented by the user the optimization stops
until the errors and warnings are processed,
This means that all command definitions
have to be corrected.
SIMULIA
Tosca Structure
Troubleshooting
******** TOSCA WARNING ********

Analysis of the command items.
The specified item was not found.
Item CONSTRAINT is missing

Please ensure that the constraint entry is part of the
command.
Search for warnings in TOSCA.OUT.
******** TOSCA WARNING ********

If you need more information to track down the problem you increase the
amount of output in TOSCA.OUT file by setting "--loglevel debug", see also
chapter 12.2.3 Logging.
Correction:
Correct the incorrect entries in the parameter file.
13.5 Program Abort During FE Analysis
If the result file of the FE program has not been generated, the following error
message appears:
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13.5.1 Error in the analysis model
User Manual 2 - 733
SIMULIA
Tosca Structure
Program Abort During FE Analysis
Message:
(INFO
(INFO
(INFO
(ERROR
(ERROR
(ERROR
(ERROR
)
)
)
)
)
)
)
on the screen and in TOSCA.OUT file:

[14:25:50|tosca_prep] Reading command : DVCON_SHAPE
[14:25:50|tosca_prep] Reading command : MESH_SMOOTH
[14:25:50|tosca_prep] Reading command : DRESP
[14:25:50|tosca_prep] **** TOSCA Structure ERROR ****
[14:25:50|tosca_prep] GROUP specified with ITEM ND_GROUP
[14:25:50|tosca_prep] was not found in the database
[14:25:50|tosca_prep] -> Enter an exisiting GROUP
Cause:
Error in the analysis model
Check the analysis model using a simple FE analysis (not using optimization-specific entries)
Check if all necessary files for the optimization have been created (e.g.,
op2 file from MSC Nastran) and check the optimization-specific entries in
the analysis model. vol.2 chapter 11 gives a description of the required FE
program-specific settings.
Correction:
Modify the analysis model.
Remark:
USER
FATAL
MESSAGE 9050 (SEKRRS)
RUN TERMINATED DUE TO EXCESSIVE PIVOT RATIOS IN MATRIX KLL.
This could be solved (see chapter 11.4.1 Files and Formats) by changing
the MAXRATIO parameter in the bulk data section of the input deck like,
e.g.:
PARAM,MAXRATIO,10.E10
2 - 734 User Manual
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1. In topology optimization in combination with Nastran the solver may stop

due to problems with the pivot ratio of the stiffness matrices.
SIMULIA
Tosca Structure
Troubleshooting
13.5.2 Error with the solver license

Message on the screen (Abaqus as an example):
ABAQUS Error: Failed to connect to license server.

ABAQUS Error: License for STANDARD is not available.
Cause:
No license available.
Locating the error:
Check the license server.
Check the validity date.
Correction:
Start the license server.
Update license.
13.5.3 Incorrect solver settings
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The path settings for the solver are set in the configuration file during the
installation of Tosca Structure (see Installation Manual and vol.2 chapter
12.3). If the solver is not found, then a check run should be made. Tosca
Structure.gui loads these settings from the configuration file. In Edit Configuration screen of Tosca Structure.gui, press "Reset to Defaults" button in order
to view these settings. In case that different settings are to be used, they have
to be set manually in this window.
13.6 Program Abort in the Optimization Module

13.6.1 FE model of the next iteration is not calculated
The first iteration was successfully completed. However, the program aborts
before the stop condition has been reached.
Message:
On the screen:
User Manual 2 - 735
SIMULIA
Tosca Structure
Program Abort in the Optimization Module
-------------------------------------------------------TOSCA Structure COMMAND_SHELL ERROR

-------------------------------------------------------TOSCA_OPT didn't finish correctly
Please check file TOSCA.OUT for WARNINGs
and ERRORs
Selected Solver : nastran
-------------------------------------------------------ERROR in TOSCA_OPT
In TOSCA.OUT:
********* TOSCA ERROR *********

NOT ALL REQUESTED RESULTS WERE FOUND IN THE RESULTS FILE
of the solver Please check SOLVER OUTPUT and SOLVER INPUT
FILE and verify that all results needed will be calculated
by the solver.
Using the solver log file (MSC Nastran in this example):
Cause:
Strongly distorted elements can appear in shape optimization if the displacements are too large or the mesh modification caused by the displacements of the design nodes is done in an unfavorable manner. It causes the
solver to fail during FE analysis.
Locating the error:
First check the error file of the solver to see if any information concerning
the distorted elements is available.
2 - 736 User Manual
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Version
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*** USER FATAL MESSAGE 4297 (EQD4D)

QUAD4 ELEMENT WITH ID =
75
HAS AN INTERIOR ANGLE POSSIBLY GREATER THAN OR
EQUAL 180 DEGREES.
SIMULIA
Tosca Structure
Troubleshooting
Check the mesh in the FE preprocessor, find the place where it became
distorted. Usually, more information can be found from the analysis of the
incorrectly calculated iterations. It should be checked if the optimization
boundary conditions have been set correctly (care should be taken with the
AUTO_FIX function, as all surface nodes that do not have DOF restrictions
will be fixed).
Correction:
Reduce the limits for displacements.
If none of these methods help: mesh the model in such a way that the surface changes only lead to a slight distortion of the mesh.
13.6.2 Insufficient disk space

The optimization is aborted if not enough disk space is available. The number
of files to be saved during the optimization loops can be determined by the
configuration file (see vol.2 chapter 12.3).
The amount of data accumulated during the analysis can be reduced by
using proper settings in the FE model.
1. In case that the settings entered in sub items of PRE_PROCESSING item in

Task Manager are incorrect, this is first revealed when Tosca Structure is
started using START_OPTIMIZATION | RUN item. If this is the case, or if
the optimization does not succeed because of another reason, the subdirectory DB_ERROR is created in the job directory and the log file
DB_ERROR/TOSCA.OUT is opened in a new window in Tosca ANSA environment (Fig. 354). Please refer to Tosca Structure for the explanations of
www.3ds.com/tosca
Version 8.1.0 Rev. 1 - 05.2014
13.7 Tosca ANSA environment Specific Tips
User Manual 2 - 737
SIMULIA
Tosca Structure
Tosca ANSA environment Specific Tips
error messages. In Ansa Info window, the message "Tosca Structure

Run, exit with errors!" is written.
2. If Tosca Structure.smooth that was started using SMOOTH |

SMOOTH_INSTANCE | RUN_SMOOTH item fails, the message "cannot
open '.../TOSCA_POST/SMOOTH_INSTANCE.onf': Invalid
argument" is written in Ansa Info window. The error messages
produced by Tosca Structure.control (the component that starts Tosca
Structure.smooth) are written to the console where Tosca ANSA environment has been started; the error messages of Tosca Structure.smooth itself
are written to the console as well as saved in TOSCA_POST/TOSCA.OUT
file.
3. When starting Tosca Structure.smooth from Tosca ANSA environment,
please make sure that TASK parameter of SMOOTH RUN PARAMETERS
window (opened by Edit command applied on RUN_SMOOTH item) is
assigned to the correct value: TASK = ISO for topology optimization or
TASK = SURFACE for shape and bead optimization.
2 - 738 User Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Fig. 354 Tosca ANSA environment: TOSCA.OUT file opened in a window.
SIMULIA
Tosca Structure
Troubleshooting
4. When selecting groups in Tosca ANSA environment, make sure that the
objects you select (nodes or elements) match the type of the group. If the
caption of the field where the group name is to be selected says ND_GROUP
(as in DESIGN_AREA command for shape or bead optimization), set the
selection mode to node selection by highlighting the line in Database
corresponding to nodes; if it says EL_GROUP (as in DESIGN_AREA
command for topology optimization), the elements should be selected and
thus the line Elements of Database should be highlighted. To highlight a
line in Database, simply click it once; in case of selecting elements, make
sure that the check box in the line is checked, otherwise the elements are
hidden. If a group of inappropriate type is selected, an empty group will
appear in Tosca Structure parameter file, and Tosca Structure run will fail.
www.3ds.com/tosca
Version 8.1.0 Rev. 1 - 05.2014
5. Once Tosca Structure started from within Tosca ANSA environment

finishes successfully, be careful not to modify any parameters of Tosca
Structure task unless you wish to repeat the optimization. When a new optimization starts, in case that the job name (the name of the item created by
New | Output command applied to PRE-PROCESSING item; default
value is Output) remains unchanged, the job directory is overwritten and
all results from the previous optimization run are lost. A new optimization is
started automatically when Update command is applied to any item situated below START_OPTIMIZATION in Task Manager (such as
RUN_SMOOTH or SOLID_MESH) in case that the item RUN under
START_OPTIMIZATION is unchecked. In case that this item is unchecked
but the optimization results are present, it is still possible to run further
actions without repeating the optimization; it suffices to apply Disable
command to START_OPTIMIZATION item (or to delete it completely).
6. When starting the validation run using SMOOTH | VALIDATE |
VALIDATION_RUN item, make sure that the paths to the solver executables are correctly written in the configuration file. See for details. Note that
you may start the validation run manually outside of Tosca ANSA environment since the validation run does not affect any further actions in Tosca
ANSA environment.
7. Although it is possible to delete certain elements or merge different models
in Tosca ANSA environment, the optimization with Tosca Structure only
takes into account the geometry from the input file mentioned under
MODEL_LINK item. However, you may modify the result of Tosca Structure.smooth prior to RECONSTRUCT and SOLID_MESH (or in between these
actions) in any way, and the changes will be reflected on the model for the
validation run.
User Manual 2 - 739
SIMULIA
Tosca Structure
Tosca ANSA environment Specific Tips
8. The options of Tosca ANSA environment are edited in the dialog opened by
Windows | Options... menu command (Fig. 355). The buttons "Save"
and "Save as" in Settings panel allow to save the configuration of Tosca
ANSA environment, including the paths to Tosca Structure and the solvers.
Saving the settings in a temporary file is a quick way to check the current
configuration.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Fig. 355 Tosca ANSA environment: Options dialog.
2 - 740 User Manual
SIMULIA
Tosca Structure
Appendix
14 Appendix
This chapter specifies functionalities covered by Tosca Structure.advanced
Licensing. Further limits of Tosca Structure are listed and the macros provided in the installation are described.
14.1 Additional Tosca Structure optimization

modules
Tosca Structure offers modules for standard topology (Tosca Structure.topology), shape (Tosca Structure.shape) and bead (Tosca Structure.bead) optimization. Furhter functionalities for high-level optimization applications are
available with the following modules:
14.1.1 Tosca Structure.durability

Shape optimization based on a durability analysis (see vol.2 chapter 11.6)
14.1.2 Tosca Structure.nonlinear

Optimizations based on nonlinear results from the used solver (independent to the optimization type)
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Version 8.1.0 Rev. 1 - 05.2014
Optimization of contact surfaces to homogenize the contact stress for

shape optimization
Shape optimization based upon a geometric non-linear analysis (see vol.2
chapter 6.7.1)
Shape optimization using non-linear materials (see vol.2 chapter 6.7.1)
Topology optimization based upon a geometric non-linear analysis
Topology optimization using non-linear materials
User Manual 2 - 741
SIMULIA
Tosca Structure
Additional Tosca Structure optimization modules
14.1.3 Tosca Structure.morph
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Automatic generation of model variants and submission of analysis runs for

these models.
2 - 742 User Manual
SIMULIA
Tosca Structure
Appendix
14.2 Limits of Tosca Structure

Limits of the FE-Models
Number
Limited by
Number of nodes
unlimited
authorization
Number of elements
unlimited
authorization
Maximum number of load cases (sub

cases)
999
program
Maximum number of materials
20.000
program
Maximum number of element properties
20.000
program
Maximum number of coordinate systems
unlimited
program
Limits of Optimization
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Version 8.1.0 Rev. 1 - 05.2014
Number
Limited by
Maximum number of node groups
unlimited
program
Maximum number of element groups
unlimited
program
Maximum number of specified solids
500
program
Maximum number of logical variables

- directly accessed from the database
- OR and AND combination
40
60
program
Maximum number of numerical variables

- directly accessed from the database
- combination of two numerical variables
500
60
program
Maximum number of stop criteria
50
program
Number of controller input definitions
10
program
Maximum number of load cases to be

considered for the optimization
999
program
Shape optimization
Number
Limited by
User Manual 2 - 743
SIMULIA
Tosca Structure
Predefined Output Macros
Maximum number of coupling conditions

(LINK_SHAPE)
unlimited
program
Maximum number of design variable

constraints (DVCON_SHAPE)
unlimited
program
Number
Limited by
Maximum number of design elements
unlimited
authorization

constraints (DVCON_TOPO)
500
program
Bead optimization
Number
Limited by
Maximum number of coupling conditions

(LINK_BEAD)
500
program

constraints (DVCON_BEAD)
500
program
program => can not be changed

authorization: => set by authorization code
Tosca Structure offers a number of predefined output macros which can be

found in the subdirectory macros of your installation directory. This macros
can be activated using the INCLUDE command in your parameter file. In
Tosca ANSA environment these are no longer required as there exist more
straightforward mechanisms for postprocessing.
Name of Macro
stop_1.mac
2 - 744 User Manual
Description
Stop condition: Variation of
ctrl_inp is smaller than 1% of
start value or maximum optimization displacement is smaller
than 1% of start displacement
Output Files
no output, program stops
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Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
14.3 Predefined Output Macros
SIMULIA
Tosca Structure
Appendix
Description
Output Files
stop_2.mac
Stop condition: Variation of

ctrl_inp is smaller than 1% of
start value
no output, program stops
uf_elem_prop.mac
Element Properties of the

group DESIGN_ELEMENTS
for every iteration
ELEM_PROP.TXT
uf_group_onf.mac
Group information as ONF file
GROUPS.onf
uf_model_onf.mac
Node and element information

of the initial FE model in global
Cartesian coordinates in ONF
format
MODEL_fem.onf
uf_model_onf_last.mac

of the optimized FE model in
global Cartesian coordinates in
ONF format
LAST_MODEL_fem.onf
uf_model_onf_ever.mac

of the FE model for each iteration in global Cartesian coordinates in ONF format
MODEL_xxx.onf
uf_shape_onf.mac
Shape optimization results in

ONF format
SHAPE_xxx.onf
uf_topo_onf.mac
Topology optimization results

in ONF format
TP_xxx.onf
uf_bead_onf.mac
Bead optimization results in

ONF format
BEAD_xxx.onf
uf_sizing_onf.mac
Sizing optimization results in

ONF format
SIZING_xxx.onf
www.3ds.com/tosca
Version 8.1.0 Rev. 1 - 05.2014
Name of Macro
User Manual 2 - 745
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
Predefined Output Macros
2 - 746 User Manual
Volume III
Commands Manual
www.3ds.com/tosca
Version 8.1.0 Rev. 1 - 05.2014
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
SIMULIA
Tosca Structure
CONFIG
CONFIG
The CONFIG commands are used to set and overwrite the Tosca Structure
8.1.0 configuration parameters. The different configuration files (installation,
user defined, job defined) are overwritten. For more detailed information see
vol.2 chapter 12.3, Configuration.
General Information
Configuration
Parameter
Example
Remarks
${tosca}
${tosca} =
"/app/tosca/
Tosca810";
Path to the Tosca Structure

installation folder. The path is
also stored in the environment
variable "tosca" ($ENV{tosca})
wich is set at the start of the
Tosca Structure 8.1.0 job.
www.3ds.com/tosca
Version 8.1.0 Rev. 1 - 05.2014
${tosca} =
$ENV{tosca};
${tosca_prep}
${tosca_prep} =
"${tosca}/bin/
tosca_prep";
Path to the TOSCA_PREP

script.
${tosca_prep_add_call
}
${tosca_prep_add_call
}="";
Additional options for

TOSCA_PREP
${tosca_opt}
${tosca_opt} =
"${tosca}/bin/
tosca_opt";
Path to the TOSCA_OPT

script.
${tosca_opt_add_call}
${tosca_opt_add_call}
="";
Additional options for

TOSCA_OPT
${ask_before_delete}
${ask_before_delete}=
"yes";
${ask_before_delete})
="no";
User request if the existing

working directory should be
deleted automatically.
FE Solver and LIFE Solver filenames

For defining command lines for FE-solver or LIFE-solver the following useful
variables can be used:
${__FE_MODEL__}
Holds the current FE-model name without file

extension.
${__FE_FILE__}
Holds the current FE-model name with file

extension.
${__LIFE_MODEL__}
Holds the current LIFE-model name without

file extension.
Commands Manual 3 - 3
SIMULIA
Tosca Structure
${__LIFE_FILE__}
Holds the current LIFE-model name with file

extension.
Example
1. See the global configuration tosca_ctrl.cfg. The above variables are used
for every call to FE-solvers and LIFE-solvers.
2. Calling a script before the solver is called with the name of the FE-input
deck:
$pre_solver = "my_script";
$pre_solver_add_call = " ${__FE_FILE__}";
The resulting call from Tosca Structure running the example "holeplate.par"
for Abaqus:
> my_script holeplate.inp
It is NOT allowed to call a script and option is a single line:

$pre_solver = "my_script ${__FE_FILE__}";
The above will result is following error:

(ERROR
) TOSCA Structure could not find my_script MODEL.inp
in the system.
(ERROR
) Checked were: absolute path, relative path, working dir and PATH.
(ERROR
) Please verify the file name.
Configuration
Parameter
Example
Remarks
${fe_solver}
${fe_solver} =
"abaqus";
Specification of the finite element solver interface. The following solvers are supported:
Abaqus, ANSYS, MSC Nastran, PERMAS, Marc.
${fe_solver_exe}
${fe_solver_exe} =
"C:/solver/solver.exe";
Path to the corresponding

executable finite element
solver.
3 - 4 Commands Manual
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
FE Solver Information
SIMULIA
Tosca Structure
CONFIG
Example
Remarks
${fe_solver_cmdline}
${fe_solver_cmdline} =
"job=
${__FE_MODEL__}";
Definition of the command line

for the finite element analysis.
All command line options
which should be used for the
solver call have to be defined
using this variable.
${fe_solver_add_call}
${fe_solver_add_call}
= "mem = 100Mb";
Additional command line

options for the solver call.
These statements are added
to the fe_solver_call variable.
${fe_check_file}
${fe_check_file}=
"${__FE_MODEL__}.
f06";
Definition of a check file that is

parsed after the finite element
analysis to check if the solver
run finished correctly.
To avoid this check set:
${fe_check_file}="";
${fe_check_string}
${fe_check_string}=
"FATAL MESSAGE";
Case sensitive string that is

searched in the check file
(${fe_check_file}). Action is
determined by
${fe_check_type}
${fe_check_type}
${fe_check_type} =
"failed";
$fe_check_file =
"succeeded";
Specification if the existence

of the check string
(${fe_check_string}) in the
check file (${fe_check_file})
defines that the job failed or
the job has succeeded.
failed: Tosca Structure 8.1.0
stops if the check string is
found in check file.
succeeded: The check string
must be found in check file for
Tosca Structure 8.1.0 to continue. Tosca Structure will also
stop if the check file is cannot
be found, assuming the FEsolver has not run correctly
www.3ds.com/tosca
Version 8.1.0 Rev. 1 - 05.2014
Configuration
Parameter
Remark
1. The solver call is assembled by the $fe_solver_exe, $fe_solver_cmdline
and $fe_solver_add_call variables during the runtime, i.e.:
> $fe_solver_exe $fe_solver_cmdline $fe_solver_add_call
SIMULIA
Tosca Structure
For the default settings for Abaqus in the tosca_ctrl.cfg:

${fe_solver_exe} = "/usr/bin/abaqus";
${fe_solver_cmdline} = "job=${__FE_MODEL__} analysis interactive";
${fe_solver_add_call}="";
this would be combined to the following call (for example holeplate.par):

> /usr/bin/abaqus job=holeplate analysis interactive
Lets assume you want to use 4 cpus for Abaqus. Set:

${fe_solver_add_call}="cpus=4";
And the new solver call would be:

> /usr/bin/abaqus job=holeplate analysis interactive cpus=4
2. Relative executable paths are allowed as well as paths using environment

variable PATH.
3. UNC Path are allowed. Valid paths are:
$tosca_prep='\\apps\tosca\bin\tosca_prep';
$tosca_prep="\\\\apps\\tosca\\bin\\tosca_prep";
$tosca_prep="//apps/tosca/bin/tosca_prep";
$tosca_prep='//apps/tosca/bin/tosca_prep';
Invalid paths are:

$tosca_prep=\\\\apps\tosca\bin\tosca_prep;
$tosca_prep="\\\\apps\tosca\bin\tosca_prep";
$tosca_prep=//apps/tosca/bin/tosca_prep;
Configuration
Parameter
Example
Remarks
${life_solver}
${life_solver} =
"femfat";
Specification of the durability

module. The following solvers
are supported:
falancs, femfat.
${life_solver_exe}
${life_solver_exe} =
"/app/..";
Path to the executable durability solver.
${life_solver_add_call}
${life_solver_add_call}
= "/scratch";

options for the durability solver
call. These statements are
added to the life_solver_call
variable.
${life_ini}
${life_ini} = "...";
Path to an (eventually) existing initialisation file.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Durability Information
SIMULIA
Tosca Structure
CONFIG
Remark
The LIFE solver call is assembled by the $life_solver_exe,
$life_solver_cmdline and $life_solver_add_call variables during the runtime
in the same way as FE-solver, see previous example.
> $life_solver_exe $life_solver_cmdline
$life_solver_add_call
www.3ds.com/tosca
Version 8.1.0 Rev. 1 - 05.2014
Tosca Structure 8.1.0 Interface Information
Configuration
Parameter
Example
Remarks
${fem_modif}
${fem_modif} =
"${tosca}/bin/
fem_modif";
Path to fem_modif script.
${fem_modif_
add_call}
${fem_modif_add_
call} =
" --loglevel warning
--logfile
TOSCA.OUT\@info";

options.
${fem2onf}
${fem2onf} =
"${tosca}/bin/fem2onf";
Path to fem2onf script.
${fem2onf_add_call}
${fem2onf_add_call} =
" --loglevel warning logfile
TOSCA.OUT\@info";

options.
${res2vtm}
${res2vtm} =
"${tosca}/bin/res2vtm";
Path to res2vtm script.
${res2vtm_add_call}
${res2vtm_add_call} =
TOSCA.OUT\@info";

options.
${life2vtm}
${life2vtm} =
"${tosca}/bin/life2vtm";
Path to life2vtm script.
${life2vtm_add_call}
${life2vtm_add_call} =
TOSCA.OUT\@info";

options.
SIMULIA
Tosca Structure
Remarks
1. To make fem2onf skip the PARAM,POST,-1 check in Nastran Interface you
can add the CONFIG-block:
$fem2onf_add_call = "--ignore_ppr 1";
The above setting is NOT recommended.
2. Changing the default result reading for Abaqus from FIL-file to SIM-file is
done adding the following command in the parameter file or generally,
adding the command in the tosca_ctrl.cfg:
CONFIG
...
$fem_modif_add_call = "--format_matrices sim";
$res2vtm_add_call = "--format_matrices sim";
...
END_
Using the SIM-file is recommended for Abaqus 6.13 or higher and for sizing
and sensitivity based shape and bead optimization.
${tosca_smooth}
${tosca_smooth} =
"${tosca}/bin/
tosca_smooth";
Path to tosca_smooth script.
${tosca_smooth_
add_call}
${tosca_smooth_add_
call} = " -logfile
TOSCA.OUT\@info";

options.
${tosca_report}
"${tosca}/bin/
tosca_report";
Path to tosca_report script
${tosca_report_add_c
all}
${tosca_report_add_
call} = " -logfile
TOSCA.OUT\@info";

options.
$post_file_replacemen
ts{text_to_find} =
"replace_text";
$post_file_replacemen
ts{__JOB_NAME__} =
"\$jobname";
For automated replacements

in REPORT or SMOOTH
macro-files. Default setting

is shown here which means
that every(!)
__JOBNAME__ in parameterfile will be replaced with
the current jobname (\$jobname). More can be added
but should be used with
caution.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Tosca Structure 8.1.0 Report and Smooth Information
SIMULIA
Tosca Structure
CONFIG
${post_overwrite} =
"<option>";
${post_overwrite}
="yes";
Tosca Structure will with

default setting (<option>="no")
always generate a new post
commands (Tosca Structure.report or Tosca Structure.smooth) and output file
when called more than once.
For use with Tosca ANSA
environment this is not
wanted, therefore must
${post_overwrite} ="yes"; be
set when calling Tosca Structure from Tosca ANSA environment.
Remarks
1. Tosca Structure will execute Tosca Structure.report and Tosca Structure.smooth automatically at the end of a successfull optimization. If
REPORT or SMOOTH commands are present these will be executed.
Also, if the OPTIONS DEFAULT_REPORT=ON or
DEFAULT_SMOOTH=ON Tosca Structure will create files called
tosca_structure_report.par, tosca_structure_smoothing_vol.par or
tosca_structure_smoothing_iso.par. These files are based on the configuration file in macro-directory in installation:
tosca_def_smooth_report_template.mac.
2. The above files all include the string __JOBNAME__. This string is replaced
with the $jobname according to the jobname of the running REPORT or
SMOOTH job.
www.3ds.com/tosca
Version 8.1.0 Rev. 1 - 05.2014
List definitions
Configuration
Parameter
Example
Remarks
set_move_per_iter_list
(lab1, lab2, lab3 )
set_move_per_iter_list
("ever", "SAVE.fil",
"name.ext");
lab1: "ever", "never",

"first_last";
lab2: Name of the SAVE directory;
lab3: File name.
Configuration
Parameter
Example
Remarks
add_move_per_iter_
list (lab1, lab2, lab3)
add_move_per_iter_
list("first_last",
"SAVE.fil",
"name.ext");

"first_last";
lab3: File name.
set_move_per_iter_
xxx_list(lab1, lab2,
lab3 )
set_move_per_iter_
xxx_list("ever",
"SAVE.fil",
"name.ext");

"first_last";
lab3: File name.
add_move_per_iter_
xxx_list (lab1, lab2,
lab3)
add_move_per_iter_
xxx_list("first_last",
"SAVE.fil",
"name.ext");

"first_last";
lab3: File name.
set_copy_solver_info_
list (lab1, lab2, lab3)
set_copy_solver_info_
list("first_last",
"SAVE.fil",
"name.ext");

"first_last";
lab3: File name.
add_copy_solver_
info_list (lab1, lab2,
lab3)
add_copy_solver_
info_list("first_last",
"SAVE.fil",
"name.ext");

"first_last";
lab3: File name.
set_move_after_opt_
list (lab1, lab2, ...,
labn)
set_move_after_opt_
list("SAVE.wrl",
"*.wrl");

lab2 - labn: File name(s).
add_move_after_opt_
list (lab1, lab2, ...,
labn)
add_move_after_opt_
list("SAVE.txt",
"liste.txt",
"result_*.txt");

lab2 - labn: File name(s).
set_opt_db_list(lab1,
..., labn)
set_opt_db_
list("TOSCA.DB");
lab1 - labn: Files of Tosca

Structure database.
add_opt_db_list(lab1,
..., labn)
add_opt_db_
list("TOSCA.DB");
lab1 - labn: Files of Tosca

Structure database.
set_include_search_
path(lab1, ..., labn)
set_include_search_
path("$tosca/bin/
macros");
lab1- labn: Paths to search for

include files.
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Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
SIMULIA
Tosca Structure
CONFIG
Configuration
Parameter
Example
Remarks
add_include_search_
path(lab1, ..., labn)
add_include_search_
path("$tosca/bin/
macros");
lab1- labn: Paths to search for

include files.
set_delete_after_opt_
list(lab1, ..., labn)
set_delete_after_opt_
list("*.log", "*.temp");
lab1 - labn: List of files that

should be deleted at the end
of the optimization.
add_delete_after_opt_
add_delete_after_opt_
list("*.log", "*.temp");

of the optimization.
set_delete_per_iter_
set_delete_per_iter_
list("*.MASTER",
"*.DBALL" )

of a design cycle.
add_delete_per_iter_
list(lab1, ... , labn)
add_delete_per_iter_
list("*.MASTER",
"*.DBALL" )

of a design cycle.
Configuration
Parameter
Example
Remarks
${pre_prep}
${pre_prep} =
"<script-name>";
Script that should be executed

before tosca_prep is started.
${pre_prep}
${pre_prep_add_call}
Options for ${pre_prep}
${post_fem2onf}
${post_fem2onf} =
"<script-name>";

after fem2onf is finished.
${post_prep}
${post_prep} =
"<script-name>";

after tosca_prep is finished.
${pre_fem_modif}
${pre_fem_modif} =
"<script-name>";

before fem_modif is started.
${post_fem_modif}
${post_fem_modif} =
"<script-name>";

after fem_modif is finished.
www.3ds.com/tosca
Version 8.1.0 Rev. 1 - 05.2014
Script calls
Configuration
Parameter
Example
Remarks
${pre_solver}
${pre_solver} =
"<script-name>";

before the start of the finite
element analysis. (In case of
multiple FE analysis, the script
is executed before each finite
element analysis.)
${post_solver}
${post_solver} =
"<script-name>";

after the finite element analysis. (In case of multiple FE
analysis, the script is executed
at the end of the solver
sequence.)
${pre_res2vtm}
${pre_res2vtm} =
"<script-name>";

before the Tosca Structure
result module.
${post_res2vtm}
${post_res2vtm} =
"<script-name>";

after the Tosca Structure result
module.
${pre_life}
${pre_life} =
"<script-name>";

before the durability solver.
${pre_lifepre_life_add
_call}
${pre_life_add_call}=""
;
Options
${post_life}
${post_life} =
"<script-name>";

after the durability solver.
${post_life_add_call}
${post_life_add_call}=
"";
Options
${pre_opt}
${pre_opt} =
"<script-name>";

8.1.0 optimization module.
${pre_opt_add_call}
${pre_opt_add_call}="
";
Options
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- 05.2014
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SIMULIA
Tosca Structure
SIMULIA
Tosca Structure
www.3ds.com/tosca
Version 8.1.0 Rev. 1 - 05.2014
CONFIG
Configuration
Parameter
Example
Remarks
${post_opt}
${post_opt} =
"<script-name>";

after the Tosca Structure 8.1.0
optimization module.
${post_opt_add_call}
${post_opt_add_call}=
"";
Options
${post_eval}
${post_eval} =
"<script-name>";

at the end if the optimization
procedure is completed
(before moving the files into
the corresponding SAVE
directories).
${post_eval_add_call}
${post_eval_add_call}
="";
Options
${pre_smooth}
${pre_smooth}=
"<script-name>";

before Tosca Structure.smooth
is started
${pre_smooth_add_ca
ll}
${pre_smooth_add_ca
ll}="";
Options
${post_smooth}
${post_smooth}=
"<script-name>";

after Tosca Structure.smooth
has run
${post_smooth_add_c
all}
${post_smooth_add_c
all}="";
Options
${pre_report}
${pre_report}=
"<script-name>";

before Tosca Structure.report
is started
${pre_report_add_call}
${pre_report_add_call}
="";
Options
${post_report}
${post_report}=
"<script-name>";

after Tosca Structure.report
has run
${post_report_add_cal
l}
${post_report_add_cal
l}="";
Options
${pre_fem_modif_
matrix}
${pre_fem_modif_
matrix} =
"<script-name>";

before fem_modif is started in
a matrix step.
${pre_fem_modif_matr
ix_add_call}
${pre_fem_modif_matr
ix_add_call}="";
Options
Configuration
Parameter
Example
Remarks
${post_fem_modif_
matrix}
${post_fem_modif_
matrix} =
"<script-name>";

after fem_modif has been finished in a matrix step.
${post_fem_modif_ma
trix_add_call}
${post_fem_modif_ma
trix_add_call}="";
Options
${pre_solver_matrix}
${pre_solver_matrix} =
"<script-name>";

before solver is started in a
matrix step.
${pre_solver_matrix_a
dd_call}
${pre_solver_matrix_a
dd_call}="";
Options
${post_solver_matrix}
${post_solver_matrix}
= "<script-name>";

after solver has been finished
in a matrix step.
${post_solver_matrix_
add_call}
${post_solver_matrix_
add_call}="";
Options
${pre_res2vtm_matrix}
${pre_res2vtm_matrix}
= "<script-name>";

8.1.0 result module while performing a matrix step.
${pre_res2vtm_matrix
_add_call}
${pre_res2vtm_matrix
_add_call}="";
Options
${post_res2vtm_
matrix}
${post_res2vtm_
matrix}=
"<script-name>";

result module while performing
a matrix step.
${post_res2vtm_matri
x_add_call}
${post_res2vtm_matri
x_add_call}="";
Options
${pre_matrix}
${pre_matrix} =
"<script-name>";

8.1.0 optimization module in
matrix step.
${pre_matrix_add_call
}
${pre_matrix_add_call
}="";
Options
${post_matrix}
${post_matrix} =
"<script-name>";

optimization module in matrix
step.
${post_matrix_add_cal
l}
${post_matrix_add_cal
l}="";
Options
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SIMULIA
Tosca Structure
SIMULIA
Tosca Structure
CONFIG
Configuration
Parameter
Example
Remarks
${fe_solver_script}
${fe_solver_script} =
"<script-name>";
Special script that be used for

calling your FE solver with a
queuing system, see number
4 at Remarks and
${execute_as_ perl_ext} =
"<script extension>";.
${life_solver_script}
${life_solver_script} =
"<script-name>";
Special script that can be used

for calling your life solver with
a queuing system, see number 4 at Remarks and
www.3ds.com/tosca
Version 8.1.0 Rev. 1 - 05.2014
${execute_as_ perl_ext} =
"<script extension>";.
${fe_solver_submit_ch
eck}
eck}= "<script-name>";
User-implemented script.
Returns:
0 - Job successfully completed
1 - Job ended with an error
5 - Job is still running
eck_cmdline}
eck_cmdline}=
"<options>";
Commandline options for

${fe_solver_submit_check}
${fe_solver_submit_int
erval}
${fe_solver_submit_int
erval} = 30
The interval in seconds with

which
${fe_solver_submit_check} is
called.
${fe_solver_submit_ti
me_out}
${fe_solver_submit_ti
me_out} = 3600
Time out is seconds. Defining

when Tosca Structure gives up
to wait for a result from submitted job.
${life_solver_submit_c
heck}
heck}= "<scriptname>";
User-implemented script.
Returns:
0 - Job successfully completed
1 - Job ended with an error
5 - Job is still running
Not allowed for MSC.Fatigue
and Falancs
heck_cmdline}
heck_cmdline}=
"<options>";
Commandline options for

${life_solver_submit_check}
SIMULIA
Tosca Structure
Configuration
Parameter
Example
Remarks
${life_solver_submit_i
nterval}
${life_solver_submit_i
nterval} = 30
The interval in seconds with

which
${life_solver_submit_check} is
called.
${life_solver_submit_ti
me_out}
${life_solver_submit_ti
me_out} = 3600
Time out is seconds. Defining

when Tosca Structure gives up
to wait for a result from submitted job.
Remarks
1. See also the Fig. 350 for a graphical view of where in the Tosca Structure.control workflow the scripts are called.
2. All scripts should be in the starting directory ($startdir). The script will be
executed within the Tosca Structure working directory, similar to:
> cd $workdir
> $start_dir/$your_script <arguments ...>
3. For the reason above your script should not use any absolute paths.
4. Versions of Tosca Structure prior 7.2 allowed to use the following syntax,
which will now lead to an error message( "Wrong configuration settings"):
THIS IS NOT ALLOWED:
$pre_prep = "echo 1 & echo 2 & my_script.cmd 3";
$pre_prep = "pre_prep_script.pl";
$pre_prep_add_call = "1 2 argument3";
6. Use of ${fe_solver_script} and ${life_solver_script} is un-supported

and the use is at own risk! It is also recommended to use
${fe_solver_submit_check} or ${life_solver_submit_check} instead.
${fe_solver_script} and ${life_solver_script} are special scripts to avoid the
normal work flow of Tosca Structure.control to be able to call FE-solver or
life-solver in a queuing environment.
The scripts should be called as a perl script to be able to access the list of
model files (defined in FEM_INPUT command FILE and LIFE_FILE items).
The arrays are called @{$::cf{model_list}} and @{$::cf{life_list}}.
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5. With Tosca Structure 8.1.0 you should make a script which contains all
these 3 calls using perl scripts or native OS scripts.
If you need additional parameters to be supplied to your script by your
configuration use the newly introduced _add_call for user scripts:
THIS IS THE CORRECT WAY:
SIMULIA
Tosca Structure
CONFIG
Example:
CONFIG
${execute_as_perl_ext} ="pl";
${fe_solver_script} = "fe_solver_script_queing.pl";
END_
- The script "fe_solver_script_queing.pl" should be able to wait for

your queuingsystem to be done. It should look something like:
----------------------------------------------------------#!/usr/bin/perl -w
foreach my $file (@{$::cf{model_list}} ) {
system("<some_que_command> $file");
}
# check if all results files are present
# and that all copy actions are done
...
-----------------------------------------------------------
www.3ds.com/tosca
Version 8.1.0 Rev. 1 - 05.2014
7. If ${fe_solver_submit_check} is set, Tosca Structure will assume that the

call ${fe_solver_exe} is a submit script, that is a script submitting a job to a
queing system. This script has to be implemented by the user, but can be
supported by your local Tosca Structure support.
The ${fe_solver_submit_check}-script is called each
${fe_solver_submit_interval} seconds. Tosca Structure will wait
${fe_solver_submit_time_out} seconds for the successful end of the solver
submit and hence positive check of the ${fe_solver_submit_check}. If the
time $fe_solver_submit_time_out is exceeded and the solver is still running
Tosca Structure will exit with an error message.
Example:
${fe_solver_exe} = "solver_script.sh";
${fe_solver_submit_check} = "fe_solver_check.pl";
${fe_solver_submit_check_cmdline} = "${__FE_MODEL__}";
${fe_solver_submit_interval} = 30;
${fe_solver_submit_time_out} = 3600;
${execute_as_perl_ext} = "pl";
8. The ${life_solver_submit_check} works similar for ${life_solver_exe} calls

and may be used with all life-solvers excepts MSC.Fatigue and Falancs.
9. The ${fe_solver_submit_check} and ${life_solver_submit_check} should
be used with caution. Checking for simple file existense is often not enough
SIMULIA
Tosca Structure
especially by large files. Please contact your local Tosca Structure support
for further information.
10.The keyword DEPENDENT_FILE in FEM_INPUT can be used together
with ${fe_solver_submit_check} and ${life_solver_submit_check} to ensure
that dependent steps are performed in the right order. Please contact your
local Tosca Structure support for further information.
Additional variables
These variables may only be used for new definitions. They should not be
overwritten.
${startdir}
Start directory of the optimization job.
${jobname}
Name of the optimization job. The $jobname variable is extracted

from the parameter file name or the -opt statement.
${parfile}
Name of the parameter file (including extension).
${modelfile}
Obsolete, see ${__FE_FILE__}.
${parname}
Name of the parameter file (without extension).
${modelname}
Obsolete, see ${__FE_MODEL__}.
${opt_ext}
Standard extension of the parameter file.
Other settings
add_files_to_work_dir
("file1.ext","file2.txt");
Obsolete: Use
FEM_INPUT COPY_FILE
instead.
lab1 - labn: Sets the list of files
that additionally should be
copied into the working directory. Wild card (*) is NOT
allowed. The files must exist
by Tosca Structure 8.1.0 start.
set_dos2unix_
list(lab1, ..., labn);
set_dos2unix_
list("*.par");
lab1 - labn: Sets the list of files

on which dos2unix should be
performed. Wild card (*) is
allowed.
add_dos2unix_
list(lab1, ..., labn);
add_dos2unix_
list("*.par");
lab1 - labn: Adds to the list of

files on which dos2unix should
be performed.
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add_files_to_work_
dir(lab1, ..., labn);
SIMULIA
Tosca Structure
CONFIG
$allow_absolute_
include_paths= <int>;
$allow_absolute_
include_paths =1;
If this variable is set to 1 absolute file paths will be tolerated

in Tosca Structure 8.1.0. This
setting is NOT recommended!

$print_tosca_includes
= <option>;
$print_tosca_includes
= "no";
Controls the printing of Tosca

Structure 8.1.0 include files in
the file
"${parfile}.tosca_includes".
<option> = "no" (Default: Not
printing file)
<option> = "yes" (Print file)
<option> = "only" (Print file
only, do not start optimization)
The latter option is handy for
queuing systems. May also be
used on command line:
tosca <jobname>
print_tosca_includes
only.
$TOSCA_KEEP_
BACKSLASH =
<string>;
www.3ds.com/tosca
Version 8.1.0 Rev. 1 - 05.2014
${script} =
"USE_DEFAULT_
SCRIPT";
$TOSCA_KEEP_
BACKSLASH
="TOSCA_KEEP_
BACKSLASH";
If this variable is set backslashes will NOT be replaced in

configuration. This setting
${pre_fem_modif_
matrix} =
"USE_DEFAULT_
SCRIPT";
To use a default script. Tosca

Structure.control searches following directories (in this
sequence):
$tosca/$fe_solver
$tosca/$life_solver
$tosca
for the first script where a part
of the name matches
"${script}".
In perl-syntax:
is NOT recommended!
$filename =~ /
${script}/i;
The found script with name
"$filename" will be called.
${execute_as_
perl_ext} =
"<script extension>";
${execute_as_
perl_ext} ="pl";

as a perl script within Tosca
Structure.control. This is
essential for using
${fe_solver_script} and
${life_solver_script}. If this is
not wanted set the value to
"do_not_execute_as_perl".
SIMULIA
Tosca Structure
$killscripts{<executable name} =
"<action>"
$killscripts{abaqus} =
"${fe_solver_exe}
job=__FE_MODEL__
terminate";
Certain solvers may have special ways of terminating on interupt signals. Tosca Structure
searches the $killscripts keys
(<executable name>) and
calls the given <action> if one
is derfined. The default action
is to pass the interupt signal
on the the child process (fesolver, life-solver, optimization
module etc.)
$copy_tosca_out_on_
success = "yes"/"no";
$copy_tosca_out_on_
success = "yes";
"yes" causes the logfile

TOSCA.OUT is copied to
TOSCA_POST directory after
optimization to imitate old handling of log file.
"no" implies that TOSCA.OUT
is only in $workdir and will not
be copied to TOSCA_POST
after optimization.
Remarks
1. The Tosca Structure configuration is completely defined in PERL syntax. It
is important to generate correct perl codes when creating user defined
configuration settings.
The variable values are enclosed in quotation marcs. Each command must
end with a semicolon.
All Perl statements (i.e. if, ...) may be used in the configuration files.
A more detailed perl documentation may be found in the world wide web:
www.perl.com.
installation configuration
$tosca/bin/tosca_ctrl.cfg
user configuration
$HOME/tosca_ctrl.cfg
job configuration
parameter file
If a CONFIG block is defined in the parameter file, a job-configuration file is

extracted. This file is called <jobname>.par_cfg.
3. The list of files for move, delete or copy actions may be defined by using
the "add_" functions (lists are expanded) or by using the "set_" functions
(lists are initialized).
The lists are expanded over the complete configuration file hierarchy. An
entry in the user defined configuration is added at the end of the list. As the
lists are executed backwards, the user defined entries are executed first.
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2. The single configuration files are overwritten in the following order:
SIMULIA
Tosca Structure
CONFIG
4. All files in the MOVE_PER_ITER_LIST are moved in the corresponding

directories at the end of each design cycle. The files get an iteration
counter extension number.
5. All files in the MOVE_PER_ITER_XXX_LIST are moved in the corresponding directories at the end of each design cycle. This list matches all
files, which already have an iteration counter extension number (like the
*.WRL files).
6. All files in the COPY_SOLVER_INFO_LIST are copied in the corresponding directories before the finite element solver call. The files get an
iteration counter extension number.
7. If the script calls are used, Tosca Structure does not explicitly check the
existence of the scripts. This allows the definition of system calls. If system
calls are used, the definition of the command line has to be set in \".
Example: ${post_solver}="\"ls -la\"";
If one would like to define multiple commands, the command sequence has
to be specified in one line. On UNIX systems, the commands have to be
separated with a ";", on Windows systems the "&" sign may be used.
Example:\"";
UNIX: ${post_prep} = "\" echo content of current directory; ls -la ;
WINDOWS: ${post_prep}="\" echo content of current directory & dir\"";
8. If the variable $fe_solver_exe is modified, the $fe_solver_call also has to
be modified.
www.3ds.com/tosca
Version 8.1.0 Rev. 1 - 05.2014
9. Dos2unix is performed at beginning of optimization on all file types in start

directory defined in the dos2unix_list by "set_dos2unix_list" or
"add_dos2unix_list". Turn dos2unix off by setting the dos2unix_list to an
empty list:
"set_dos2unix_list();"
10.It is not recommended to set the variable
"$allow_absolute_include_paths". This should only be done if the user is
certain that Tosca Structure 8.1.0 will not change anything in the referenced files.
11.Tosca Structure replaces all "\" with "/" in configuration files before reading
them. If you really need backslashes use "\\". Another option is to turn this
search and replace action off. Set following line in the configuration file:
$TOSCA_KEEP_BACKSLASH = "TOSCA_KEEP_BACKSLASH";
12.Scripts with the extension "${execute_as_perl_ext}" will be called with
Tosca Structure.control as a perl (version 5.8) script using the perl function:
do "$script";
SIMULIA
Tosca Structure
Hereby are all Tosca Structure.control variables accesible. All variables can
be seen in the "tosca.restart" file if the optimization has not ended correctly.
The most important arrays are @{$::cf{model_list}} and @{$::cf{life_list}}
which lists the FE-solver and life-solver input decks, respectively.
If the script has arguments they will be parsed to the usual @ARGV variable and available as when calling the perl script on the command line.
Examples
CONFIG
add_move_per_iter_list("first_last", "SAVE.op2",
"my_model.op2");
add_move_after_opt_list("SAVE.txt", "my_results.txt");
$fe_solver_exe
= "/usr/bin/nastran";
$fe_solver_call = "$fe_solver_exe $modelfile -batch=no notify=no";
END_
CONFIG
$pre_prep = "my_test.pl will now test my perl-script";
$execute_as_perl_ext = "pl";
END_
Let the file my_test.pl be following simple perl-script:

my $i = 0;
for each my $arg
(@ARGV) {print " $i : $arg "; $i++;}
The above configuration will then print the following line the logfile before the
preprocessor:
1 : now
2 : test
3 : my
4 : perl-script
Special Abaqus configuration settings

See also vol.2 chapter 11.1, Abaqus for information about Abaqus interface.
$abaqus_datacheck =
<option>;
$abaqus_datacheck =
"yes";
Tosca Structure will execute

an Abaqus datacheck
sequence before Abaqus run if
parameters are found in the
Abaqus input deck by the
default setting:
$abaqus_datacheck = "yes";
If this behaviour is not wanted
set:
$abaqus_datacheck = "no";
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1 - 05.2014
0 : will
SIMULIA
Tosca Structure
CONFIG
$flatten_abaqus_input
= "yes";
Tosca Structure will execute

an Abaqus datacheck
sequence before Abaqus run if
Parts and Assemblies are
found in the Abaqus input
deck by the default setting:
$flatten_abaqus_input = "yes";
If this behaviour is not wanted
set:
$flatten_abaqus_input = "no";
www.3ds.com/tosca
Version 8.1.0 Rev. 1 - 05.2014
$flatten_abaqus_input
= <option>;
SIMULIA
Tosca Structure
CONSTRAINT
Definition of an equality or inequality (less or equal/ greater or equal) constraint. The constraint is defined with respect to a design response. For more
detailed information see vol.2 chapter 4.3, Constraints
ID_NAME
= <name_of_constraint>
Name of the CONSTRAINT definition
DRESP
= <name_of_dresp>
Name of the design

response that should be
restricted
MAGNITUDE = ABS
= REL
Constraints can be given

in absolute or relative values
EQ_VALUE
= <value>
Value of equality constraint
GE_VALUE
= <value>
Value of greater or equal

constraint
LE_VALUE
= <value>
Value of less or equal

constraint
Remarks
1. Only one ITEM of the following list of ITEMs can be used within a constraint
definition:
2. MAGNITUDE: relative values always refer to the design response of the

start model for the optimization. Example: The relative value 0.8 represents
80%.
Please note: In topology optimization the start model for the optimization is
the model used for the first finite element analysis in the optimization
procedure (iteration 0). The element densities may differ from the initial
model (e.g. when no volume constraint is present they are set to 50% of
the original density). Take this into account when defining, e.g., relative
displacement or frequency constraints. This behaviour can be controlled by
the user with the parameter DENSITY_INITIAL in the OPT_PARAM
command.
3. For EQ_VALUE only a value greater equal to zero can be set for MAGNITUDE=REL.
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- EQ_VALUE
- GE_VALUE
- LE_VALUE
SIMULIA
Tosca Structure
CONSTRAINT
4. For shape optimization a volume constraint may be defined for an element

group which contains the complete mesh_smooth area.
5. Inequality constraints can only be used for the sensitivity based bead,
sizing, shape and topology optimization.
6. Equality constraints can be used for controller based shape, bead and
topology optimization. If accidentally an equality constraint is defined for a
sensitivity based optimization an error message is shown.
7. Special care must be taken when using relative magnitude in an inequality
constraint with a negative start model design response value:
When converting the relative magnitude to absolute, the inequality is multiplied with a negative number and thus the constraint type changes from
"lesser equal" to "greater equal" and vice versa.
Examples
For sensitivity based topology optimization:
CONSTRAINT
ID_NAME
DRESP
MAGNITUDE
LE_VALUE
=
=
=
=
my_constraint
volume_part_1
REL
0.8
END_
For controller based bead optimization:
ID_NAME
DRESP
MAGNITUDE
EQ_VALUE
=
=
=
=
bead_height_constraint
dresp_bead_height
ABS
20.0
END_
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Version 8.1.0 Rev. 1 - 05.2014
CONSTRAINT
SIMULIA
Tosca Structure
CONTOURPLOT
The CONTOURPLOT command combines result data to a fringe plot later
referenced in a postprocessing report (REPORT command). For more
detailed information see vol.2 chapter 10.1, Generation of Postprocessing
Data.
=
<id_name_of_contourplot>
TITLE
= <title>
DESCRIPTION
= <description for vtfx>
TYPE_
PROPERTY
= <type of result properties for vtfx case>

Values for this item must be one from
the following list:
= MODEL
= MODEL_SET
= ELEMENT_FILL_FILTER
= ELEMENT_
CONTINUOUS_FILTER
= ELEMENT_THICKNESS
= ELEMENT_DELTA_THICKNESS
= NODAL_CONTINUOUS
= NODAL_DISPLACEMENT
This parameter is
required in every contour
plot described in the
parameter file:
model
model with groups
relative material value
continuous value for elements
shell element thickness
shell thickness change
continuous nodal value
displacement for nodes
FRINGE_
RESULT
= <name of fringe results>
Defines fringe plot on

model, refers to result
data available in ONF
result files. If no result is
specified, only model will
be shown
DISP_
RESULT
= <displacement result
name>
Defines node based displacement results shown

as displacements on
model
FILTER
= <min>
= <max>
minimum and maximum

filter value applies to
fringe result. This parameter is optional. If it is
skipped filtering will be
disabled
FRINGE
= <min>
= <max>
Default: AUTO
Minimum and maximum

value for the fringe visualisation. This parameter
is optional
www.3ds.com/tosca
Version
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ID_NAME
SIMULIA
Tosca Structure
www.3ds.com/tosca
Version 8.1.0 Rev. 1 - 05.2014
CONTOURPLOT
GROUP_
FILE
= <name of group file>

More than one entry is allowed.
Group file(s) containing

the groups referenced in
GROUP parameter.
GROUP
= <name of group>
Only this group will be

written to vtfx if this
parameter is not specified, all group information
from group file will be
available in vtfx file and
can be selected later in
the viewer.
ITERATION
= <sequence of numbers in
TOSCA numbering style>
e.g. 3,4-9:2,17
Custom iteration indices

(if an ONF file for some
iteration is missing, this
iteration is skipped)
= ALL
All available iterations.
= ORIGINAL
Iteration of the first available ONF file.
= LAST
Iteration of the last available ONF file.
LEGEND_
TITLE
= <name of legend>
Title of the legend.
REVERT_
LEGEND_
COLORING
=YES
=NO
Upturning of the legend

colours.
ADD_UNDEFORMED
_MODEL
=YES
=NO
Displaying of the undeformed model superimposed to the specified

contourplot of
TYPE_PROPERTY =
NODAL_CONTINUOUS |
NODAL_DISPLACEMEN
T.
Examples
For topology optimization:
CONTOURPLOT
ID_NAME
= TOPO_MAT
TYPE_PROPERTY = ELEMENT_FILL_FILTER
TITLE
= "Relative Material Distribution,
soft elements filtered"
DESCRIPTION
= "TOSCA Structure.topology
SIMULIA
Tosca Structure
FRINGE_RESULT
FILTER
ITERATION
GROUP_FILE
= MAT_PROP_NORMALIZED
= 0.05,1
= ALL
END_
For sizing optimization: shell thickness will be mapped as fringe plot

CONTOURPLOT
ID_NAME = SIZING_THICKNESS
TYPE_PROPERTY = ELEMENT_THICKNESS
TITLE = Thickness from Sizing Optimization
DESCRIPTION = TOSCA Structure.sizing Optimization Result
FRINGE_RESULT = THICKNESS
ITERATION = ALL
GROUP_FILE = "SAVE.onf\GROUPS.onf"
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END_
SIMULIA
Tosca Structure
CS_DEF
CS_DEF
Defines coordinate systems with reference to an existing coordinate system
or three nodes. For more information refer to vol.2 chapter 3.8, Coordinate
Systems (CS_DEF).
ID_NAME
= <name_of_coord_system>
Name of the coordinate

system
CS_TYPE
= RECTANGULAR
= CYLINDRICAL
= SPHERICAL
Type of new coordinate

system
DEF_TYPE
= LOCAL
LOCAL definition refers

to an existing coordinate
system
= NODE
Definition using three

nodes
Items for DEF_TYPE = LOCAL
CS_REF
Existing reference coordinate system
ORIGIN_123
= <coord_1>, <coord_2>,
<coord_3>
Coordinate values of the

origin
ROTATION_
321
= <rot_3>, <rot_2>, <rot_1>
Rotations that should be

superimposed on the reference coordinate system
www.3ds.com/tosca
Version 8.1.0 Rev. 1 - 05.2014
Items for DEF_TYPE = NODE
CS_AXIS
NODE_
ORIGIN
Specifies the axis and the plane

defined by the three nodes.
= X_XY
X-axis and the XY plane

are defined by the three
nodes.
= X_XZ
X-axis and XZ-plane are

defined by the nodes.
= Z_XZ
Z-axis and XZ-plane are

defined by the nodes.
= <node_id_of_origin>
ID of node which defines

the origin.
SIMULIA
Tosca Structure
NODE_AXIS
= <node_id_on_axis>
ID of the node on the

axis
NODE_
PLANE
= <node_id_on_plane>
ID of the node on the

given plane and the second axis
Remarks
1. The rotation angle in the command ROTATION_321 is in degrees. The
single rotations are carried out around the axis of the global cartesian coordinate system.
Examples
The following command defines a cylindrical coordinate system with origin
(10,20,0) with respect to the global cartesian coordinate system CS_0. The
polar axis and longitudinal axis are obtained by rotating the x-axis and z-axis
of CS_0 respectively by 45 around the z-axis and by 15 around the y-axis of
CS_0.
CS_DEF
ID_NAME
CS_TYPE
DEF_TYPE
CS_REF
ORIGIN_123
ROTATION_321
=
=
=
=
=
=
my_cs_01
CYLINDRICAL
LOCAL
cs_0
10.0, 20.0, 30.0
45.0, 15.0, 0.0
END_
CS_DEF
ID_NAME
CS_TYPE
DEF_TYPE
CS_AXIS
NODE_ORIGIN
NODE_AXIS
NODE_PLANE
END_
=
=
=
=
=
=
=
my_cs_02
RECTANGULAR
NODE
X_XY
10
100
101
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Version
Version
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- 05.2014
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The following command defines a rectangular (cartesian) coordinate system with origin through the node with ID number 10. The x-axis is defined
by the nodes 10 and 100. Node 101 defines a point in the xy-plane.
SIMULIA
Tosca Structure
DRESP
DRESP
The Design Response command defines the system response for the current
analysis model. The DRESP command extracts one scalar value from a given
result field. Permitted dimensions can be load case independent or load case
dependent (parameter DEF_TYPE = SYSTEM) as well as certain combinations of values (parameter DEF_TYPE = OPER).
The design responses are referenced in the definition of the constraints and
the objective functions. For a general overview of design responses see vol.2
chapter 4.4, Design Responses, more detailed information about their use
can be found in vol.2 chapter 5, Topology Optimization, vol.2 chapter 6,
Shape Optimization and vol.2 chapter 7, Bead Optimization in the Tosca
Structure 8.1.0 user manual.
ID_NAME
= <id_name_of_dresp>
Name of the design

response definition.
DEF_TYPE
= SYSTEM
The design response is

determined from the system (loadcase dependent
and loadcase independent data).
= OPER
The design response is

the difference between
two design responses of
the same type for the
same loadcase(s) or a
weighted combination of
several displacement
responses.
www.3ds.com/tosca
Version 8.1.0 Rev. 1 - 05.2014
LIST
TYPE
Determines output format for design

response
= NO_LIST
No output of values.
= LIST
Detailed output of values.
= LIST_HIS
Detailed output and history.
see table with available types
Type of the design

response. For the different optimization algorithms the available
design responses for the
constraints and the
objective function can be
chosen according to the
table below.
SIMULIA
Tosca Structure
Types for design responses

E: Element based value
N: Node based value
S: Scalar value
N E : Node with additional element information

Allowed optimization strategy for this design responses
(see OPTIMIZE item STRATEGY)
TOPO_CONTROLLER
ABQ_ND_
PEEQ
TOPO_S
TOPO_SENSITIVITY
SHAPE_C
Abaqus PEEQ nodal

value
BEAD_HEIGHT
BEAD_C
CENTER_
GRAVITY_X
TOPO_S
SIZE
BEAD_S
TOPO_S
SIZE
BEAD_S
Center of gravity for

the x-direction.
CENTER_
GRAVITY_Y
TOPO_S
SIZE
BEAD_S
TOPO_S
SIZE
BEAD_S

the y-direction.
CENTER_
GRAVITY_Z
TOPO_S
SIZE
BEAD_S
TOPO_S
SIZE
BEAD_S

the z-direction.
SHAPE_C
Damage value from

durability analysis.
DAMAGE
Height of the bead.
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Version
Version
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- 05.2014
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TOPO_C
Description
SIZING_SENSITIVITY
BEAD_SENSITIVITY
usable as
OBJ_FUNC
SIZE
BEAD_S
usable as
CONSTRAINT
SHAPE_CONTROLLER
Selection
area
SHAPE_C
Loadcase
dependent
BEAD_CONTROLLER
Variable Type
BEAD_C
SIMULIA
Tosca Structure
www.3ds.com/tosca
Version 8.1.0 Rev. 1 - 05.2014
DENSITY_
MEASURE
Description
Selection
area
usable as
OBJ_FUNC
Loadcase
dependent
DAMAGE_LC
usable as
CONSTRAINT
Variable Type
DRESP
SHAPE_C
Damage value from

durability analysis
with loadcase information.
NOTE:
Mustuse ONF 601.
TOPO_S
TOPO_S
Measurement of the
amount of intermediate densities.
DISP_ABS
BEAD_S
SIZE
TOPO_S
BEAD_S
SIZE
TOPO_S
Absolute nodal displacement.
DISP_X
BEAD_S
SIZE
TOPO_S
BEAD_S
SIZE
TOPO_S
Nodal displacement
in x-direction for
global coordinate
system or in an user
defined coordinate
system.
DISP_X_ABS
BEAD_S
SIZE
TOPO_S
BEAD_S
SIZE
TOPO_S
Absolute nodal displacement in x-direction for global

coordinate system or
in an user defined
coordinate system.
DISP_Y
BEAD_S
SIZE
TOPO_S
BEAD_S
SIZE
TOPO_S
Nodal displacement
in y-direction for
global coordinate
defined coordinate
system.
DISP_Y_ABS
BEAD_S
SIZE
TOPO_S
BEAD_S
SIZE
TOPO_S
Absolute nodal displacement in y-direction for global

in an user defined
coordinate system.
Loadcase
dependent
Selection
area
usable as
CONSTRAINT
usable as
OBJ_FUNC
Description
DISP_Z
BEAD_S
SIZE
TOPO_S
BEAD_S
SIZE
TOPO_S
Nodal displacement
in z-direction for
global coordinate
defined coordinate
system.
DISP_Z_ABS
BEAD_S
SIZE
TOPO_S
BEAD_S
SIZE
TOPO_S
Absolute nodal displacement in z-direction for global

in an user defined
coordinate system.
DYN_FREQ
BEAD_S
SIZE
TOPO_S
BEAD_C
BEAD_S
SHAPE_C
SIZE
TOPO_S
Eigenfrequency from
modal analysis.
DYN_FREQ_
KREISSEL
BEAD_S
SHAPE_C
SIZE
TOPO_S
Eigenfrequency calculated with Kreisselmaier-Steinhauser

formula.
SIZE
TOPO_S
SIZE
TOPO_S
Energy stiffness
measure
ENERGY_
STIFF_
MEASURE
INERTIA_XX
TOPO_S
SIZE
BEAD_S
TOPO_S
SIZE
BEAD_S
Moment of inertia
around x-x-direction.
INERTIA_XY
TOPO_S
SIZE
BEAD_S
TOPO_S
SIZE
BEAD_S
Moment of inertia
around x-y-direction.
INERTIA_XZ
TOPO_S
SIZE
BEAD_S
TOPO_S
SIZE
BEAD_S
Moment of inertia
around x-z-direction.
INERTIA_YY
TOPO_S
SIZE
BEAD_S
TOPO_S
SIZE
BEAD_S
Moment of inertia
around y-y-direction.
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Version
Version
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Variable Type
SIMULIA
Tosca Structure
SIMULIA
Tosca Structure
usable as
OBJ_FUNC
Description
TOPO_S
SIZE
BEAD_S
TOPO_S
SIZE
BEAD_S
Moment of inertia
around y-z-direction.
INERTIA_ZZ
TOPO_S
SIZE
BEAD_S
TOPO_S
SIZE
BEAD_S
Moment of inertia
around z-z-direction.
INTERNAL_
FORCE_ABS
NE
BEAD_S
SIZE
TOPO_S
BEAD_S
SIZE
TOPO_S
Absolute nodal internal force .
INTERNAL_
FORCE_X
NE
BEAD_S
SIZE
TOPO_S
BEAD_S
SIZE
TOPO_S
Nodal internal force

in x-direction for
global coordinate
defined coordinate
system.
INTERNAL_
FORCE_
X_ABS
NE
BEAD_S
SIZE
TOPO_S
BEAD_S
SIZE
TOPO_S
Absolute nodal internal force in x-direction for global

in an user defined
coordinate system.
INTERNAL_
FORCE_Y
NE
BEAD_S
SIZE
TOPO_S
BEAD_S
SIZE
TOPO_S

in y-direction for
global coordinate
defined coordinate
system.
INTERNAL_
FORCE_
Y_ABS
NE
BEAD_S
SIZE
TOPO_S
BEAD_S
SIZE
TOPO_S
Absolute nodal internal force in y-direction for global

in an user defined
coordinate system.
www.3ds.com/tosca
Version 8.1.0 Rev. 1 - 05.2014
Selection
area
E
Loadcase
dependent
INERTIA_YZ
Variable Type
usable as
CONSTRAINT
DRESP
usable as
CONSTRAINT
usable as
OBJ_FUNC
Description
NE
BEAD_S
SIZE
TOPO_S
BEAD_S
SIZE
TOPO_S

in z-direction for
global coordinate
defined coordinate
system.
INTERNAL_
FORCE_Z_ABS
NE
BEAD_S
SIZE
TOPO_S
BEAD_S
SIZE
TOPO_S
Absolute nodal internal force in z-direction for global

in an user defined
coordinate system.
INTERNAL_
MOMENT_ABS
NE
BEAD_S
SIZE
TOPO_S
BEAD_S
SIZE
TOPO_S
Absolute nodal internal moment.
INTERNAL_
MOMENT_X
NE
BEAD_S
SIZE
TOPO_S
BEAD_S
SIZE
TOPO_S
Nodal internal
moment around xdirection for global
in an user defined
coordinate system.
INTERNAL_
MOMENT_X_
ABS
NE
BEAD_S
SIZE
TOPO_S
BEAD_S
SIZE
TOPO_S
Absolute nodal internal moment around

x-direction for global
in an user defined
coordinate system.
INTERNAL_
MOMENT_Y
NE
BEAD_S
SIZE
TOPO_S
BEAD_S
SIZE
TOPO_S
Nodal internal
moment around ydirection for global
in an user defined
coordinate system.
INTERNAL_
MOMENT_Y_
ABS
NE
BEAD_S
SIZE
TOPO_S
BEAD_S
SIZE
TOPO_S

y-direction for global
in an user defined
coordinate system.
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Version
Version
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Selection
area
INTERNAL_
FORCE_Z
Variable Type
Loadcase
dependent
SIMULIA
Tosca Structure
SIMULIA
Tosca Structure
Selection
area
usable as
CONSTRAINT
usable as
OBJ_FUNC
Description
INTERNAL_
MOMENT_Z
NE
BEAD_S
SIZE
TOPO_S
BEAD_S
SIZE
TOPO_S
Nodal internal
moment around zdirection for global
in an user defined
coordinate system.
INTERNAL_
MOMENT_Z_
ABS
NE
BEAD_S
SIZE
TOPO_S
BEAD_S
SIZE
TOPO_S

z-direction for global
in an user defined
coordinate system.
REACTION_
FORCE_ABS
BEAD_S
SIZE
TOPO_S
BEAD_S
SIZE
TOPO_S
Absolute nodal reaction force.
REACTION_
FORCE_X
BEAD_S
SIZE
TOPO_S
BEAD_S
SIZE
TOPO_S
Nodal reaction force

in x-direction for
global coordinate
defined coordinate
system.
REACTION_
FORCE_
X_ABS
BEAD_S
SIZE
TOPO_S
BEAD_S
SIZE
TOPO_S
Absolute nodal reaction force in x-direction for global

in an user defined
coordinate system.
REACTION_
FORCE_Y
BEAD_S
SIZE
TOPO_S
BEAD_S
SIZE
TOPO_S

in y-direction for
global coordinate
defined coordinate
system.
REACTION_
FORCE_
Y_ABS
BEAD_S
SIZE
TOPO_S
BEAD_S
SIZE
TOPO_S
Absolute nodal reaction force in y-direction for global

in an user defined
coordinate system.
www.3ds.com/tosca
Version 8.1.0 Rev. 1 - 05.2014
Variable Type
Loadcase
dependent
DRESP
usable as
CONSTRAINT
usable as
OBJ_FUNC
Description
BEAD_S
SIZE
TOPO_S
BEAD_S
SIZE
TOPO_S

in z-direction for
global coordinate
defined coordinate
system.
REACTION_
FORCE_Z_ABS
BEAD_S
SIZE
TOPO_S
BEAD_S
SIZE
TOPO_S
Absolute nodal reaction force in z-direction for global

in an user defined
coordinate system.
REACTION_
MOMENT_ABS
BEAD_S
SIZE
TOPO_S
BEAD_S
SIZE
TOPO_S
Absolute nodal reaction moment.
REACTION_
MOMENT_X
BEAD_S
SIZE
TOPO_S
BEAD_S
SIZE
TOPO_S
Nodal reaction
moment around xdirection for global
in an user defined
coordinate system.
REACTION_
MOMENT_X_
ABS
BEAD_S
SIZE
TOPO_S
BEAD_S
SIZE
TOPO_S
Absolute nodal reaction moment around

x-direction for global
in an user defined
coordinate system.
REACTION_
MOMENT_Y
BEAD_S
SIZE
TOPO_S
BEAD_S
SIZE
TOPO_S
Nodal reaction
moment around ydirection for global
in an user defined
coordinate system.
REACTION_
MOMENT_Y_
ABS
BEAD_S
SIZE
TOPO_S
BEAD_S
SIZE
TOPO_S

y-direction for global
in an user defined
coordinate system.
www.3ds.com/tosca
Version
Version
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- 05.2014
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Selection
area
REACTION_
FORCE_Z
Variable Type
Loadcase
dependent
SIMULIA
Tosca Structure
SIMULIA
Tosca Structure
Selection
area
usable as
CONSTRAINT
usable as
OBJ_FUNC
Description
REACTION_
MOMENT_Z
BEAD_S
SIZE
TOPO_S
BEAD_S
SIZE
TOPO_S
Nodal reaction
moment around zdirection for global
in an user defined
coordinate system.
REACTION_
MOMENT_Z_
ABS
BEAD_S
SIZE
TOPO_S
BEAD_S
SIZE
TOPO_S

z-direction for global
in an user defined
coordinate system.
ROT_ABS
BEAD_S
SIZE
TOPO_S
BEAD_S
SIZE
TOPO_S
Absolute rotation.
ROT_X
BEAD_S
SIZE
TOPO_S
BEAD_S
SIZE
TOPO_S
Nodal rotation around

x-axis for global coordinate system or in
an user defined coordinate system.
ROT_X_ABS
BEAD_S
SIZE
TOPO_S
BEAD_S
SIZE
TOPO_S
Absolute nodal rotation around x-axis for

global coordinate
defined coordinate
system.
ROT_Y
BEAD_S
SIZE
TOPO_S
BEAD_S
SIZE
TOPO_S

y-axis for global coordinate system or in
ROT_Y_ABS
BEAD_S
SIZE
TOPO_S
BEAD_S
SIZE
TOPO_S
Absolute nodal rotation around y-axis for

global coordinate
defined coordinate
system.
www.3ds.com/tosca
Version 8.1.0 Rev. 1 - 05.2014
Variable Type
Loadcase
dependent
DRESP
Loadcase
dependent
Selection
area
usable as
CONSTRAINT
usable as
OBJ_FUNC
Description
ROT_Z
BEAD_S
SIZE
TOPO_S
BEAD_S
SIZE
TOPO_S

z-axis for global coordinate system or in
ROT_Z_ABS
BEAD_S
SIZE
TOPO_S
BEAD_S
SIZE
TOPO_S
Absolute nodal rotation around z-axis for

global coordinate
defined coordinate
system.
SIG_1
E/N
SHAPE_C
Maximum principal
stress.
SIG_2
E/N
SHAPE_C
2nd. principal stress.
SIG_3
E/N
SHAPE_C
Minimum principal
stress.
SIG_11
E/N
SHAPE_C
11-component of
stress tensor.
SIG_22
E/N
SHAPE_C
22-component of
stress tensor.
SIG_33
E/N
SHAPE_C
33-component of
stress tensor.
SIG_12
E/N
SHAPE_C
12-component of
stress tensor.
SIG_23
E/N
SHAPE_C
23-component of
stress tensor.
SIG_13
E/N
SHAPE_C
13-component of
stress tensor.
SIG_ABS_123
E/N
SHAPE_C
Maximum of the
absolute value of the
principal stresses.
SIG_ABS_3
E/N
SHAPE_C
Absolute value of the

minimum principal
stress.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Variable Type
SIMULIA
Tosca Structure
SIMULIA
Tosca Structure
Loadcase
dependent
Selection
area
usable as
OBJ_FUNC
Description
usable as
CONSTRAINT
Variable Type
www.3ds.com/tosca
Version 8.1.0 Rev. 1 - 05.2014
DRESP
SIG_BELTRAMI
E/N
SHAPE_C
Beltrami stress
hypothesis.
SIG_CONTACT
_PRESSURE
SHAPE_C
Contact stress pressure.
SIG_CONTACT
_SHEAR
SHAPE_C
Total shear contact

stress.
SIG_CONTACT
_SHEAR_X
SHAPE_C
Shear X Contact
stress.
SIG_CONTACT
_SHEAR_Y
SHAPE_C
Shear Y Contact
stress.
SIG_CONTACT
_TOTAL
SHAPE_C
Total Contact stress.
SIG_DRUCKER
_PRAGER
E/N
SHAPE_C
Drucker-Prager
stress hypothesis.
SIG_GALILEI
E/N
SHAPE_C
Galilei stress hypothesis.
SIG_KUHN
E/N
SHAPE_C
Kuhn stress hypothesis.
SIG_
MARIOTTE
E/N
SHAPE_C
Mariotte stress
hypothesis.
SIG_MISES
E/N
SHAPE_C
von Mises stress

hypothesis.
SIG_TOPO_
MISES
TOPO_S
Scaled centroidal von

Mises stress.
SIG_SANDEL
E/N
SHAPE_C
Sandel stress
hypothesis.
SIG_SAUTER
E/N
SHAPE_C
Sauter stress hypothesis.
SIG_TRESCA
E/N
SHAPE_C
Tresca stress hypothesis.
STRAIN_
ELASTIC
SHAPE_C
Elastic Strain.
Only Abaqus and
ANSYS
TOPO_S
usable as
OBJ_FUNC
Description
STRAIN_
PLASTIC
SHAPE_C
Plastic Strain.
Only Abaqus and
ANSYS
STRAIN_
TOTAL
SHAPE_C
Total Strain (elastic +

plastic).
Only Abaqus and
ANSYS
STRAIN_
ENERGY
E/N
BEAD_C
BEAD_S
SIZE
TOPO_C
TOPO_S
Strain energy.
STRAIN_
ENERGY_
DENS
E/N
SHAPE_C
Strain energy density.
BEAD_S
SIZE
TOPO_S
VOLUME
SHAPE_C
SIZE
TOPO_C
TOPO_S
SIZE
TOPO_S
Volume of element.
WEIGHT
SHAPE_C
SIZE
TOPO_S
SIZE
TOPO_S
Weight of element.
Selection area for DEF_TYPE = SYSTEM
EL_GROUP
= <name_of_element_group>
Name of an element
group in which the value
of the design response is
to be determined.
ND_GROUP
= <name_of_node_group>
Name of a node group in

which the value of the
design response is to be
determined.
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
Selection
area
usable as
CONSTRAINT
Loadcase
dependent
Variable Type
SIMULIA
Tosca Structure
SIMULIA
Tosca Structure
DRESP
ELEM
= <number_of_element>
Number of an element to
be used for the design
response (alternative to
EL_GROUP).
NODE
= <number_of_node>
Number of a node to be
used for the design
ND_GROUP).
CS_REF
= <coordinate_system>
Default coordinate system is the global coordinate system CS_0.

Can be used for displacements, internal forces,
reaction forces,center of
gravity and accelerations.
GROUP_
OPER
Operator for determining the design

response that is used within the
selection area.
= MAX
Maximum value of the

selection area.
= MIN
Minimum value of the

selection area.
= SUM
Sum of all values of the

selection area.
= COUNT
Determines the number

of values of the selection
area.
www.3ds.com/tosca
Version 8.1.0 Rev. 1 - 05.2014
Items for loadcase dependent design responses (DEF_TYPE=SYSTEM)

LC_SET: Loadcase combination used to determine the value of the design
response (can be specified several times). If the LC_SET option is not specified the default setting LC_SET = ALL, ALL, ALL is assumed.
LC_SET = <approach>, <loadcase>, <substep>, <shell_layer>
<approach>
Approach / analysis type

ALL
All analysis types will be considered
STATIC
Static analysis
MODAL
Modal analysis
NONLINEAR
Non-linear analysis
SIMULIA
Tosca Structure
DAMAGE
Durability analysis
<loadcase>
Load case
ALL
All load cases will be considered
<no_of_loadcase>
Number of a specific load case
<substep>
Substep
ALL
All substeps will be considered
<no_of_substep>
Number of a specific substep
<shell_layer>
Location for calculation of shell

stresses
TOP
Top-layer of shell
MID
Mid-layer of shell (part of membrane)
BOT
Bottom layer of shell
MAX
max (TOP, MID, BOT)
MIN
min (TOP, MID, BOT)
= MAX

selected load cases (see
LC_SET)
= MIN
Minimum value of the selected

load cases (see LC_SET)
= SUM
SUM of the selected load

cases (see LC_SET)
Combination of design responses (DEF_TYPE = OPER) for the sensitivity

based algorithms
VAR_
OPER
Operator linking the variables VAR_A to VAR_D

Operators with 2 operands
= SUB
Subtraction
A-B
= SUB_ABS
absolute value of the

Subtraction
|A-B|
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Combination of selected loadcase
LC_SEL
SIMULIA
Tosca Structure
DRESP
Operator with up to 10
operands
= COMBINE
weighted sum of up to
10 Variables
Var1*w1 +
Var2*w2 +...
Specifying the operands for SUB and SUB_ABS

with their ID_NAME
VAR_A
= <var_id_a>
VAR_B
= <var_id_b>
VARIABLE
Specification of operands
for COMBINE with their
ID_NAME
Can be specified several times
= <var_id>,<weight>
only displacements and

rotations, modal eigenfrequencies or reaction
forces and internal
forces are allowed
if the weight parameter
is not specified it is
assumed to be 1
Combination of design responses (DEF_TYPE = OPER) for the controller

based algorithms
VAR_OPER Operator linking the variables VAR_A to
VAR_D
www.3ds.com/tosca
Version 8.1.0 Rev. 1 - 05.2014
Operators with 2 to 4
operands
= ADD
Addition
A+B+C+D
= MULT
Multiplication
A*B*C*D
= MIN
Minimun
min(A,B,C,D)
= MAX
Maximum
max(A,B,C,D)
= SUB
Subtraction
A-B
= DIV
Division
A/B
Operators with 1 operand
= ABS
absolute value
abs(A)
= SIN
Sinus
sin(A)
= COS
Cosinus
cos(A)
= CUT_OFF
Cutoff Operator
to remove peaks
(parameters are
specified with
additional settings)
max
(CUT_OFF_LOW,
min(A,CUT_OFF
_HIGH))
= TAN
Tangens
tan(A)
= LOG
Common logarithm
log(A)
= EXP
Exponential
function
exp(A)
= FILTER
Filter function for

vectors used as
terms for the
controller based
algorithms
(parameters are
specified with
additional settings)
filter(A)
= LN
Nat. Logarithm
ln(A)
= NORM
Norm for vectors (maximum

norm) used as
terms for the
controller based
algorithms
= NORM_FIRST
Norm for vectors (maximum

norm) used as
terms for the
controller based
algorithms
(norm value
(highest value is
determined in
the first iteration)
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SIMULIA
Tosca Structure
SIMULIA
Tosca Structure
www.3ds.com/tosca
Version 8.1.0 Rev. 1 - 05.2014
DRESP
= NPOWER
N-th power to A
(parameter is
specified with
EXPONENT
Item)
= NROOT
N-th root
(parameter is
specified with
EXPONENT
Item)
= SQRT
Square root
sqrt(A)
= INT
Integer
int(A)
= NINT
Nearest integer
number
nint(A)
= SIGN
Sign function
sign(A)
= DELTA_1
Difference
between
2 iterations
A(i) - A(i-1)
= DELTA_2
Difference
between
2 iterations
A(i) - A(i-2)
= DELTA_3
Difference
between
2 iterations
A(i) - A(i-3)
= DELTA_4
Difference
between
2 iterations
A(i) - A(i-4)
= DELTA_5
Difference
between
2 iterations
A(i) - A(i-5)
= DELTA_6
Difference
between
2 iterations
A(i) - A(i-6)
Operators with up to 10
operands
operands
defined by item
VARIABLE
SIMULIA
Tosca Structure
= COMBINE
weighted addition
w1*VAR1 +
w2*VAR2 ...
Specifying the operands with their ID_NAME

= <var_id_a>
VAR_B
= <var_id_b>
VAR_C
= <var_id_c>
VAR_D
= <var_id_d>
Additional settings for the

operator FILTER
See also:
RADIUS
= <radius value>
real value
The radius defines

the maximum distance for influencing neighbour
nodes
EXPONENT
= <exponent value>
real value
(default:1.0)
SIGMA
= <value>
real value
Sigma defines the

reduction of the
radius depending
on the surface
bending
(default:0.2)
vol.2 chapter
6.8.4, Filter
function for the
optimization
displacements
(FILTER)
Additional settings for the

operator CUT_OFF
CUT_OFF_
LOW
= <value>
real value
Lower bound of the

vector value. All
values under this
value will be
treated as zero.
CUT_OFF_
HIGH
= <value>
real value
Upper bound of the

vector value. All
values higher than
this value will be
set to the cut off
value.
Operands for VAR_OPER = COMBINE
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VAR_A
SIMULIA
Tosca Structure
DRESP
VARIABLE
= <var_id_1>,
<weight1>
ID_NAME of
variable VAR1
with weight factor w1 (default 1)
for combination
up to 10 different variables can be specified
Remarks
1. No variables with TYPE FIX are permitted, i.e. DESIGN RESPONSE is
determined using SYSTEM or OPER type.
2. DESIGN RESPONSES are a special type of VARIABLES with a limited set
of possible types and definition types
3. Relative DESIGN RESPONSES can be created by defining two design
responses with the same type and def_type and with the definition of an
OPER design response which creates the difference in the values of the
first two design responses. The node- or element groups can only contain
one node or element per definition.
www.3ds.com/tosca
Version 8.1.0 Rev. 1 - 05.2014
4. Only variables of TYPE DISP_X, DISP_Y, DISP_Z and ROT_X, ROT_Y,

ROT_Z and REACTION_FORCE_X, REACTION_FORCE_Y,
REACTION_FORCE_Z and REACTION_MOMENT_X,
REACTION_MOMENT_Y, REACTION_MOMENT_Z and
INTERNAL_FORCE_X, INTERNAL_FORCE_Y, INTERNAL_FORCE_Z
and INTERNAL_MOMENT_X, INTERNAL_MOMENT_Y,
INTERNAL_MOMENT_Z are admitted for VAR_OPER = SUB, SUB_ABS
or COMBINE. Absolute displacements are not allowed for combination
(COMBINE). Mean values of displacements can be calculated using this
option, see example beneath.
5. Design Responses can only be combined using DEF_TYPE = OPER if
they refer to the same group.
6. For sensitivity based topology optimization design responses can only be
combined using DEF_TYPE = OPER if they refer to the same loadcases.
Combination of design responses with OPER cannot be done for two separate loadcases.
7. The parameter VARIABLE can also be used to define operands for
VAR_OPER = SUB or SUB_ABS. In this case only two entries are
admitted, weights are not admissible and their order is significant.
SIMULIA
Tosca Structure
8. For center of gravity and moment of inertia, the reference coordinate

system is always interpreted as rectangular (Cartesian) coordinate system.
Cylindrical and spherical coordinate systems are not supported.
9. Plastic strain values (TYPE = STRAIN_PLASTIC) are calculated by Tosca
Structure and may differ slightly from your solver results.
Examples
Load case independent:
DRESP
ID_NAME
DEF_TYPE
TYPE
GROUP_OPER
EL_GROUP
=
=
=
=
=
volume
SYSTEM
VOLUME
SUM
all_elements
=
=
=
=
=
first_eign_freq
SYSTEM
DYN_FREQ
MIN
MODAL,1, ALL
END_
Load case dependent:

DRESP
ID_NAME
DEF_TYPE
TYPE
LC_SEL
LC_SET
END_
Relative displacement of two nodes:
ID_NAME
DEF_TYPE
TYPE
LC_SEL
LC_SET
NODE
=
=
=
=
=
=
disp_x_first_node
SYSTEM
DISP_X
MAX
STATIC,1, ALL
3399
=
=
=
=
=
=
disp_x_second_node
SYSTEM
DISP_X
MAX
STATIC,1, ALL
3398
END_
DRESP
ID_NAME
DEF_TYPE
TYPE
LC_SEL
LC_SET
NODE
END_
DRESP
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
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- 05.2014
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DRESP
SIMULIA
Tosca Structure
DRESP
ID_NAME
DEF_TYPE
VAR_A
VAR_B
VAR_OPER
=
=
=
=
=
relative_displacement
OPER
disp_x_first_node
disp_x_second_node
SUB_ABS
END_
Mean displacement of two nodes (Variable definition see above):

DRESP
ID_NAME
DEF_TYPE
VARIABLE
VARIABLE
VAR_OPER
=
=
=
=
=
mean_displacement
OPER
disp_x_first_node,0.5
disp_x_second_node,0.5
COMBINE
www.3ds.com/tosca
Version 8.1.0 Rev. 1 - 05.2014
END_
SIMULIA
Tosca Structure
DVCON_AUTO_SHAPE
Automatic generation of design variable constraints (DVCON_SHAPE commands) with link conditions (LINK_SHAPE command) for shape optimization.
ID_NAME
=<id_family_name_
dvcon_shape>*
Name of the
DVCON_AUTO_SHAPE
definition. This ID_NAME
will also be used as family name for the
DVCON_SHAPE definitions.
ND_GROUP
_FAMILY
= <nd_group_family_name>*
Family name of the node

groups which are
selected for the coupling
using the
definitions.
CHECK_
LINK
= <link_shape_name>
Name of the
LINK_SHAPE definition
Remarks
2. This command can be used quite well in combination with

GROUP_AUTO_DEF because the child groups begin with the same prefix.
In referencing the group names in DVCON_AUTO_SHAPE, the underline _
after the family name is very important because otherwise the
DVCON_SHAPE entry is also set for the parent group. This can lead to
unwanted side effects.
Examples
DVCON_AUTO_SHAPE
ID_NAME
= my_dvcon_*
ND_GROUP_FAMILY= ND_SIDE_A_*
CHECK_LINK
= my_link_shape_01
END_
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Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
1. The operators ID_NAME and ND_GROUP_FAMILY are given the symbol *

to identify the use of a family name in the command. The symbol represents any string of symbols and must be entered for both operators. Each
node group with the given family name receives a design variable
constraint with the present family name. The string of symbols * given to
the node group (supplementary to the full name of the node group) is
defined and listed as having the identical string of characters * to the
ID_NAME of the generated DVCON_SHAPE.
SIMULIA
Tosca Structure
DVCON_BEAD
DVCON_BEAD
www.3ds.com/tosca
Version 8.1.0 Rev. 1 - 05.2014
Defines restrictions of the design variables in bead optimization. For more

detailed information see vol.2 chapter 7.3.2, Restrictions (DVCON_BEAD) in
the Tosca Structure 8.1.0 user manual.
ID_NAME
= <name_of_dvcon_shape>
Name of the
DVCON_BEAD definition
ND_GROUP
Name of the node group

which is valid for the
restriction.
CHECK_
SOLID
= <solid_name>
Name of the solid which

is checked for penetration
CHECK_
ELGR
Name of the element

group which is checked
for penetration
CHECK_
GROW
= <grow_value>
Maximum grow value

(referring to the initial
design)
(grow_value 0 )
CHECK_
SHRINK
= <shrink_value>
Maximum shrink value

(referring to optimization
displacement in the negative normal direction of
the initial design). Only
allowed for sensitivity
based bead optimization.(shrink_value
0)
CHECK_BC
= YES
= NO
Accepts (YES) or ignores

(NO) the nodal fixations
read by the FE-interface
as constraints on the
selected node group.
CHECK_DOF
= <cs_name>,<dof1>,<dof2>,
<dof3>
(<dof*> = FIX, FREE)
The displacement in the

corresponding coordinate
direction in the referenced coordinate system is constrained (FIX)
or allowed (FREE).
Default = FREE
CHECK_LINK
= <link_shape_name>
Assign a LINK_BEAD
definition.
SIMULIA
Tosca Structure
Remarks
1. CHECK_SOLID (up to 6 operators with CHECK_SOLID are permitted) is
the name of a solid already defined (SOLID). All nodes are checked for
penetration in the solid (restricted solid) and against leaving the solid area
(variational solid).
2. CHECK_ELGR (up to 6 operators with CHECK_ELGR are permitted) is the
name of an element group already defined. All nodes in the node group
(ND_GROUP) are checked for penetrating the element group.
3. CHECK_BC (optional): YES -> The boundary conditions that are loaded
with OPTIONS,READ_BC = ALL, are considered for the nodes of the node
group. NO -> The BC entries are not considered.
4. CHECK_DOF (optional): Fixing the named node coordinates with FIX to
the given coordinate system.
5. When several CHECK_* entries are specified in a DVCON_BEAD definition, they are used in the following sequence: CHECK_GROW,
CHECK_SOLID, CHECK_ELGR, CHECK_SPC, CHECK_DOF. If there are
conflicts in the sequence of the CHECK_* entries, the last entry overwrites
the previous one. If there are no conflicts in the sequence of the CHECK_*
entries, all the defined restrictions are considered.
6. CHECK_LINK can only be called with the design variable node-group
(defined in DV_BEAD)
Examples
ID_NAME
ND_GROUP
CHECK_DOF
CHECK_GROW
=
=
=
=
my_dvcon_bead_01
nd_side_a
csys1, FREE, FIX, FIX
5.0
END_
DVCON_BEAD
ID_NAME
CHECK_LINK
ND_GROUP
END_
= my_bead_symmetry_link
= my_link_condition
= my_design_variables
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Version
Version
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- 05.2014
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DVCON_BEAD
SIMULIA
Tosca Structure
DVCON_SHAPE
DVCON_SHAPE
Defines restrictions of the design variables in shape optimization. For more
detailed information see vol.2 chapter 6.3.3, Restrictions (DVCON_SHAPE)
in the Tosca Structure 8.1.0 user manual.
ID_NAME
= <name_of_dvcon_shape>
Name of the
DVCON_SHAPE definition
ND_GROUP

which is valid for the
restriction. The node
group should be a subset
of the nodes of the
MESH_SMOOTH command.
CHECK_
GROW
= <grow_value>
Maximum grow value

design)
( grow_value 0 )
CHECK_
SHRINK
= <shrink_value>
Maximum shrink value

design)
www.3ds.com/tosca
Version 8.1.0 Rev. 1 - 05.2014
( shrink_value 0 )
CHECK_
MIN_MEM
= <radius>
Minimum member size:

orthogonal to the surface
material of minimum
2*radius thickness must
remain
CHECK_
MAX_MEM
= <radius>
Maximum member size:

orthogonal to the surface
material of maximum
2*radius thickness must
remain
CHECK_
SOLID
= <solid_name>
Name of the solid which

is checked for penetration
CHECK_
ELGR
Name of the element

group which is checked
for penetration
CHECK_
NDGR
=<membersize_check_node_gro
up>
Name of surface node

group for check of membersize
SIMULIA
Tosca Structure
CHECK_BC
= YES
= NO (default)
Accepts (YES) or ignores

(NO) the nodal fixations
read by the FE-interface
as constraints on the
selected node group.
CHECK_DOF
= <cs_name>,<dof1>,<dof2>,
<dof3>
(<dof*> = FIX, FREE)
The displacement in the

corresponding coordinate
direction in the referenced coordinate system is constrained (FIX)
or allowed (FREE).
Default = FREE
CHECK_
SLIDE
= <link_shape_name>
Assign a slide surface

defined with a
LINK_SHAPE command.
CHECK_LINK
= <link_shape_name>
Assign a LINK_SHAPE
definition.
FEASIBLE_
START
= YES (default)
= NO
premise feasible node

group (YES) or accept
infeasible node group
(NO) in the start model
TOLERANCE
=<tolerance_value>
Tolerance value for membersize check (absolute

positive real value)
Remarks
2. CHECK_ELGR (up to 6 operators with CHECK_ELGR are permitted) is the

name of an element group already defined. All nodes in the node group
(ND_GROUP) are checked for penetrating the element group. Shell and
element groups are admitted.
3. CHECK_SPC (optional): YES -> The boundary conditions that are loaded
with OPTIONS, READ_BC = ALL, are considered for the nodes of the node
group. NO -> The BC entries are not considered.
4. CHECK_DOF (optional): Fixing the node coordinates named with FIX for
the given coordinate system.
5. CHECK_LINK (optional): Identification name of a link condition (defined
with LINK_SHAPE) which should be used for the node group.
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1. CHECK_SOLID (up to 6 operators with CHECK_SOLID are permitted) is

the name of a solid already defined (SOLID). All nodes are checked for
penetrating the solid (restricted solid) and against leaving the solid area
(variational solid), respectively.
SIMULIA
Tosca Structure
DVCON_SHAPE
6. When several CHECK_* entries are specified in a DVCON_SHAPE definition, they are used in the following sequence: CHECK_GROW /
CHECK_SHRINK, CHECK_MAX_MEM, CHECK_MIN_MEM,
CHECK_SOLID, CHECK_ELGR, CHECK_SPC, CHECK_DOF,
CHECK_LINK. If there are conflicts in the sequence of the CHECK_*
entries, the last entry overwrites the previous one. If there are no conflicts
in the sequence of the CHECK_* entries, all the defined restrictions are
considered.
7. Apart from CHECK_SOLID and CHECK_ELGR entries (which can be used
up to 6 times) only one entry of each other type is admitted in a
DVCON_SHAPE definition. That means, e.g., that I cannot combine two
CHECK_LINK entries in one DVCON_SHAPE definition but have to define
two DVCON_SHAPE entries instead. On the other hand, one
CHECK_LINK and CHECK_SPC entry, for example, can be combined.
Examples
DVCON_SHAPE
ID_NAME
ND_GROUP
CHECK_DOF
CHECK_GROW
=
=
=
=
my_dvcon_shape_01
nd_side_a
csys1, FREE, FIX, FIX
5.0
www.3ds.com/tosca
Version 8.1.0 Rev. 1 - 05.2014
END_
SIMULIA
Tosca Structure
DVCON_SIZING
Defines restrictions of the design variables in sizing optimization. For more
detailed information see vol.2 chapter 8.3.2, Manufacturing conditions and
geometrical restrictions in the Tosca Structure 8.1.0 user manual.
ID_NAME
= <name_of_dvcon_sizing>
Name of the
DVCON_SIZING definition
EL_GROUP
Name of an element
group already defined
with which
DVCON_SIZING should
react.
= FROZEN
All elements of the element group <name_of_

element_group> which
do not undergo any
changes during optimization.
= THICKNESS_BOUNDS
Upper and lower bounds

(relative or absolute) for
shell thickness
= CLUSTER_GROUPS
Clustering of shell elements with the same

shell thickness. Several
EL_GROUP items can
be defined with this
CHECK_TYPE.
= MIN_CLUSTER_WIDTH
Minimum width filter (definition of the minimum

width of structures of
same shell thickness created by sizing)
= LINK_SIZING
Definition of symmetry
and link conditions
Items for CHECK_TYPE = THICKNESS_BOUNDS
MAGNITUDE = REL
= ABS
Relative (relative x start

value) or absolute value
for choice of shell thickness
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CHECK_
TYPE
SIMULIA
Tosca Structure
DVCON_SIZING
LOWER_
BOUND
=<lower_bound>
Lower bound for shell

thickness. For MAGNITUDE=REL the lowest
value for shell thickness
is lower_bound x
initial_shell_
thickness
UPPER_
BOUND
=<upper_bound>
Upper bound for shell

thickness. For MAGNITUDE=REL the highest
value for shell thickness
is upper_bound x
initial_shell_
thickness
Items for CHECK_TYPE = MIN_MEMBER

WIDTH
= <width>
Minimum width of the

structure
www.3ds.com/tosca
Version 8.1.0 Rev. 1 - 05.2014
Items for CHECK_TYPE = LINK_SIZING
CHECK_
LINK
= <name_of_link_sizing>
Reference of the corresponding LINK_SIZING

definition.
RADIUS
= <radius>
The specification of the

radius is optional. If a
radius value is specified,
it should be about 50% of
the average element
edge length.
Remarks
1. The element group which should be restricted must be a subset of the
referenced element group of DV_SIZING, i.e. all elements that should to be
restricted must lie in this design area.
2. For CHECK_TYPE = CLUSTER_GROUPS multiple element groups can
be assigned using EL_GROUP parameter several times.
3. For CHECK_TYPE = THICKNESS_BOUNDS relative values (positive real
values) can be used to create lower and upper bounds based on the initial
shell thickness. In this case the shell thicknesses can vary between
SIMULIA
Tosca Structure
lower_bound x initial_thickness and upper_bound x

initial_thickness.
4. The combination of a minimum member size constraint and a maximum
member size constraint is not allowed. Please use the MIN_WIDTH parameter in the maximum member size constraint instead!
Examples
DVCON_SIZING
ID_NAME
EL_GROUP
CHECK_TYPE
MAGNITUDE
LOWER_BOUND
UPPER_BOUND
=
=
=
=
=
=
my_dvcon_sizing_01
my_element_group
THICKNESS_BOUNDS
REL
0.8
1.2
=
=
=
=
my_dvcon_sizing_02
my_element_group1
my_element_group2
CLUSTER_GROUPS
END_
DVCON_SIZING
ID_NAME
EL_GROUP
EL_GROUP
CHECK_TYPE
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. 1Rev.
- 05.2014
1 - 05.2014
END_
SIMULIA
Tosca Structure
DVCON_TOPO
DVCON_TOPO
www.3ds.com/tosca
Version 8.1.0 Rev. 1 - 05.2014
Defines restrictions of the design variables in topology optimization. For more

detailed information see vol.2 chapter 5.3.2, Manufacturing conditions and
geometrical restrictions in the Tosca Structure 8.1.0 user manual.
ID_NAME
= <Id_name_of_dvcon_topo>
Name of the
DVCON_TOPO-definition
EL_GROUP
Name of an element
group already defined
with which
DVCON_TOPO should
react.
CHECK_
TYPE
= FROZEN
All elements of the element group

<name_of_element_grou
p> which do not undergo
any changes during optimization.
= CAST
Manufacturing restrictions to guarantee the

manufacturing of the elements
= MIN_MEMBER
Minimum Member Size

Filter (definition of the
minimum structural diameter)
= MAX_MEMBER
Maximum Member Size

Filter (definition of the
maximum structural
diameter)
= LINK_TOPO
Definition of symmetry
and link conditions
Items for CHECK_TYPE = MIN_MEMBER

THICKNESS
= <thickness>
Minimum thickness of the

structure
Items for CHECK_TYPE = MAX_MEMBER

THICKNESS
= <thickness>
Maximum thickness of
the structure
SIMULIA
Tosca Structure
DISTANCE
= <distance value>
Distance between two

supports for the maximum membersize control (optional, default = 0
= automatically determined )
MIN_
THICKNESS
= <thickness>
Minimum thickness of the

structure when using a
Maximum member size
constraint (optional,
defaults to THICKNESS)
The resulting structures
have a thickness
between
MIN_THICKNESS and
THICKNESS
Items for CHECK_TYPE = LINK_TOPO
CHECK_
LINK
= <name_of_link_topo>
Reference of the corresponding LINK_TOPO

definition.
RADIUS
= <radius>
The specification of the

radius is optional. If a
radius value is specified,
it should be about 50% of
the average element
edge length.
PULL_DIR
= <X_COMP>, <Y_COMP>,
<Z_COMP>
Pull direction for the element groups in the form

of a vector with reference
to CS_0
ANGLE
= <draft_angle>
Removal Angle (default

= 0), 0<= ANGLE < 20
CHECK_
GROUP
Name of the element

group which is used for
the collision check of the
removed elements.
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Items for CHECK_TYPE = CAST
SIMULIA
Tosca Structure
DVCON_TOPO
MID_PLANE
no definition of a central
plane, i.e. the elements
are only deformed in the
direction of PULL_DIR
= AUTO
Automatic determination
of the central plane.
Using the central plane
as the starting point. The
elements are removed
either in the direction of
the deformation or in the
opposite direction.
= AUTO_TIGHT
No holes are generated

in the central plane.
= POINT, <X_COMP>,
<Y_COMP>, <Z_COMP>
A point within the central

plane from which the
deformation vector is
positioned perpendicular
to.
= SURFACE
The elements are

demolded at the actual
surface of the DVCON
group.
= STAMP
The element group is

demolded keeping a
stampable structure.
= <name_of_coordinate_system>
Coordinate system for

the definition of the pull
direction. If a cylindrical
coordinate system is referenced, the casting
restrictions are performed in cylindrical coordinates.
(default = CS_0)
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PULL_CS
= NONE
SIMULIA
Tosca Structure
RADIUS
= <radius>
Specifying the radius is

optional.
If a value is entered, it
should be about 50% of
the average edge length
of the element. (This
value is used internally
for the collision check
during the removal of the
elements).
In Combination with MIDPLANE=AUTO_TIGHT
the thickness of the midplane is defined by
2*RADIUS.
CREATE_
PULL_
GROUP
= YES
= NO
Element groups for the

demolded elements are
automatically generated.
No elementgroups are
generated.
FILTER_MAT
= NO | YES
Additional material based

filtering after the optimization for stricter avoidance of undercuts.
Remarks
2. A check group must be entered for CHECK_TYPE=CAST. This can be an

upper set of design variables and must contain the element group that
needs to be restricted (operator EL_GROUP). The CHECK_GROUP is the
element group which will be checked for collision with the elements which
should be removed. If this group contains more elements than the optimization group, the elements outside the optimization group is considered to
be a barrier, i.e. the elements in the optimization group can not be
deformed "over" these element. For example, if an engine bracket is optimized and if a part of the engine block is still retained in the analysis model,
the check group should be restricted to the engine bracket because the
engine block does not play a significant role for the casting restriction of the
engine bracket during manufacture. If the engine bracket is connected to
the engine, the engine block must be added to the CHECK_GROUP, otherwise elements from the optimization area will be removed that must be
"drawn" from the engine block.
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1. The element group which should be restricted must be a subset of the

referenced element group of DV_TOPO, i.e. all elements that should to be
restricted must lie in this design area.
SIMULIA
Tosca Structure
DVCON_TOPO
3. If no RADIUS is entered for CHECK_TYPE=CAST, the optimization system

will decide the radius from the elements of the check group
(CHECK_GRP). The value is determined by the OUTPUT of the command.
(Specifying the value is only important for elements in a model that has
very different magnitudes.)
4. If the option CREATE_PULL_GROUP is selected, the elements are
grouped in the following element groups:
-
Elements in the group POS_DIR_.... positive demold direction

Elements in the group NEG_DIR_... negative demold direction
Elements in the group NO_PULL_... no demold
Elements in the group MID_PLANE_.. are elements of the mid plane
5. The combination of a minimum member size constraint and a maximum

member size constraint is not allowed. Please use the MIN_THICKNESS
parameter in the maximum member size constraint instead!
6. If no DISTANCE parameter is specified for
CHECK_TYPE=MAX_MEMBER in general the distance between two
supports will be at least the thickness value.
7. The maximum member size constraint can only be used with the sensitivity
based algorithm. Maximum member size constraints with the controller
algorithm are not supported.
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8. For a more strict avoidance of undercuts an additional material filter

(FILTER_MAT = YES) can be switched on which is applied after each optimization cycle. The optimization result is changed based on purely
geometric aspects. This may influence the objective values and even the
convergence in a negative way. Thus apply only, if the standard casting
restriction does not lead to sufficient results.
Examples
DVCON_TOPO
ID_NAME
EL_GROUP
CHECK_TYPE
= my_dvcon_topo_01
= el_grp_startarea
= FROZEN
END_
DVCON_TOPO
ID_NAME
EL_GROUP
CHECK_TYPE
= my_dvcon_topo_02
= el_grp_cast
= CAST
SIMULIA
Tosca Structure
CHECK_GROUP
PULL_DIR
MID_PLANE
= ALL_ELEMENTS
= 0.,0.,1.
= NONE
END_
DVCON_TOPO
ID_NAME
EL_GROUP
CHECK_TYPE
THICKNESS
MIN_THICKNESS
DISTANCE
=
=
=
=
=
=
my_dvcon_topo_03
el_grp_max_membersize
MAX_MEMBER
10.
2.
20.
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END_
SIMULIA
Tosca Structure
DV_BEAD
DV_BEAD
Definition of the design nodes for bead optimization. For more detailed information see vol.2 chapter 7.3.1, Design variables (DV_BEAD) in the Tosca
ID_NAME
= <id_name_of_dv_shape>
Name of the DV_BEAD

definition
ND_GROUP
Remarks
1. Only surface nodes are regarded as being DESIGN_NODES.
2. Single standing nodes are not regarded as being DESIGN_NODES.
3. Midside nodes are not considered to be DESIGN_NODES. The midside
nodes will be placed between the edge nodes at the end of the design
cycle.
4. Only nodes at shell elements may be defined as DESIGN_NODES
Examples
DV_BEAD
ID_NAME
ND_GROUP
= my_dv_bead
= design_node_grp
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END_
SIMULIA
Tosca Structure
DV_SHAPE
Definition of the design nodes for shape optimization. For more detailed information see vol.2 chapter 6.3.1, Design variables (DV_SHAPE) in the Tosca
ID_NAME
= <id_name_of_dv_shape>
Name of the DV_SHAPE

definition
ND_GROUP
Remarks
1. Only surface nodes are regarded as being DESIGN_NODES.
2. Single standing nodes are not regarded as being DESIGN_NODES.
3. Midside nodes are not considered to be DESIGN_NODES. The midside
nodes will be placed between the edge nodes at the end of the design
cycle.
Examples
DV_SHAPE
ID_NAME
ND_GROUP
= my_dv_shape
= design_node_grp
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SIMULIA
Tosca Structure
DV_SIZING
DV_SIZING
Definition of the design elements for sizing optimization. For more detailed
information see vol.2 chapter 5.3.1, Design variables in the Tosca Structure
8.1.0 user manual.
ID_NAME
= <id_name_of_dv_sizing>
Name of the DV_SIZING

definition
EL_GROUP
Name of the element

group
Remarks
1. All elements in the element group may be modified during optimization.
2. Only certain types of elements (for more information see vol.2 chapter 11,
Solver Specific Features) are permitted to be optimization elements. Tosca
Structure.sizing supports only single layered shells. All elements not
permitted are removed from the group.
Examples
DV_SIZING
ID_NAME
EL_GROUP
= dv_sizing_name
= design_elem_grp
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Version 8.1.0 Rev. 1 - 05.2014
END_
SIMULIA
Tosca Structure
DV_TOPO
Definition of the design elements for topology optimization. For more detailed
information see vol.2 chapter 5.3.1, Design variables in the Tosca Structure
8.1.0 user manual.
ID_NAME
= <id_name_of_dv_topo>
Name of the DV_TOPO

definition
EL_GROUP
Name of the element

group
INITIAL_DV_
FIELD
= <name_of_file>
Name of the file with the

initial material distribution field to be used for
the optimization
Remarks
1. All elements in the element group may be modified during optimization.
2. Only certain types of elements (for more information see the User Manual
or the Interface Manual) are permitted to be optimization elements. All
elements not permitted are removed from the group.
3. The INITIAL_DV_FIELD option is only available for sensitivity based optimization.
5. When using a material distribution of a previous optimization run for the

new optimization it is recommended to rename the file TP_XXX.onf (e.g. to
INITIAL_MAT.onf) . Otherwise name conflicts with the running optimization
(with newly generated material distribution files TP_YYY.onf) may lead to
confusion in the postprocessing: the start file TP_XXX.onf may be considered and shown as last iteration (if XXX is larger as the last iteration in the
actual optimization). (see also chapter 5.3.1.1 Results from previous runs
as initial material distribution).
6. The former parameter RESTART_FILE was renamed to
INITIAL_DV_FIELD to avoid confusion with the restart of unintentionally
stopped optimization runs (see vol.2 chapter 12.2.9, Restart modes).
7. INITIAL_DV_FIELD for topology optimization means an initial material
distribution for design variables.
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4. The RESTART File containing the initial material distribution must be

located in the start directory of the optimization job. The format of the
RESTART File has to be ONF (Optmization Neutral File). The initial material distribution is extracted from the datablock 740 with the title
MAT_PROP_NORMALIZED.
SIMULIA
Tosca Structure
DV_TOPO
Examples
DV_TOPO
ID_NAME
EL_GROUP
= dv_topo_name
= design_elem_grp
www.3ds.com/tosca
Version 8.1.0 Rev. 1 - 05.2014
END_
SIMULIA
Tosca Structure
FEM_INPUT
ID_NAME
= <id_name_of_fem_input>
Name of the
FEM_INPUT definition
FILE
= <name_of_input_file>,
<fe-solver>
Name of the input file.

Second label is optional.
Can be used instead of
commandline
"-solver <fe-solver>".
LIFE_FILE
<life-solver>
Name of the input file.

Second label is optional.
Can be used instead of
commandline
"-life <life-solver>".
TEMPERATURE_FILE
<fe-solver>
Name of the input file for

temperature pre-run.
Second label is optional,
but must be the same as
by "FILE"
ADD_FILE
= <name_of_add_input_
file>
Name of the additional

input file
COPY_FILE
= <name_of_copy_file>
Name of the additional

file
FILE_
SOLVER_
EXE
= <fe_solver_executable>
FE-solver executable
FILE_
CMDLINE
= <arguments for FE-solver>
Arguments for FE-solver
FILE_ADD_
CALL
= <more arguments for FEsolver>
More arguments for FEsolver
LIFE_FILE_
SOLVER_
EXE
=
<life_solver_executable>
LIFE-solver executable
LIFE_FILE_
CMDLINE
= <arguments for LIFEsolver>
Arguments for LIFEsolver
LIFE_FILE_
ADD_CALL
= <more arguments for

LIFE-solver>
More arguments for

LIFE-solver
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Specifies the Finite Element Input Files for the optimization. Also additional
files with nodes and elements for defining restrictions can be imported. For
more detailed information see vol.2 chapter 3.4, Loading FE Data in the
Tosca Structure 8.1.0 user manual.
SIMULIA
Tosca Structure
FEM_INPUT
DEPEN
DENT_FILE
= <name_of_input_file>
Name of a previously
defined FILE or
LIFE_FILE.
Remarks
1. The item FILE can be repeated several times. The first file in the list of files
will be handled as master file, which means that the configuration of the
finite element model will be read from this file. The second and all later
referenced files will be used to perform a finite element calculation. The
model in these files have to be identical to the original FE model. The files
will be modified during the optimization.
2. Second label in FILE item can be used to define the FE-solver. It may be
used instead of commandline:
"-solver <fe-solver>"
Only one FE-solver and one kind of input decks are allowed.
3. The item LIFE_FILE can be repeated several times, but only for life solvers
that support ONF 601-block (femfat, femsite, ... ). The files will not be
modified during the optimization.
4. The item TEMPERATURE_FILE may be used to define a temperature preanalysis. This feature is currently only supported with Abaqus.
5. The item ADD_FILE can be repeated several times. All nodes and
elements stored in the file referenced with this item will not be used for the
optimization. This item can be used for the specification of neighboring
elements for the definition of manufacturing constraints.
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Version 8.1.0 Rev. 1 - 05.2014
6. The item COPY_FILE can be repeated several times. The file(s) are copied
in to the working directory at the start of the optimization. See also configuration possibility "add_files_to_work_dir".
7. All files must differ in the filenames without suffix.
FEM_INPUT
FILE
ADD_FILE
ADD_FILE
END_
= MODEL.INP
= MODEL.ADD
! WRONG
= MODEL_ADD.INP ! CORRECT
8. FILE_SOLVER_EXE, FILE_CMDLINE, FILE_ADD_CALL must be defined

after a FILE-item. These statements are analogue to $fe_solver_exe,
$fe_solver_cmdline, $fe_solver_add_call in the configuration but relates
ONLY to the last FILE-statement before this command.
SIMULIA
Tosca Structure
9. LIFE_FILE_SOLVER_EXE, LIFE_FILE_CMDLINE,
LIFE_FILE_ADD_CALL must be defined after a LIFE_FILE-item.These
statements are analogue to $life_solver_exe, $life_solver_cmdline,
$life_solver_add_call in the configuration but relates ONLY to the last
LIFE_FILE-statement before this command.
10.DEPENDENT_FILE can be used when having parallel submit scripts, that
have dependencies on each other. One or more FILEs can have dependency only on 1 FILE. It would mean that they can be called simultaneously, if the submit script setup allows this. (See information about
${fe_solver_submit_check} and ${life_solver_submit_check} in CONFIG)
Please note: DEPENDENT_FILE can only be used in combination with
submit scripts (${fe_solver_submit_check} or ${life_solver_submit_check}
is set). In standard setup without submit scripts this entry is ignored.
Default is DEPENDENT_FILE = None, which means the FILE (or
LIFE_FILE) has no dependencies. Please contact your local Tosca Structure support for further information.
Examples
FEM_INPUT
ID_NAME
FILE
ADD_FILE
ADD_FILE
=
=
=
=
my_finite_element_models
my_fe_model.bdf
restriction_elements_left.bdf
restriction_elements_right.bdf
END_
FEM_INPUT
ID_NAME = model
FILE = input1.inp
FILE_ADD_CALL = cpus=24
FILE = input2.inp
FILE_ADD_CALL = cpus=12 globalmodel=input1.odb
FILE = input3.inp
FILE_ADD_CALL = cpus=12 globalmodel=input1.odb
END_
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If you have three Abaqus jobs where the first one is a pre-load step which is
to be used in the two following jobs. Also, the first job is run with 24 CPUs, the
other ones with just 12 CPUs. Your FEM_INPUT command could then look
like the following:
SIMULIA
Tosca Structure
GROUP_AUTO_DEF
GROUP_AUTO_DEF
Automatic definition of node groups. For more detailed information see vol.2
chapter 3.6.5, Automatic node group definition (GROUP_AUTO_DEF) in the
ND_GROUP
Name of the parent node

group
CS

system
TOL
= <tol_1>, <tol_2>, <tol_3>
Tolerance values in the

coordinate directions of
the referenced coordinate system
SEARCH
_TYPE
Search criterion
SEARCH_
DIR
= CONTINUOUS
Continuous search
= DISCRETE
Discrete search
= CS_MULTI
Search for nodes with the

same coordinate values
in the specified coordinate systems
= <cs_dir>
Search direction
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Version 8.1.0 Rev. 1 - 05.2014
<cs_dir> =
+1, -1, +2, -2, +3, -3
positive (+) or negative () direction of 1st, 2nd or

3rd axis of coordinate
system CS
SEARCH_
LEN
= <value>
Search length
DISCRETE_
LEN
= <value>
Discrete length
SEARCH_
CS
= <name_of_search_cs>
Name of the search coordinate system
Remarks
1. The command is applied only to nodes that have been selected. The child
node group only contains the necessary parent nodes for the case the
parent nodes are also selected.
2. The command GROUP_AUTO_DEF does not have its own ID_NAME.
SIMULIA
Tosca Structure
3. ND_GROUP is compulsory. The name of the parent node group with an

attached '_' plus a numbered index is used for all child node groups.
Should the name end with the symbol '_', no other symbol '_' is attached.
4. CS is compulsory.
5. TOL is compulsory. The tolerance values must be positive. At least one of
the three tolerance values must be accepted. For tolerance values not
accepted, the smallest of the given tolerance values is acceptable. The
three tolerance values are coordinate values that refer to the three coordinate directions of the CS. In a cartesian coordinate system all three values
have the longitudes tol_* . In a cylindrical coordinate system tol_1 and tol_3
are longitudes and tol_2 is an angle measured in degrees. In a spherical
coordinate system tol_1 is a longitude and tol_2 and tol_3 are angles
measured in degrees. Tolerance values should be big enough to include
the individual nodes and small enough not to include the neighboring
nodes not wanted.
6. SEARCH_TYPE is compulsory. The relevant criteria is that of Version 3.0.
8. SEARCH_LEN is compulsory for the command

SEARCH_TYPE=CONTINUOUS and SEARCH_TYPE=DISCRETE. For
SEARCH_TYPE=CS_MULTI, the command SEARCH_LEN is not necessary. The length of the search is a general length and can also be an angle
measured in degrees in the case of a cylindrical or spherical coordinate
system. The length of the search must also be positive. It is recommended
to choose a larger search length as the relevant tolerance.
9. DISCRETE_LEN is compulsory for the command
SEARCH_TYPE=DISCRETE. For SEARCH_TYPE=CONTINUOUS and
SEARCH_TYPE=CS_MULTI, the command DISCRETE_LEN is not necessary. The discrete length is a general length and can also be an angle
measured in degrees in the case of a cylindrical or spherical coordinate
system. The discrete length must be positive. It is recommended that the
discrete length is smaller than the search length and larger than the relevant tolerance.
10.SEARCH_CS is compulsory for the command
SEARCH_TYPE=CS_MULTI. For SEARCH_TYPE=CONTINUOUS and
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7. SEARCH_DIR is compulsory for the command SEARCH_TYPE=CONTINUOUS and SEARCH_TYPE=DISCRETE. For

SEARCH_TYPE=CS_MULTI, the command SEARCH_DIR is not necessary. The direction of search refers to the relevant coordinate direction of
the CS. A positive (negative) symbol means a search in a positive (negative) coordinate direction.
SIMULIA
Tosca Structure
GROUP_AUTO_DEF
SEARCH_TYPE=DISCRETE, the command SEARCH_CS is not necessary. A total of up to 32 separate SEARCH_CS entries can be accepted.
The second to the 32th entry is optional. It is recommended that all coordinate systems CS and SEARCH_CS are the same type, that is either cartesian, cylindrical or spherical.
11.Note: Using the command DVCON_AUTO_SHAPE, DVCON_SHAPE
entries for node groups with the same name log can be generated automatically.
Examples
GROUP_AUTO_DEF
ND_GROUP
CS
TOL
SEARCH_TYPE
SEARCH_DIR
SEARCH_LEN
DISCRETE_LEN
=
=
=
=
=
=
=
my_nodes_01
cs_1
0.1, 1.0, 0.1
CONTINUOUS
+2
360
45
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Version 8.1.0 Rev. 1 - 05.2014
END_
SIMULIA
Tosca Structure
GROUP_DEF
Manual definition of groups by lists of elements or nodes, materials or properties or by assigning a previously defined selection. For more detailed information see vol.2 chapter 3.6.4, Manual group definition in Tosca Structure.gui in
ID_NAME
= <Id_name_of_group>
Name of the group
TYPE
= ELEM
= NODE
Type of the group
FORMAT
= SELECTED
= LIST
= LIST_MAT
= LIST_PROP
= LIST_ND_ALL
= LIST_ND_ANY
= LIST_NDGR_ALL
= LIST_NDGR_ANY
Format, through selection

or by explicit specification
of a list of elements or
nodes (= LIST), a list of
materials (= LIST_MAT)
or a list of properties
(=LIST_PROP) or a list of
nodes or node groups
where all elements which
contain all listed nodes
(_ALL) or one of the
listed nodes (_ANY) are
added.
LIST_BEGIN
for FORMAT = LIST*
Beginning of list entries
<entries of group list>

...
...
List entries
Remarks
2. FORMAT = LIST: This group contains all elements (in TYPE=ELEM) or

nodes (in TYPE=NODE) which are listed following the parameter
LIST_BEGIN.
3. FORMAT = LIST_MAT: This list contains materials which for the selection
of elements.
4. FORMAT = LIST_PROP: This list contains properties for the selection of
elements.
5. FORMAT = LIST_ND_ALL: This list contains nodes for the selection of
elements. All elements which contain only nodes from this list are added to
the group.
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1. FORMAT = SELECTED: This group contains all elements (in

TYPE=ELEM) and nodes (in TYPE=NODE) that are selected with the
command SELECT.
SIMULIA
Tosca Structure
GROUP_DEF
6. FORMAT = LIST_ND_ANY: This list contains nodes for the selection of

elements. All elements which contain at least one node from this list are
added to the group.
7. FORMAT = LIST_NDGR_*: This list contains node groups for the selection
of elements. All elements which contain at least one (ANY) or all (ALL)
nodes from the listed node groups are added to the group.
8. Entering LIST_BEGIN is required with FORMAT = LIST* and must be
placed at the end of the command. The list with the numbered areas
follows this entry. The standard conventions for commentary lines are
applicable. The list is closed with END_. The default separate characters
for numbered areas are as follows: Thru-Character='-', Increment-Character=':', Separator-Character=','
Examples
GROUP_DEF
ID_NAME
= my_elem_group
TYPE
= ELEM
FORMAT
= LIST
LIST_BEGIN
1,5,10-25, 45-60:5
END_
GROUP_DEF
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Version 8.1.0 Rev. 1 - 05.2014
ID_NAME
TYPE
FORMAT
LIST_BEGIN
7
= my_elem_group
= ELEM
= LIST_MAT
END_
! Useful for shape optimization :

! Selecting all elements for surface identification
select,elgr,s,elgr,ALL_ELEMENTS
select,elem,s,elgr
SF_IDENT
! select surface nodes
select,node,s,ND_SF
GROUP_DEF
SIMULIA
Tosca Structure
ID_NAME
TYPE
FORMAT
= my_surface_node_group
= NODE
= SELECTED
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END_
SIMULIA
Tosca Structure
GROUP_IMPORT
GROUP_IMPORT
Import of groups from files in different group definition formats.
ID_NAME
= <name_of_group_import>
Name of Group import

command
FORMAT
= M4W
Group import in MSC

Nastran for Windows
neutral file format
= FEMAP
Group import in FEMAP

neutral file format
= ONF
Optimization neutral file

format
<file_name>
> Name of the file from

which the data is loaded
FILE_NAME
Remarks
On using the file name (operator FILE_NAME):
1. File names are used in the given style of writing. Using capital letters is not
necessary.
On loading the M4W neutral files:
1. The complete model must be written in the file otherwise the allocation of
group names will not occur.
2. Groups must be evaluated, i.e. the group entities must exist in a list in a
neutral file.
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Version 8.1.0 Rev. 1 - 05.2014
3. Group names are changed to group name_E and group name_N as long
as the groups contain nodes and elements.
Examples
Loading group information from the file GROUPS.NEU. The file is written in
ASCII format in MSC Nastran for Windows and is given in the current directory.
GROUP_IMPORT
FILE_NAME
FORMAT
= DESIGN.NEU
= M4W
END_
SIMULIA
Tosca Structure
INCLUDE
Integration of other files which contain complex or repetitive commands. If no
path is given, the current directory is searched. The multistage path is then
searched which can be set with the command PATH. For more detailed information see vol.2 chapter 3.5, Include Files.
INCLUDE, filename, path
filename
File name
path
Relative or absolute path to the file
Remarks
1. The command INCLUDE allows nesting of three stages. This means, a
loaded (stage 1) can occur again in INCLUDE (stage 2) whereby this file
can also be contained in an INCLUDE command (stage 3). In the directories where INCLUDE files exist, path allocations must be set (e.g. with
PATH).
Examples
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Complex group definitions within a parameter file can be written in a separate

file groups.par which is connected to the actual parameter file via the command INCLUDE,groups.par. Predefined macros are also connected in this
way.
SIMULIA
Tosca Structure
LINK_BEAD
LINK_BEAD
Defines link conditions (coupling conditions) for nodes in shape optimization.
For more detailed information see vol.2 chapter 7.3.2.6, Symmetry conditions
(CHECK_LINK) in the Tosca Structure 8.1.0 user manual.
ID_NAME
= <Id_name_of_link_bead>
Name of LINK_BEAD
definition
CS

system in which the link
condition is defined.
TYPE
Type of link condition

= PLANE_SYM, AXIS_1
= PLANE_SYM, AXIS_2
= PLANE_SYM, AXIS_3
A symmetrical displacement of the nodes referring to the plane which

lies normal to the given
axis of the coordinate
system.
= POINT_SYM
A symmetrical displacement of the nodes referring to the origin of the

coordinate system is
enforced.
= ROTATIONAL_SYM, AXIS_1

system.
Remarks
www.3ds.com/tosca
Version 8.1.0 Rev. 1 - 05.2014
1. Only cartesian coordinate systems are allowed in the CS-definition.

2. The possibility of creating MASTER and CLIENT groups can NOT be done
in LINK_BEAD.
Examples
LINK_BEAD
ID_NAME
TYPE
CS
END_
= MY_LINK_01
= PLANE_SYM, AXIS_3
= CS_0
SIMULIA
Tosca Structure
LINK_SHAPE
Defines link conditions (coupling conditions) for nodes in shape optimization.
For more detailed information see vol.2 chapter 6.3.3.8, Assigning link/coupling conditions (CHECK_LINK) in the Tosca Structure 8.1.0 user manual.
= <Id_name_of_link_shape>
MASTER
Determination of the master node
CLIENT
Name of LINK_SHAPE
definition
= MAX
Maximum growth and

minimum shrinkage.
Allowed for all CLIENT
types.
= MIN
Maximum shrinkage and

minimum growth.
Allowed for all CLIENT
types.
= NODE, <node_nr>
Node <node_nr> is the

master node. Only
allowed for the following
CLIENT types:
PLANE_SYM
POINT_SYM
VECTOR
DIRECTION
LENGTH
DISP_CS
= NDGR, <ndgr_name>
Master is determined
from the nodegroup
<ndgr_name>. From
each link-shape group,
one node must exist in
the master group. Only
allowed for the following
CLIENT types:
PLANE_SYM
POINT_SYM
ROTATION_SYM
DIRECTION
DISP_CS
SURF_TURN
FREE_FORM
VECTOR
LENGTH
Determination rule for the client

nodes
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ID_NAME
SIMULIA
Tosca Structure
www.3ds.com/tosca
Version 8.1.0 Rev. 1 - 05.2014
LINK_SHAPE
= PLANE_SYM, AXIS_1
= PLANE_SYM, AXIS_2
= PLANE_SYM, AXIS_3

system.
= POINT_SYM
A symmetrical displacement of the nodes referring to the origin of the

coordinate system is
enforced.
= ROTATION_SYM, AXIS_1
A rotational symmetric
displacement of the
nodes referring to the
given axis of the coordinate system is enforced.
= VECTOR
= VECTOR,ON/OFF,ON/OFF,ON/
OFF
All displacement components are coupled. The

choice of which components to couple and
which not to couple is
done using the ON or
OFF switch. The first
switch controls the first
component etc. Default is
ON, ON, ON.
= DIRECTION
All displacement components are coupled. The

resulting displacement
vector is scaled to the
original absolute value of
displacement.
= LENGTH
Only the amount of displacement is coupled
= DISP_CS
= DISP_CS,ON/OFF,ON/OFF,ON/
OFF
The displacement is coupled in the relevant displacement coordinate

system. The choice of
which components to
couple and which not to
couple is done using the
ON or OFF switch. The
first switch controls the
first component etc.
Default is ON, ON, ON.
SIMULIA
Tosca Structure
=SURF_STAMP, AXIS_1
=SURF_STAMP, AXIS_2
=SURF_STAMP, AXIS_3
Conserve a stampable
surface. The stamping
direction is defined via
the axis of the coordinate system.
=SURF_TURN, AXIS_1
=SURF_TURN, AXIS_2
=SURF_TURN, AXIS_3
Conserve a turnable surface. The rotation axis is

defined via the coordinate system axis
=SURF_DRILL, AXIS_1
=SURF_DRILL, AXIS_2
=SURF_DRILL, AXIS_3
Conserve a drillable surface. The generated surface is demoldable and

turnable. The drilling axis
is defined via the coordinate system axis.
=SURF_DEMOLD, AXIS_1
Conserve a demoldable
surface for casting. The
demold direction is
defined via the coordinate system axis.
= PLANE_SYM

lies normal to the axis
specified by
CLIENT_DIR.
=ROTATION_SYM
Conserve a rotational
symmetric surface with
rotational symmetric
mesh. Symmetry groups
are determined automatically according to the
axis specified by
CLIENT_DIR parameter.
=SURF_PLANE_SYM
Conserve plane symmetry for non-symmetric

meshes. The symmetry
axis is defined via
CLIENT_DIR
=SURF_CYCLIC_SYM
Conserve cyclic symmetry for non-symmetric

meshes
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Determination rule for the client

nodes with CLIENT_DIR or
DEMOLD_DIR parameter
SIMULIA
Tosca Structure
=SURF_CYCLIC_PLANE_SYM
Conserve cyclic and

plane symmetry for nonsymmetric meshes simultaneously.
=SURF_STAMP
Conserve a stampable
surface. The stamping
direction is defined via
the CLIENT_DIR parameter. An additional
demold direction can be
defined using
DEMOLD_DIR.
=SURF_TURN
Conserve a turnable surface. The rotation axis is

defined via the
=SURF_DRILL
Conserve a drillable surface. The generated surface is demoldable and

turnable. The drilling axis
is defined via the
=SURF_DEMOLD
Conserve a demoldable
surface for casting. The
demold direction is
defined via the
DEMOLD_DIR parameter. (CLIENT_DIR is also
supported, but not recommended).
=FREE_FORM
The node group referenced via MASTER=NDGR,

<node_group> defines a
free form surface;
can only be used if this
command is referenced
via DVCON_SHAPE,
CHECK_SLIDE
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LINK_SHAPE
CLIENT_DIR
= <x_1>, <x_2>, <x_3>
Direction of the axis for

the restrictions
PLANE_SYM,
ROTATION_SYM,
SURF_STAMP,
SURF_TURN,
SURF_DRILL,
SURF_DEMOLD,
SURF_PLANE_SYM,
SURF_CYCLIC_SYM,
SURF_CYCLIC_PLANE
_SYM with reference to
the specified coordinate
system.
DEMOLD_DIR
= <x_1>, <x_2>, <x_3>
Demolding direction for

the restrictions
SURF_STAMP and
SURF_DEMOLD
(CLIENT_DIR also possible) with reference to the
specified coordinate system.
CS

system in which the link
condition is defined (i.e.
which the axis or
CLIENT_DIR/
DEMOLD_DIR refer to).
TOL
= <tol_1>, <tol_2>, <tol_3>
Tolerances in the three

axial directions for symmetrical recognition of
CLIENT = PLANE_SYM,
POINT_SYM,
ROTATION_SYM,
SURF_STAMP,
SURF_TURN,
SURF_DRILL,SURF_PL
ANE_SYM,
SURF_CYCLIC_SYM,
SURF_CYCLIC_PLANE
_SYM or
SURF_DEMOLD
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SIMULIA
Tosca Structure
SIMULIA
Tosca Structure
LINK_SHAPE
Items for CLIENT = SURF_STAMP, SURF_TURN, SURF_DRILL
SURF_
PARAM
= <masterareas>, <net points>
Parameters for the surface algorithms

4 < net points < masterareas - 10%
SURF_SYM_
TYPE
=PLANE_SYM, AXIS_1
=PLANE_SYM, AXIS_2
=PLANE_SYM, AXIS_3
plane symmetry linking

for surfaces defined with
the SURF_* parameters.
= POINT_SYM
point symmetry linking for

surfaces defined with the
SURF_* parameters.
SURF_SYM_
CS

system for the
SURF_SYM symmetry
Linking
SURF_SYM_
NDGR
= <name_of_nodegroup>
node group defining the

master surface for a
SURF_SYM definition.
ANGLE
= <real>
Draw angle for demold

restriction
( 0 angle 45 )
UNDERCUT_TOL
= <real>
messure > 0 for tolerable

undercut in the demolding area
Items for CLIENT = SURF_DEMOLD
CHECK_GROUP
= <name of node group>
Name of the check group for

the demold definition.
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Version 8.1.0 Rev. 1 - 05.2014
Items for CLIENT = SURF_STAMP, SURF_DRILL, SURF_DEMOLD
SIMULIA
Tosca Structure
Items for CLIENT = ROTATION_SYM, SURF_CYCLIC_SYM,

SURF_CYCLIC_PLANE_SYM
ANGLE
= <real>
= 0 < angle < 360

Angle for the repeating
segments
= 0 if the nodes are rotational
symmetric but not in a periodical order
Items for CLIENT = SURF_CYCLIC_SYM, SURF_CYCLIC_PLANE_SYM
CYCLIC_SYM_
START
= <x_1>, <x_2>, <x_3>
Defines the starting point

for the partitioning. Its
coordinates are given with
reference to the global cartesian coordinate system. It
must not lie on the rotational axis.
Remarks
1. The allocation is only permitted for design nodes (defined via the command
DV_SHAPE) and mesh smooth nodes (second order design nodes).
Case 1
Case 2
Case 3
Case 4
ALL_GROWTH
ALL_SHRINK
MORE_SHRINK
MORE_GROWTH
max_growth
min_growth
OBJ_FUNC
max_growth
max_growth
OBJ_FUNC
min_shrink
OBJ_FUNC
max_shrink
max_shrink
OBJ_FUNC
max_shrink
MASTER
Selected Master Displacement Value
MAX
max_growth
min_shrink
max_growth
max_growth
MIN
min_growth
max_shrink
max_shrink
max_shrink
3. The CLIENT specification determines the displacement of the client nodes

from the Master_Node of the optimization displacement.
= PLANE_SYM:
The surface which lies normal to the specified axis is a symmetrical
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2. The MASTER specification determines the master nodes.
SIMULIA
Tosca Structure
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Version 8.1.0 Rev. 1 - 05.2014
LINK_SHAPE
surface. The nodes (allocated via DVCON_SHAPE operator ND_GROUP)

are checked against each other for their symmetry and symmetrical
surfaces. Symmetrical nodes are combined to a symmetrical group (2
symmetrical nodes per symmetrical group is the norm). The master node of
the symmetrical group is then determined and the displacement of the
client node is calculated so it displaces in a surface symmetrical fashion to
the master node.
= POINT_SYM:
The point defined by the origin of the coordinate system CS is called the
symmetrical point. The nodes (allocated via DVCON_SHAPE operator
ND_GROUP) are checked against each other for their symmetry with reference to the symmetrical point. Symmetrical nodes are combined to a
symmetrical group (2 symmetrical nodes per symmetrical group is the
norm). The master node of the symmetrical group is then determined and
the displacement of the client node is calculated so it displaces point
symmetrical to the master node. For both symmetrical couplings the given
coordinate system in the operator CS must be cartesian (rectangular). The
operator MASTER must have MAX or MIN.
= ROTATION_SYM:
The specified axis defines the rotation axis of the surface of revolution. The
nodes (allocated via DVCON_SHAPE operator ND_GROUP) are checked
for their symmetry in the given rotation axis. All nodes at the same parallel
of the surface of revolution are combined to a symmetrical group. The
master node of the symmetrical group is then determined and the displacement of the client node is calculated so it displaces in a surface symmetrical fashion to the master node.
= VECTOR:
Referring to the coordinate system entered in the operator CS, the difference between the current coordinates and the start coordinates of the
master nodes is calculated. With reference to the coordinate system the
start coordinates of the client nodes are then calculated, the difference in
the master nodes are determined and the current coordinates of the client
nodes are calculated. With VECTOR=ON/OFF, ON/OFF, ON/OFF these
coordinates are activated and transferred. The coordinates deactivated
remain unchanged.
= DIRECTION:
The procedure is similar to that of CLIENT = VECTOR with coupling of all
three coordinates. The difference is that the obtained displacement vector
is scaled to the original absolute value of the displacement of the client
node.
SIMULIA
Tosca Structure
= DISP_CS:
The optimization displacement of the master nodes based upon the FE
displacement coordinate system is transferred directly in the FE displacement coordinate system of the client nodes. The coupled FE displacement
coordinate systems must be of the same kind, i.e. either cartesian, cylindrical or spherical. With DISP_CS=ON/OFF, ON/OFF, ON/OFF these coordinates that are activated are transferred. The coordinates deactivated
remain unchanged.
= SURF_PLANE_SYM:
The nodes are checked to be symmetric with respect to the given
symmetry plane in symmetric but non-symmetric meshed models. The
node corrections are applied in node normal direction only.
= SURF_CYCLIC_SYM
Couples nodes in a not neccessary symmetric mesh that reoccur in a cyclic
manner around a rotational axis.
= SURF_CYCLIC_PLANE_SYM
Combination of SURF_CYCLIC_SYM and SURF_PLANE_SYM. Nodes
are first coupled in a cyclic manner and then plane symmetry is enforced
within each cyclic section. The position of the plane symmetric sections is
controlled with the CYCLIC_SYM_START parameter.
=SURF_STAMP:
The nodes are linked to keep a stampable surface. Master nodes are
determined automatically.
=SURF_TURN:
The nodes are linked to keep a turnable surface. Master nodes are determined automatically.
=SURF_DRILL:
The nodes are linked to keep a turnable surface. Master nodes are determined automatically. The drill restriction is a special combination of the turn
and demold restriction.
=SURF_DEMOLD:
The nodes are linked to keep a castable surface.
4. The CLIENTS PLANE_SYM, ROTATION_SYM, SURF_STAMP,
SURF_TURN, SURF_DRILL, SURF_DEMOLD, SURF_CYCLIC_SYM,
SURF_PLANE_SYM, SURF_CYCLIC_PLANE_SYM can be used without
the AXIS_* parameter. Thus, an arbitrary axis direction <x,y,z> can be
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= LENGTH:
The absolute value of displacement of the master nodes is calculated. The
displacement of the client nodes is scaled so the absolute value of the
obtained displacement of the master node remains.
SIMULIA
Tosca Structure
LINK_SHAPE
specified with reference to CS with the entry CLIENT_DIR = x,y,z. For

SURF_STAMP an additional demolding direction can be defined using the
DEMOLD_DIR parameter, also available for the definition of the demolding
direction for SURF_DEMOLD.
5. CS: Name of the coordinate system that operates LINK_SHAPE. Specifying the coordinate system is essential for CLIENT=PLANE_SYM,
POINT_SYM, ROTATION_SYM, VECTOR, DIRECTION, SURF_STAMP,
SURF_TURN, SURF_DRILL, SURF_DEMOLD, SURF_CYCLIC_SYM,
SURF_PLANE_SYM or SURF_CYCLIC_PLANE_SYM. Specifying the
coordinate system for CLIENT=LENGTH or DISP_CS is unnecessary. With
CLIENT=PLANE_SYM and POINT_SYM only cartesian coordinate
systems are permitted.
6. TOL: Specifying the tolerance values for CLIENT=PLANE_SYM,
POINT_SYM, ROTATION_SYM or SURF_DEMOLD is essential. Specifying the tolerance values for CLIENT=VECTOR, DIRECTION, LENGTH,
DISP_CS, SURF_STAMP, SURF_TURN, SURF_DRILL,
SURF_CYCLIC_SYM, SURF_PLANE_SYM or
SURF_CYCLIC_PLANE_SYM is unnecessary. The tolerance values must
be positive. At least one of three tolerance values must be entered. For
tolerance values not given, the smallest of the given tolerance values is
acceptable. The three tolerance values are also coordinate values referring
to the three coordinate directions of the CS. The values of tolerance should
be large enough to cover the individual nodes and small enough not to
cover any not wanted neighboring nodes.
Examples
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Version 8.1.0 Rev. 1 - 05.2014
LINK_SHAPE
ID_NAME
MASTER
CLIENT
CS
TOL
=
=
=
=
=
my_link_01
MAX
PLANE_SYM, AXIS_3
cs_0
0.01, 0.01, 0.01
=
=
=
=
=
DEMOLD_AREA
MAX
SURF_DEMOLD, AXIS_2
cs_0
1.5
END_
LINK_SHAPE
ID_NAME
MASTER
CLIENT
CS
ANGLE
SIMULIA
Tosca Structure
TOL
CHECK_GROUP
= 0.01, 0.01, 0.01

= CHK_NDGRP_DEMOLD
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END_
SIMULIA
Tosca Structure
LINK_SIZING
LINK_SIZING
Definition of symmetry and link conditions for sizing optimization. For more
detailed information see vol.2 chapter 5.3.2.7, Symmetry conditions in the
ID_NAME
= <Id_name_link_sizing>
www.3ds.com/tosca
Version 8.1.0 Rev. 1 - 05.2014
TYPE
Name of the link condition

Type of the link condition
= POINT_SYM
Point symmetry referring

to the origin of the coordinate system.
= PLANE_SYM, AXIS_1
= PLANE_SYM, AXIS_2
= PLANE_SYM, AXIS_3
Plane symmetry referring to the plane which

lies perpendicular to the
given axis of the coordinate system.
Rotational symmetry
referring to the axis of the
coordinate system. The
angle for the repeating
segments may be
defined by the user.
= CYCLIC_SYM, AXIS_1
Cyclic symmetry definition
= LINK_SYM
Coupling of single element groups
CS

system that should be
used for the link definitions
IGNORE_
FROZEN
= FALSE, TRUE
The frozen elements may

be excluded from the link
definitions
Items for TYPE = ROTATION_SYM
ANGLE
= <angle>
Angle for the segment

repeating. Must be
greater then 2.
SIMULIA
Tosca Structure
Items for TYPE = CYCLIC_SYM

TRANSLATION
= <translation>
Translation amount for

the segments
Items for TYPE = LINK_SYM
GROUP_
MASTER
Name of the element

group that defines the
reference segment
CS_CHILD

system that defines the
position of the corresponding segment referring to the
GROUP_MASTER element group. Multiple
child coordinate systems
may be defined.
MASTER
= AUTO
(default) "AVG" for sensitivity based optimizations
= AVG
The average value of the

equivalent elements
defines the symmetry
= GROUP
The reference group

overwrites the child
groups.
LINK_SIZING
ID_NAME
TYPE
CS
= PLANE_SYMMETRY
= PLANE_SYM, AXIS_2
= CS_0
END_
LINK_SIZING
ID_NAME
TYPE
CS
GROUP_MASTER
CS_CHILD
CS_CHILD
END_
=
=
=
=
=
=
LINK_CONDITION
LINK_SYM
CS_0
EL_MASTER
CS_CHILD1
CS_CHILD2
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Examples
SIMULIA
Tosca Structure
LINK_TOPO
LINK_TOPO
Definition of symmetry and link conditions for topology optimization. For more
detailed information see vol.2 chapter 5.3.2.7, Symmetry conditions in the
ID_NAME
= <Id_name_of_link_topo>
www.3ds.com/tosca
Version 8.1.0 Rev. 1 - 05.2014
TYPE
Name of the link condition

Type of the link condition
= POINT_SYM
Point symmetry referring

to the origin of the coordinate system.
= PLANE_SYM, AXIS_1
= PLANE_SYM, AXIS_2
= PLANE_SYM, AXIS_3
Plane symmetry referring to the plane which

lies perpendicular to the
given axis of the coordinate system.
Rotational symmetry
referring to the axis of the
coordinate system. The
angle for the repeating
segments may be
defined by the user.
Cyclic symmetry definition
= LINK_SYM
Coupling of single element groups
CS

system that should be
used for the link definitions
IGNORE_
FROZEN
= FALSE, TRUE
The frozen elements may

be excluded from the link
definitions
Items for TYPE = ROTATION_SYM
ANGLE
= <angle>
Angle for the segment

repeating. Must be
greater then 2.
SIMULIA
Tosca Structure
Items for TYPE = CYCLIC_SYM

TRANSLATION
= <translation>
Translation amount for

the segments
GROUP_
MASTER
Name of the element

group that defines the
reference segment
CS_CHILD

system that defines the
position of the corresponding segment referring to the
GROUP_MASTER element group. Multiple
child coordinate systems
may be defined.
MASTER
= AUTO
(default) AUTO will

switch to "MAX" for controller based optimizations and to "AVG" for
sensitivity based optimizations
= MAX
The maximum value of

the equivalent elements
= AVG
The average value of the

equivalent elements
= GROUP
The reference group

overwrites the child
groups.
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Items for TYPE = LINK_SYM
SIMULIA
Tosca Structure
LINK_TOPO
Coordinate System Definitions for TYPE = LINK_SYM
CS
CS_CHILD
Examples
LINK_TOPO
ID_NAME
TYPE
CS
= PLANE_SYMMETRY
= PLANE_SYM, AXIS_2
= CS_0
END_
ID_NAME
TYPE
CS
GROUP_MASTER
CS_CHILD
CS_CHILD
=
=
=
=
=
=
LINK_CONDITION
LINK_SYM
CS_0
EL_MASTER
CS_CHILD1
CS_CHILD2
END_
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LINK_TOPO
SIMULIA
Tosca Structure
LIST
List compilation of information during optimization preprocessing
LIST, object, info Information (info) is given about the objects (object). Only
objects selected with the command SELECT are considered.
info
= NODE
Information referring to
nodes, nodes selected
from the node list
NO
Node IDs (default)
SF
Node IDs of the surface

nodes. The surface node
must have prior identification. (see
READ_OPTION or
SF_IDENT).
LOC
Global node coordinates

and the relevant displacement coordinate
system.
BC
Output of the boundary

conditions that are
loaded with OPTIONS,
READ_BC=, ... and the
relevant displacement
coordinate system.
VEC
Direction of the Shape

Basis Vector of the
design nodes (see
DV_SHAPE and OPTIMIZE)
= ELEM
ELEM Information referring to elements, selected

elements from the element list.
NO
Element ID (default)
ND
Quantity and number of

the node of the element
PROP
Properties (type of element, property, material)
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object
SIMULIA
Tosca Structure
LIST
QUAL
Quality (if more than

three elements are
selected, output switches
from detailed to short).
VOL
Total volume of the

selected elements
LIST, object, selection (objects selectable with the SELECT command)

Object specific information (objects selectable with the SELECT command)
object
selection
= CS
Coordinate systems
= ELGR
= ALL
All coordinate systems

selected are listed
(default)
= <cs_name>
The entered coordinate

system is listed
Element group
= (no entry)
Element IDs of active

groups of elements
(default, i.e without entering selection)
= ALL
Element IDs of all groups

of elements
= <element_group_name>
Element IDs of group

entered
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Version 8.1.0 Rev. 1 - 05.2014
= EPROP
Element Property
Sets
= (no entry)
Active element property

sets (default, i.e without
entering selection)
= ALL
All element property sets
= <element_property_number>
Specified element property
= ETYPE
Element type
= (no entry)
Active element types

(default, i.e
without entering selection)
SIMULIA
Tosca Structure
= ALL
All element types
= <element_type_name>
Specified element type
= MAT
Material
= (no entry)
Active materials (default,

i.e without entering selection)
= ALL
All materials
= <material_number>
Specified material
= NDGR
Node group
= (no entry)
Node IDs of active

groups of nodes (default,
i.e without entering selection)
= ALL
Node IDs of all node

groups
= <node_group_name>
Node IDs of group

entered
= SOLID
Solid definitions
= (no entry)
Active solids (default, i.e

without entering selection)
= ALL
All solids
= <solid_name>
Solid entered
Object specific information (objects not selectable with the SELECT command)
object
selection
= CONSTRAINT
Constraint information
= ALL
All constraints (default)
= <constraint_name>
Specified constraint
= DRESP
Design response information

= ALL
All design response definitions (default)
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LIST, object, selection (objects not selectable with the SELECT command)
SIMULIA
Tosca Structure
LIST
= <dresp_name>
= DVCON_
SHAPE
Design variable constraint information for

shape optimization
= ALL
All design variable constraints for shape

(default)
= <dvcon_shape_name>
Specified design variable

constraint (shape)
= <dvcon_shape_family>*
All design variable constraints (shape) with

stated family name
= DVCON_
TOPO
Design variable constraint information for

topology optimization
= ALL
All design variable constraints for topology

(default)
= <dvcon_topo_name>

constraint (topo)
= <dvcon_topo_family>*
All design variable constraints (topo) with stated

family name
Version 8.1.0 Rev. 1 - 05.2014
= DV_
SHAPE
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Specified design
response definition
Design variable information for shape optimization

= ALL
All design variable definitions for shape(default)
= <dv_shape_name>

definitions (shape)
= DV_TOPO
Design variable information for topology optimization

= ALL
All design variable definitions for topology

(default)
= <dv_topo_name>

definition (topo)
SIMULIA
Tosca Structure
= LINK_
SHAPE
Link shape information

= ALL
All link shape definitions

(default)
= <link_shape_name>
Specified link shape definition
= LOGICAL
Logical variable information

= ALL
All logical variable definitions (default)
= <logical_name>
Specified logical variable

definition
= MESH_
SMOOTH
Mesh smoothing information

= ALL
All mesh smooth definitions (default)
= <mesh_smooth_name>
Specified mesh smooth

definition
= OBJ_
FUNC
Objective function information

= ALL
All objective functions

(default)
= <obj_func_name>
Specified objective function
= OPTIMIZE
= ALL
All optimize definitions

(default)
= <optimize_name>
Specified optimize definition
= OPT_
PARAM
Opt_param information
= ALL
All Optimization parameter definitions (default)
= <opt_param_name>
Specified Optimization
parameter definition
= STOP
Stop condition information
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Optimize information
SIMULIA
Tosca Structure
LIST
= ALL
All stop conditions

(default)
= <stop_name>
Specified stop condition
= USER_
FILE
User file information

= ALL
All user file definitions

(default)
= <user_file_name>
Specified user file definitions
= VARIABLE
Variable information
All variable definitions
(default)
= <variable_name>
Specified variable definition
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= ALL
SIMULIA
Tosca Structure
LIST, info
General information
info
= AUTHOR
Authorization
= PATH
Selected PATH
= PRINT_OPTION
Selected print option
= READ_OPTION
All read options
= SIZE
Limits of model-size (memory limit)
Examples
Listing of the adjusted model limits:
LIST, SIZE
Listing of the coordinate values of the nodes 1-10:
SELECT, NODE, S, NODE, 1, 10, 1
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LIST, NODE, LOC
SIMULIA
Tosca Structure
LOGICAL
LOGICAL
Definition of logical variables. For more detailed information see vol.2 chapter
10.5.2, Logical variables (LOGICAL) in the Tosca Structure 8.1.0 user manual. .
ID_NAME
= <Id_name_of_logical_
variable>
Name of the logical variable
DEF_TYPE
= BASE
Definition of a logical
variable by comparison of
existing numerical variables
= BOOLEAN
Definition by linking logical variables with Boolean operations
OPER
DEF_TYPE = BASE:
= GE
Variable A is greater than

and equal to variable B
= LE
Variable A is less than

and equal to variable B
= GT
Variable A is larger than

variable B
= LT
Variable A is smaller than

variable B.
= EQ
Variable A equals variable B
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DEF_TYPE = BOOLEAN:
= AND
and-linkage of logical
variable LOG_A to
LOG_D
= OR
or-linkage of logical variable LOG_A to LOG_D
Items for DEF_TYPE = BASE
Items for DEF_TYPE = BASE:
VAR_A
<name_of_1st_variable>
Name of a defined
numerical variable
VAR_B
<name_of_2nd_variable>
Name of a defined
numerical variable
SIMULIA
Tosca Structure
FIX_VAL
<value>
Real-value
Items for DEF_TYPE = BOOLEAN
LOG_A
<name_of_1st_logical
_variable>
Name of a defined logical

variable
LOG_B
<name_of_2nd_logical
_variable>

variable
LOG_C
<name_of_3rd_logical
_variable>

variable
LOG_D
<name_of_4th_logical
_variable>

variable
Remarks
1. The direct definition of logical variables (DEF_TYPE = BASE) can be done
by a comparison of two numerical variables or one numerical variable and
a fixed value. The numerical variables must already be defined.
2. Definitions relating to Boolean operations (DEF_TYPE = BOOLEAN) must
include at least two already defined logical variables that are referenced. A
maximum of up to four logical variables may be combined.
Examples
LOGICAL
END_
=
=
=
=
=
my_logical_01
BASE
LT
volume_part_a
100.0
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ID_NAME
DEF_TYPE
OPER
VAR_A
FIX_VAL
SIMULIA
Tosca Structure
MESH_SMOOTH
MESH_SMOOTH
Definition of parameters for the mesh smoothing algorithm for shape optimization. For more detailed information see vol.2 chapter 6.3.2, Mesh smoothing (MESH_SMOOTH) in the Tosca Structure 8.1.0 user manual.
ID_NAME
= <name_of_mesh_SMOOTH>
Name of the
MESH_SMOOTH definition
EL_GROUP
Name of the element

group for which
MESH_SMOOTH is done
MS_LAYER
= <name_of_node_group>,
<number_of_elementlayers>
The mesh smooth element group is defined

automatically. Starting
with the referenced node
group and the defined
number of grouped element layers
FREE_SF
= FIX
= FIX, <number_of_node_layers>
Free surface nodes of the

MESH_SMOOTH area
which is completely fixed
(number of node layers
<number_of_node_layer
s> depending upon the
remaining free design
nodes Default=0).
= FREE
Free surface nodes of the

MESH_SMOOTH
remaining free area (not
fixed).
= FIX
Nodes on the border of

the mesh smooth area
are fixed.
= FREE
No nodes are automatically fixed.
= CONSTRAINED_LAPLACIAN
Use constrained laplacian mesh smooth strategy (default).
= LOCAL_GRADIENT
Use local gradient mesh

smooth strategy; not recommended for models
with many nodes in mesh
smooth area.
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BOUNDARY
STRATEGY
LEVEL_QUAL
= NOT, LOW, MEDIUM, HIGH
Parameter to set the

quality of the mesh.
Increasing mesh quality
with NOT -> LOW ->
MEDIUM -> HIGH
QUAL_LIST
= YES
List of the qualitative bad

elements.
= NO
No list of the qualitative

bad elements.
QUAD_LOW_
ANGLE
= <value>
Angle between 0 and 89

degrees
(default=20).
QUAD_HIGH_
ANGLE
= <value>
Angle between 91 and

180 degrees
(default=160).
TRIA_LOW_
ANGLE
= <value>
Angle between 0 and 59

degrees
(default=20 ).
TRIA_HIGH_
ANGLE
= <value>
Angle between 61 and

180 degrees
(default=140).
TETRA_LOW_
ASPECT
= <value>
Value between 0.00177

and 1.30
(default=0.222)
TETRA_
HIGH_
ASPECT
= <value>
Value between 1.36 and

999
(default=8)
SOLVER_
CHECK
= YES
The solver quality criteria

are checked.
= NO
The solver quality criteria

are not checked.
= YES
Optimization will be
stopped if quality criteria
are not satisfied.
= NO
No stop
Q4TAPER
= <value>
Value for Q4TAPER

(greater or equal 0,
default = 0.5)
Q4SKEW
= <value>
Angle for Q4SKEW

default = 30)
SOLVER_
STOP
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SIMULIA
Tosca Structure
SIMULIA
Tosca Structure
MESH_SMOOTH
TETRAAR
= <value>
Value for TETRAAR

default = 100)
T3SKEW
= <value>
Angle for T3SKEW

default = 10)
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Items for STRATEGY = CONSTRAINED_LAPLACIAN
LEVEL_CONV
= LOW, MEDIUM, HIGH
Convergence parameter
of mesh_smooth
LEVEL_
DVCON
= NOT, LOW, MEDIUM, HIGH
Parameter for checking

frequency of
DVCON_SHAPE entries
during MESH_SMOOTH.
CORRECT_
ELEMENTS
= YES, NO
Correct tetrahedral elements that got inverted or

too high aspect ratios
during optimization
CE_CORREC
TION_FACTO
R
= 0 <= value < 1 (default: 0.5)
Correct elements by multiplication of optimization

displacements with this
factor
CE_CORREC
TION_LOOPS
= <int_value>
Trying to correct a single

element <int_value>
times.
CE_FAIL_
ACTION
= RESET, CONTINUE
RESET: When an element could not be corrected, its optimization

displacement is set to
zero for the current iteration.
CONTINUE: Do nothing
and risk a solver crash.
Items for STRATEGY = LOCAL_GRADIENT
FEATURE_
RECOGNITION
= <value>
Angle used for recognition of edges and corners

default = 30)
SIMULIA
Tosca Structure
Remarks
1. In MESH_SMOOTH certain elements are not permitted (e.g. beam
elements, for more information please refer to the User Manual). From the
user-defined element group a system-defined element group with the
name Mesh_smooth_id_name_'ELEM' is created in which the nonpermitted elements are eliminated and a system-defined node group
Mesh_smooth_id_name_'NODE' is generated that contains all the necessary boundary nodes.
2. The calculation time for MESH_SMOOTH increases with an increase in the
number of iterations, i.e. LEVEL_CONV=LOW is faster as HIGH. A higher
convergence parameter gives a better result in MESH_SMOOTH. The aim
for the user is: to work with the lowest convergence parameter as possible
and only switch to the next highest convergence parameter when having
problems.
4. FREE_SF: Free surface nodes include all surface nodes of the

MESH_SMOOTH area that are neither design nodes (command
DV_SHAPE operator ND_GROUP) or restricted in any way (command
DVCON_SHAPE operator ND_GROUP). The specified number of node
layers <number_of_node_layers> controls the area which is used for
remeshing. If surface nodes are fixed with FREE_SF=FIX, a node group
Mesh_smooth_id_name'_SF' is automatically created and a
DVCON_SHAPE entry Mesh_smooth_id_name'_SFIX' is generated. The
relevant entry for DVCON_SHAPE is then automatically activated in OPTIMIZE.
5. Calculation time for MESH_SMOOTH increases when the sequence is
changed, LEVEL_DVCON = NOT -> LOW -> MEDIUM -> HIGH. The user
should work with the lowest parameter possible and only switch to the next
highest parameter when problems arise.
6. LEVEL_QUAL: Calculation time for MESH_SMOOTH increases in the
sequence LEVEL_QUAL = NOT -> LOW -> MEDIUM -> HIGH. The user
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3. BOUNDARY: MESH_SMOOTH is working on an element group and

changes due to mesh smoothing should remain within this group. The
BOUNDARY=FIX option is used to fix the nodes (inner and surface nodes)
at the border of the mesh smooth area defined by the element group. In
common, this behaviour is preferred. All nodes fixed due to this settings are
stored a node group with the name <Mesh_smooth_id_name>_BOUN. If
you do not want the "border" nodes to be fixed, you can select the
BOUNDARY = FREE option. Then you are responsible to fix the proper
nodes by yourself via DVCON_SHAPE entries.
SIMULIA
Tosca Structure
MESH_SMOOTH
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should work with the lowest parameter possible and only switch to the next
highest parameter when problems arise. With LEVEL_QUAL=NOT the
entries for QUAL_LIST, QUAD_LOW_ANGLE, QUAD_HIGH_ANGLE,
TRIA_LOW_ANGLE, TRIA_HIGH_ANGLE, TETRA_LOW_ASPECT,
TETRA_HIGH_ASPECT do not have any influence.
7. Determining quality:
To determine the quality of an element, the angle of the element is determined. Tetrahedron elements have the additional quality determination of
the aspect ratio. The value of quality is between 1 (the best element
quality) and 0 (the worst element quality).
QUAD surfaces (QUAD element, side surfaces from HEXA elements):
Optimal angle is 90 degrees -> Quality=1.
Angle less than and equal to QUAD_LOW_ANGLE -> Quality=0.
Angle greater than and equal to QUAD_HIGH_ANGLE ->
Quality=0.
TRIA surfaces (TRIA elements, side surfaces from TETRA elements):
Optimal angle is 60 degrees -> Quality=1.
Angle less than and equal to TRIA_LOW_ANGLE -> Quality=0.
Angle greater than and equal to TRIA_HIGH_ANGLE -> Quality=0.
TETRA elements:
Optimal aspect ratio is 1.33 degrees -> Quality=1.
Aspect ratio less than and equal to TETRA_LOW_ASPECT ->
Quality=0.
Aspect ratio greater than and equal to TETRA_HIGH_ASPECT ->
Quality=0.
Using the parameter QUAL_LIST the list of specifications of the worst
elements are controlled with a quality of zero. Important: The internal
quality determination in MESH_SMOOTH is coupled with the determination
of the quality that is activated with READ_OPTION, ELEM_QUALITY, ON
for the complete model. The values shown with the help of QUAL_LIST are
only internal values for MESH_SMOOTH and are different from the global
values that are given from the Patran interface or via the command LIST,
ELEM, QUAL.
8. Solver criteria of quality:
SOLVER_CHECK must be activated so SOLVER_STOP can be executed.
With SOLVER_CHECK=NO the entries SOLVER_STOP, Q4TAPER,
Q4SKEW, TETRAAR, T3SKEW have no effect. The values found in Tosca
Structure should be identical to the values which have been set in the
solver. A meaningful program stop in Tosca Structure due to bad mesh
quality is better than having errors in the solver!
SIMULIA
Tosca Structure
Example
MESH_SMOOTH
ID_NAME
EL_GROUP
FREE_SF
= my_mesh_smooth
= all_alements
= FIX, 3
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END_
SIMULIA
Tosca Structure
MORPH
MORPH
Definition of morphing tasks for creation of model variants. In this commands
different predefined morphing areas are connected to an experiment plan
defining the changes for the morphing areas. For more detailed information
see vol.2 chapter 6.10, Morphing in the Tosca Structure 8.1.0 user manual. .
ID_NAME
= <Id_name_of_morph>
Name of the morphing

definition
OPTIMIZE
= <optimization_name>
Corresponding optimization task
MORPH_
AREA
= <name_of_morph_area>
Morphing area
MORPH_
PARAM_
FILE
= <morph_csv_file_name>
Morphing parameter file

containing the model
changes for each variant
NUMBER_
OF_
PARALLEL_
JOBS
= <number_of_parallel_jobs>
Optional parameter for

parallelization (number of
jobs run in parallel,
default 1); If omitted or =1
a sequential run will be
executed
SMOOTHING
= YES | NO
Optional parameter to
switch on/off surface
smoothing of the nodes
in the moved morphing
areas.
Remarks
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Version 8.1.0 Rev. 1 - 05.2014
1. Morph is not running in parallel on Windows. Thus, the

NUMBER_OF_PARALLEL_JOBS must be set to 1.
2. The morphing parameter file is an external file in the same directory as he
parameter file. The first line contains the referenced MORPH_AREA
commands. Each further line refers to one experiment (i.e. one model
design variant). For more details and an example of a morphing parameter
file see vol.2 chapter 6.10.1.2, Morphing displacement.
Examples
MORPH
ID_NAME
OPTIMIZE
MORPH_AREA
MORPH_AREA
=
=
=
=
My_morph_job
My_optimization_job
MORPH1
MORPH2
SIMULIA
Tosca Structure
MORPH_AREA
= ...
MORPH_PARAM_FILE=morphing_experiment_plan.csv
NUMBER_OF_PARALLEL_JOBS=6
SMOOTHING = NO
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SIMULIA
Tosca Structure
MORPH_AREA
MORPH_AREA
Defines a single morph area (node group) and the type of morphing to be
done with this area. Currently, only NORMAL is supported, where all nodes in
ND_GROUP are moved in node-normal direction.
For more detailed information see vol.2 chapter 6.10.1.1, Morphing areas in
ID_NAME
= <Id_name_of_morph_area>
Name of the morphing

area
ND_GROUP
= <morph_area_nd_group>

which...
TYPE
= NORMAL
Morphing type (actually

only NORMAL allowed)
TRANSITION_
ZONE
= <number>
Number of nodes uses as

transition zone. Default 0
(no transition zone), otherwise positive integer
Remarks
1. For one optimization several independent (non-intersecting) morphing
areas can be defined.
2. All nodes in any MORPH_AREA-area must be part of the design area.
Examples
MORPH_AREA
ID_NAME
=
ND_GROUP
=
TYPE
=
TRANSITION_ZONE
MORPH1
Morphing_zone1
NORMAL
= 0
END_
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3. As mesh smoothing in general does not allow smooth transitions between

single, in particular adjacent morphing areas a transition zone has to be
defined. This allows for a number of nodes at the border of the morphing
area to move with an interpolated morphing displacement (see Fig. 220).
Note that the transition zone is situated within the defined morph area.
SIMULIA
Tosca Structure
OBJ_FUNC
Defines the objective function of the optimization. For more detailed information see vol.2 chapter 4.2, Objective Function in the Tosca Structure 8.1.0
user manual.
ID_NAME
= <Id_name_of_OBJ_FUNC>
DRESP
= <name_of_DRESP>, <weight_fact>, <ref_val>
TARGET
Name of the objective

function
<name_of_DRESP>
Name of the design

response
<weight_fact>
Weight of the design

response
<ref_val>
reference value
= MIN
Tareget is to minimize the

list of design responses
(DRESP)
= MAX
Target is to maximize the

list of design responses
DRESP
= MINMAX
Target is the MINMAX

formulation of the list of
design responses
Remarks
1. The item DRESP can be repeated several times.
3. The reference value is only used for the MINMAX formulation. The default
value is 0.0.
4. The parameters norm_operator and cut_off are only available for controller
based optimization.
Examples
For BEAD:
Minimize the design response dresp_compliance
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2. The weight factor has a default value of 1.0. If more than one DRESP entry
is specified in the objective function the weight factor defines the weight of
the particular entry of the objective function.
SIMULIA
Tosca Structure
OBJ_FUNC
OBJ_FUNC
ID_NAME
DRESP
TARGET
= objective
= dresp_compliance
= MIN
END_
For SHAPE:
Minimize the design response maximum_stress
OBJ_FUNC
ID_NAME
DRESP
TARGET
= objective
= maximum_stress
= MIN
END_
For sensitivity based topology optimization:

Minimize the objective function consistent of the volume (weight factor 1.0)
plus the displacement design response with the factor 1.5.
OBJ_FUNC
ID_NAME
DRESP
DRESP
TARGET
=
=
=
=
objective
volume
DISP_X_ND_113,1.5
MIN
END_
Minimize the maximum difference of the DRESP entry to the specified reference value for the entered DRESP.
ID_NAME
DRESP
DRESP
DRESP
TARGET
=
=
=
=
=
objective
FREQ_1,1.0, 100.0
FREQ_2,1.0, 120.0
FREQ_3,1.0, 130.0
MINMAX
END_
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OBJ_FUNC
SIMULIA
Tosca Structure
OPTIMIZE
ID_NAME
=<Id_name_of_OPTIMIZE>
Name of the optimization

problem
DV
=<name_of_DV_TOPO> |
<name_of_DV_SHAPE> |
<name_of_DV_BEAD> |
<name_of_DV_SIZING>
Name of a DV_TOPO,
DV_SHAPE, DV_BEAD,
or DV_SIZING entry
OBJ_FUNC
=<name_of_OBJ_FUNC>
Name of the OBJ_FUNC

definition
DVCON
=<name_of_DVCON_TOPO>
<name_of_DVCON_SHAPE>
<name_of_DVCON_BEAD>
<name_of_DVCON_SIZING>
Name of a
DVCON_TOPO,
DVCON_SHAPE,
DVCON_BEAD or
DVCON_SIZING entry or
a
name log followed by '*'.
<family_name_
dvcon_entries>*
CONSTRAINT
=<name_of_CONSTRAINT>
Name of a CONSTRAINT
definition
MESH_
SMOOTH
=<name_of_MESH_SMOOTH>
Name of a
MESH_SMOOTH definition
STRATEGY
=<Optimization strategy>
BEAD_SENSITIVITY
BEAD_CONTROLLER
SIZING_SENSITIVITY
SHAPE_CONTROLLER
TOPO_SENSITIVITY
TOPO_CONTROLLER

strategy which should be
used.
Remarks
1. Several DVCON entries can be referenced together. It is possible to only
enter the name log followed by '*' . For example, DVCON = MY_DVCON_*
means the same as DVCON = MY_DVCON_1, DVCON=MY_DVCON_2,
DVCON=MY_DVCON_XXX etc.
2. There is only one CONSTRAINT for controller based shape, bead and
3. For sensitivity based topology, bead and sizing optimization there are
several entries for the item CONSTRAINT possible.
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Defines the optimization task. For more detailed information see vol.2 chapter
5.2, The Optimization Task for topology optimization, vol.2 chapter 6.2, The
Optimization Task for shape optimization or vol.2 chapter 7.2, The Optimization Task for bead optimization in the Tosca Structure 8.1.0 user manual.
SIMULIA
Tosca Structure
OPTIMIZE
4. If no Mesh-Smooth entry is referenced in shape optimization

(MESH_SMOOTH with the name <id_name_of_optimize>), an attached
character string '_MESH' is internally created and allocated to OPTIMIZE.
5. In SHAPE optimization the DVCON entries have the sequence according
to their order in OPTIMIZE. Nodes can be addressed several times. The
DVCON entries already entered can be modified by the following DVCON
entries.
6. Only for topology optimization a user defined controller input is specified in
the OPTIMIZE command. For shape and bead optimization the controller
input can be referenced in the DRESP command.
7. With Tosca Structure 8.1.0 the item STRATEGY is no longer required. The
following defaults are used automatically by Tosca Structure:
bead and shape optimization: controller method
topology and sizing optimization: sensitivity method.
8. The automatic strategy determination has some lightweight intelligence
included. If exactly one equality constraint for topology optimization is
found, then the controller method is used.
9. For easing the change of strategy from sensitivity based to controller
strategy inequality constraints are accepted for controller strategy as well.
This means you can change from a sensitivity based topology optimization
to controller based by simply changing the STRATEGY parameter in OPTIMIZE - assuming that the optimization problem is admissible for both strategies, .i.e. minimize compliance with a volume constraint.
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Version 8.1.0 Rev. 1 - 05.2014
Examples
OPTIMIZE
ID_NAME
DV
DVCON
OBJ_FUNC
CONSTRAINT
MESH_SMOOTH
STRATEGY
END_
=
=
=
=
=
=
=
SHAPE_OPTIMIZATION
DESIGN_NODES
DVCON_FIX_*
MISES_STRESS
CONSTANT_VOLUME
EL_OF_MESH_SMOOTH
SHAPE_CONTROLLER
controller based TOPOLOGY optimization

OPTIMIZE
ID_NAME
SIMULIA
Tosca Structure
DV
DVCON
DVCON
OBJ_FUNC
CONSTRAINT
STRATEGY
END_
=
=
=
=
=
=
DESIGN_ELEMENTS
DVCON_FROZEN
DVCON_CAST
MIN_ENERGY
CONSTR_VOLUME
TOPO_CONTROLLER
sensitivity based TOPOLOGY optimization:

=
=
=
=
=
=
=
=
=
DESIGN_ELEMENTS
DVCON_FROZEN
DVCON_CAST
MIN_ENERGY
CONSTR_VOLUME
CONSTR_DISP_X_113
CONSTR_REACTFORCE_1
TOPO_SENS
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OPTIMIZE
ID_NAME
DV
DVCON
DVCON
OBJ_FUNC
CONSTRAINT
CONSTRAINT
CONSTRAINT
STRATEGY
END_
SIMULIA
Tosca Structure
OPTIONS
OPTIONS
Determines the attributes (nodal boundary conditions) of the FE model which
should be loaded in TOSCA_PREP and TOSCA_OPT and which other
actions should be considered during loading (e.g. automatic determination of
the surface nodes). This command has to be defined before the FEM_INPUT
command in the parameterfile to be known during model import.
By default in TOSCA_PREP only the nodes and elements are loaded with the
command FEM_INPUT. In TOSCA_OPT all required stresses and displacements are loaded.
Additionally, parameters for the output of information during the optimization
may be defined. For more detailed information see vol.2 chapter 3.4.7,
Options for loading FE Data (OPTIONS) in the Tosca Structure 8.1.0 user
manual.
Remark:
OPTIONS command must be before FEM_INPUT command in parameter
file.
Read Parameters
= ON
= OFF
Determination of the surface nodes for shape

optimization while reading the finite element
model.
ON: Surface nodes are
identified
OFF: Surface nodes are
not identified
READ_SF_
MIDNODE
= ON
= OFF
Treatment of the midside

nodes during the determination of the surface
nodes.
ON: Midside nodes are
considered during the
determination of the surface nodes.
OFF: Midside nodes are
not considered during the
determination of the surface nodes.
www.3ds.com/tosca
Version 8.1.0 Rev. 1 - 05.2014
READ_SF_
IDENT
READ_BC
Treatment of the boundary conditions of the finite

element model.
SIMULIA
Tosca Structure
= ALL
Boundary conditions are

read (DEFAULT)
= NOT
No boundary conditions
are read.
= ID, <id_1>, <id_2>, ...
Only some boundary

condition sets are read.
(dependent on the interface)
READ_LOAD
= ON
= OFF
Loaded nodes / elements are identified while

reading the finite element
model.
READ_ELEM_
QUALITY
= ON
= OFF
Check the element qualities during the import of

the finite element model.
Parameters for the optimization run
Checking the presence of

the finite element results.
= STRICT
Optimization is stopped if
results are missing.
= IGNORE
Optimization is continued even if some results

are missing.
IGNORE_
NUM_OF_
CONSTRAINTS
= YES
= NO
Continue with the optimization if the definition of

the problem exceeds the
number of 50 constraints
IGNORE_
NUM_OF_
OBJF_TERMS
= YES
= NO
Continue with the optimization if the definition of

the problem exceeds the
number of 50 objective
functions terms
IGNORE_
OBJ_FUNC_
TYPE
= YES
= NO
Ignore the limitation for

MIN_MAX objective function func-type for controller based optimization
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READ_
RESULTS
SIMULIA
Tosca Structure
www.3ds.com/tosca
Version 8.1.0 Rev. 1 - 05.2014
OPTIONS
SHAPE_
FORCE_
VOLUME
= ON
= OFF
Shape optimization
forces volume constraint
in first design cycle.
It is not recommended to
turn this setting OFF. If
the mesh is distorted in
first iteration, your volume constraint is probably too small/large.
Changing this to OFF will
simply cause more
design cycles before the
mesh is corrupted.
SHAPE_AUT
O_REMOVE_I
NNER_NODE
S
= ON
= OFF
Shape optimization
removes inner nodes
from design area automatically. Inner nodes
may still cause trouble by
certain DVCON_SHAPE
whwre inner nodes are
not allowed.
SHAPE_FOR
CE_MIDSIDE_
INTERPOL
= YES
= NO
Shape optimization interpolates midside nodes

linear if one of the neighbors has been moved.
If set to YES, midside
nodes are always interpolated for meshsmooth
elements.
IGNORE_UNK
NOWN_NODE
S
= YES
= NO
If an input deck references nodes that are

unknown to TOSCA,
these nodes can be
ignored and a warning is
printed (YES) or the optimization is aborted (NO)
Output parameters
CONSTRAINT_
OUTPUT
Controls the output of the

CONSTRAINTs in
TOSCA.OUT
SIMULIA
Tosca Structure
REPORT_
FILE
= DEFAULT
Default output is that a

satified CONSTRAINT <
1.0 for the NORM output. It does not matter if
the CONSTRAINT is
LE_VALUE, GE_VALUE
or EQ_VALUE
= STANDARD
Constraint value is
normed with the constraint value
= NONORM
Do not normalize constraints
= STANDARD
= ALL
= NONE
Descriptors of what is
printed to the file
"optimization_report.csv".
See Remark.
= D,F,W,R,C
(See "Code" in table
PLOT_CTRL_
INP_MINUS_
REF
= YES
= NO
Plot the CTRL_INPUT

with the subtracted reference value or with its
original value
This can make differences if more than one
entry is present for the
objective function.
DEFAULT_
SMOOTH
= ON
= OFF
Default smoothing task

(settings corresponding
to tosca_def_smooth
_report_template.mac).
Only available for topology optimization
DEFAULT_
REPORT
= ON
= OFF
Default report generation

(settings corresponding
to tosca_def_smooth
_report_template.mac).
DEFAULT_
SMOOTH_
ADD_TO_
REPORT
= ON
= OFF
add default smooth

task(s) to default report
file or not.
DEFAULT_
SMOOTH_
ISOVALUE
= <value>
iso value for smoothing

(between 0 and 1)
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Table 1)
SIMULIA
Tosca Structure
OPTIONS
DEFAULT_
SMOOTH_
VOLUME
= <value>
= __final_iteration_value__
target volume for smoothing, relative value set by

user (between 0 and 1)
or automatic transfer of
volume value from final
iteration
DEFAULT_
SMOOTH_
GROUP
= __MODEL__
= <GROUP_NAME>
= __DESIGN__
smoothing performed for

all elements, specified
group (from analysis
model or parameter file)
or design area.
DEFAULT_
REPORT_
GROUP
= __MODEL__
= <GROUP_NAME>
= __DESIGN__
Report generated for all

elements, specified
group (from analysis
model or parameter file)
or design area.
Remarks
1. The REPORT_FILE item may be used to change the output in the file
optimization_report.csv:
Iteration number and value of the objective function (OBJ_FUNC) is always
written to optimization_report.csv. This is the only output by option
"NONE".
The default is ("STANDARD") output is:
DRESP, OBJ_FUNC:DRESP and CONSTRAINT values.
All outputs in following table are active by option "ALL".
2. Using the letter codes in the REPORT_FILE item the output may be
customized.
www.3ds.com/tosca
Version 8.1.0 Rev. 1 - 05.2014
Output name
Description
Code
DRESP
All DRESPs referenced in OBJ_FUNC real values
OBJ_FUNC:DRESP
The value of DRESP in OBJ_FUNC

[weight*(dresp_value ref_value) ]
OBJ_FUNC:DRESP:
Weight
Weight of DRESP in OBJ_FUNC
OBJ_FUNC:DRESP:
Ref
Reference value of DRESP in OBJ_FUNC

This value can be interesting for shape optimization
CONSTRAINT
The value of DRESP in CONSTRAINTs
SIMULIA
Tosca Structure
Table 1
Descriptors for the TOSCA_REPORT item.
3. Default result reports and smooth runs can be activated in the parameterfile to be created after the optimization (an example can be found in the
macro tosca_def_smooth_report_template.mac). To get a report with your
topology optimization results including the smoothed model with the
volume of the final optimization step, you could add the following to your
parameter file:
OPTIONS
DEFAULT_SMOOTH
DEFAULT_REPORT
DEFAULT_SMOOTH_ADD_TO_REPORT
DEFAULT_SMOOTH_VOLUME
DEFAULT_SMOOTH_GROUP
DEFAULT_REPORT_GROUP
=
=
=
=
=
=
ON
ON
ON
__final_iteration_value__
__MODEL__
__MODEL__
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END_
SIMULIA
Tosca Structure
OPT_PARAM
OPT_PARAM
Defines parameters to control optimization. For more detailed information see
vol.2 chapter 5.8, Settings(toplogy optimization), vol.2 chapter 6.8, Settings
(shape optimization), vol.2 chapter 7.8, Settings (bead optimization) and
vol.2 chapter 8.8, Settings (sizing optimizataion) in the Tosca Structure 8.1.0
user manual.
ID_NAME
= <Id_name_of_OPT_PARAM>
Name of the
OPT_PARAM definition
OPTIMIZE
= <Name_of_OPTIMIZE>

problem (OPTIMIZE)
which is relevant for the
parameter.
Parameters for SENSITIVTY BASED bead, sizing and topology optimization

For eigenvalue optimization:
MODETRACKING
<option>
Switch for modetracking
= OFF
Modetracking is deactivated
= ON
Modetracking is activated
= ON, <node_group>
Modetracking is activated
for specified nodegroup
MODETRAC
K_REFEREN
CE
Number of modes
included in the modetracking.
Default: 5
= INITIAL
Modes of present optimization iteration are

tracked with respect to
the modes of the initial
optimization iteration
= PREVIOUS
Modes of present optimization iteration are

tracked with respect to
the modes of previous
optimization iteration
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Version 8.1.0 Rev. 1 - 05.2014
MODENUMBERS
SIMULIA
Tosca Structure
For frequency response optimization:

DAMP_
STRUCTURAL_
MASS
= <real_value>
Structural mass damping

for design element (or
elements at design
nodes)
DAMP_
STRUCTURAL_
STIFF
= <real_value>
Structural stiffness damping for design element (or

elements at design
nodes)
DAMP_
VISCOUS_
MASS
= <real_value>
Viscous mass damping

for design element (or
elements at design
nodes)
DAMP_
VISCOUS_
STIFF
= <real_value>
Viscous stiffness damping for design element (or

elements at design
nodes)
SUM_Q_
FACTOR
= <real_value>
Weighting function for

peaks in frequency spectrum.
Default: 6.0
SCALE
= <real_value>
= <r_grow>,<r_shrink>
The displacements determined by the optimization

algorithms are multiplied
with the <real_value>
(Default scale=1). To
switch the optimization
direction of the controller
a negative value can be
entered (this is only available in the module Tosca
Structure.nonlinear). If
two values are defined,
the first value is the scale
for nodes with growth
and the second value the
scale for nodes with
shrinkage.
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Parameters for shape optimization
SIMULIA
Tosca Structure
www.3ds.com/tosca
Version 8.1.0 Rev. 1 - 05.2014
OPT_PARAM
MID_NODES
= LINEAR
= INTERPOLATE
Treatment of the midside

nodes during the optimization.
LINEAR: midside node
positions are linearly
interpolated from the
optimized position of the
connected corner nodes
INTERPOLATE: midside
node optimization displacements are interpolated from the
optimization displacement of the corner nodes
CURV_
SMOOTH
= <elem_edge_length>
The nodal optimization

movement vector is modified in areas of high curvature to prevent a
collapse of the mesh for
large volume changes. A
bigger radius causes a
bigger curvature based
modification of the optimization movement vector. (Default=5.0 element
edge lengths; OFF=0.0)
FILTER
= <radius>, <sigma>, <exponent>
Filter for the nodal equivalence stress. The radius

defines the maximum
distance for influencing
neighbour nodes, sigma
defines the reduction of
the radius depending on
the surface bending
(default: 0.2), the exponent defines the weighting function depending
on the distance (default:
1.0)
VECTOR
= EVER
= FIRST
Update of the shape

basis vectors occurs in
every (EVER) or only in
the first (FIRST) design
cycle.
SIMULIA
Tosca Structure
DISP
= MINIMUM
= AVERAGE
The permitted absolute

step size is controlled by
the medium node displacement (AVERAGE)
or the minimum node displacement (MINIMUM).
TOL_VALUE
= <real_value>
tolerance value for the

constraint (relative value)
The default is 0.001
Parameters for controller based topology optimization
SPEED size of increment

= VERY_SLOW
Very small stepsize
= SLOW
Small stepsize
= MODERATE
Moderate stepsize
= MEDIUM
Medium stepsize
= FAST
FAST large step

size(only permitted in
optimization of stiffness
with volume constraint)
= ITER, <no. of iterations>
Step size is modified

dynamically, so the optimization end after the
given number of iterations. The default value
for the number of iterations is 15.
= ITER,15
START_
DELETE
= <operator>, <value>
<operator>
= PERC
= ABS
<value>
AUTO_
FROZEN
<option>
Setting the volume that

can be removed immediately in the first design
cycle
Specifying the volume in
percent
Specifying the absolute
volume
Volume that is deleted in
the first design cycle
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SPEED
SIMULIA
Tosca Structure
OPT_PARAM
= LOAD
(default for all algorithms)
all loaded elements and

elements with loaded
nodes are excluded from
the optimization via a
automated
DVCON_TOPO FROZEN statement
= OFF
Loaded elements are

treated normally (are
optimizable)
= SPC
Elements with boundary

conditions are excluded
from the optimization
= BOTH

nodes and with boundary conditions are
excluded from the optimization via a automated
Parameters for sensitivity based topology optimization
www.3ds.com/tosca
Version 8.1.0 Rev. 1 - 05.2014
DENSITY_
UPDATE
<option>
Parameter for how the

densities are updated in
the method of moving
asymptotes (MMA).
= NORMAL
Normal strategy
= CONSERVATIVE
Conservative strategy
= AGGRESSIVE
Aggressive strategy
DENSITY_
INITIAL
= <real_value>
Initial values of density

(when no material constraint is present).
Default: 0.5
DENSITY_
UPPER
= <real_value>
Upper bound on design

variables.
Default: 1.0
DENSITY_
LOWER
= <real_value>
Lower bound on design

variables.
Default: 0.001
DENSITY_
MOVE
= <real_value>
Move limit on design variables.

Default: 0.25
FILTER_
RADIUS
= <radius>
Filter for mesh independence and minimum size.

Default: 1.3 * average
element edge length
FILTER_TYPE
= STANDARD
The convential filter

applied in topology optimization.
= LOW
A modified filter applied

in topology optimization
useful for coarse
meshes.
<option>
Material interpolation
scheme (Relation
between relative density
and relative element stiffness).
= SIMP
Solid Isotropic Material

with Penalization
= RAMP
Rational Approximation
of Material Properties
MAT_
PENALTY
= <real_value>
Penalty factor for interpolation scheme. Default:

3.0
PROCESSORS
<option>
Number if CPU-processors for Abaqus in combination with sensitivity

based topology optimization
= SINGLE
Default. Abaqus only, single CPU-processor in

combination with sensitivity based topology optimization
= MULTI
Abaqus only, several

CPU-processors in combination with sensitivity
based topology optimization
MAT_INTERPOLATION
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SIMULIA
Tosca Structure
SIMULIA
Tosca Structure
OPT_PARAM
www.3ds.com/tosca
Version 8.1.0 Rev. 1 - 05.2014
STOP_
CRITERION_
LEVEL
<option>
Parameter for if both stop

criteria should be used.
= BOTH
Use both criteria
= SINGLE
Just one of the two criteria has to be fulfilled
STOP_
CRITERION_
OBJ
= <real_value>
Stop criterion based upon

the change in objective
function.
Default: 0.001
STOP_
CRITERION_
DENSITY
= <real_value>

the change in element
densities.
Default: 0.005
STOP_
CRITERION_
ITER
= <real_value>
Parameter defining from

which optimization iteration should the two criteria be checked.
Default: 4
SOFT_
DELETE_
METHOD
= <method>,
<soft_delete_threshold_
value>
<method>
Method selection for

SOFT_DELETE
= STANDARD
Removal of elements is
done when component
check was sucessful
(check for disconnected
parts of the component)
= AGGRESSIVE
done on base of the rel.
density without any further checks.
= MAX_SHEAR_STRAIN
based upon maximum
elemental shear strain
(with positive shear
threshold)
= MIN_PRINCIPAL_STRAIN
Removal of elements
based upon minimal elemental principal strain
(with negative minimum
principal threshold)
= PLASTICITY
Removal of elements
based upon maximum
effective elastoplastic
strain (only to use for
elastoplastic constitutive
material law)
= VOLUME_CHANGE
Removal of elements
based upon the minimum
relative deformed elemental volume ((Vdeform Vorg) / Vorg) with negative threshold value
<soft_delete_threshold_v
alue>
Method = STANDARD or
AGGRESSIVE:
relative material density
value for indentification of
elements to be removed
(element with a value
below will be removed
from the finite element
calculation file), default
0.05
other methods: corresponding thresholds
must be defined (no
default value available,
for details see vol.2
chapter 5.8.2.3,
Removing soft elements for increasing
performance).
SOFT_
DELETE
= <el_group>, <radius>
<el_group>
Name of the element

group in which the soft
elements should be
deleted during optimization
<radius>
Average element edge

length of the model (for
Method = STANDARD or
AGGRESSIVE)
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SIMULIA
Tosca Structure
SIMULIA
Tosca Structure
OPT_PARAM
AUTO_
FROZEN
<option>
= LOAD
= OFF
= SPC
= BOTH

automated
Loaded elements are
treated normal (are optimizable)
Parameters for sensitivity based sizing optimization
www.3ds.com/tosca
Version 8.1.0 Rev. 1 - 05.2014
THICKNESS_
UPDATE
<option>

thicknesses are updated
in the method of moving
asymptotes (MMA).
= NORMAL
Normal strategy
= CONSERVATIVE
Conservative strategy
= AGGRESSIVE
Aggressive strategy
THICKNESS_
MOVE
= <real_value>
Move limit on design variables.

Default: 0.25
FILTER_
RADIUS
= <radius>
Filter for mesh independence and minimum size.

Default: 1.3 * average
element edge length
FILTER_TYPE
= STANDARD
The convential filter

applied in sizing optimization.
SIMULIA
Tosca Structure
= LOW
A modified filter applied

in sizing optimization
useful for coarse
meshes.
<option>
Parameter for if both stop

criteria should be used.
= BOTH
Use both criteria
= SINGLE
Just one of the two criteria has to be fulfilled
STOP_
CRITERION_
OBJ
= <real_value>

the change in objective
function.
Default: 0.001
STOP_
CRITERION_
THICKNESS
= <real_value>

the change in element
densities.
Default: 0.005
STOP_
CRITERION_
ITER
= <real_value>
Parameter defining from

which optimization iteration should the two criteria be checked.
Default: 4
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STOP_
CRITERION_
LEVEL
SIMULIA
Tosca Structure
OPT_PARAM
AUTO_
FROZEN
<option>
= OFF
(default for sizing)
No AUTO_FROZEN
applied, loaded elements
are treated normally (are
optimizable)
= LOAD

automated
DVCON_SIZING FROZEN statement
= SPC

= BOTH

DVCON_SIZING FROZEN statement
www.3ds.com/tosca
Version 8.1.0 Rev. 1 - 05.2014
Parameters for CONTROLLER bead optimization
VECTOR
=FIRST
=EVER
Update of the optimization displacement vector

occurs in first (default) or
in each design cycle.
SCALE
= <real_value>
Definition of the direction

of the optimization displacement.
BEAD_
WIDTH
= <real_value>
Bead wide
BEAD_ITER
= <int_value>
Definition of the number

of iterations.
SIMULIA
Tosca Structure
BEAD_
MIN_
STRESS
= <real_value>
Value, relative to the

highest Von Mises stress
in the design area, under
which, no optimization
should be performed.
Value between 0.0 and
1.0, where 1.0 is equal
the highest Von Mises
stress. Default is 0.001
BEAD_
MAX_
MEMBRANE
= <real_value>
Value of the maximal

membrane stress relative to maximal bending
stress in original model
under which no optimization is performed. (> 0)
Default 1.0.
CURV_
SMOOTH
= <elem_edge_length>
Default 5.0
Filtering the normals,

effect for curved geometries. Value is relative to
the medium element
edge lenght. (Default is 5
elements)
BEAD_
NODE_
SMOOTH
= <real_value>
This defines the minimum distacne between a

node at zero optimization displacement and
one at maximal bead
height. Default is 0.25 (of
BEAD_WIDTH)
FILTER_
RADIUS
= <real_value>,
<ABS/REL-switch>
Default: 4.0, REL
FILTER_RADIUS is the
radius with which the
sensitivties are filtered.
REL is RELative to
medium edge length of
elements in the design
area. Values may also be
set ABSolute, fx. :
FILTER_RADIUS = 5.0,
ABS
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Parameters for SENSITIVITY BASED bead optimization
SIMULIA
Tosca Structure
OPT_PARAM
ONLY_DES_
NODES
= YES / NO
Default: YES
Calculate sensitivities for

only design nodes by
"YES" which is default.
ALL_NODES are used in
sensitivity calculation by
"NO" which is not recommended.
NODAL_
MOVE
= <real_value>
Default: 0.1
Relative move limit of

nodal optimization
displacement pr iteration.
0.0 < <real_value>
< 1.0
NODAL_
UPDATE
= CONSERVATIVE

nodal displacements are
updated in the method of
moving asymptotes
(MMA).
PERTURBATION
= <real_value>
Deafult: 0.0001
= NORMAL
= AGGRESSIVE
Sets perturbation size for

finite differences (relative
to medium element edge
lenght)
Remarks
1. As the form of the component changes during optimization the shape
basis vector must be continually adjusted. The settings VECTOR=FIRST is
only to be used when a node displacement along the initial vector is explicitly required.
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Version 8.1.0 Rev. 1 - 05.2014
2. SCALE is the direction of the optimization displacement. 1.0 for the same
direction as the surface normals, -1 for the opposite.
3. MODETRACKING can be activated for a specific nodegroup (e.g. every
fifth node on the surface). This results in a significant gain of performance.
4. Setting FILTER_TYPE = LOW can be recommend for optimizations having
no casting constraints, a low mass constraint (<5%) and/or a coarse mesh.
This will lead to less optimization iterations and more clear designs.
5. Generally, setting FILTER_TYPE = LOW gives raise more to clear solidvoid designs compared to FILTER_TYPE =STANDARD.
6. The main disadvantage of setting FILTER_TYPE = LOW is that the optimization result can contain checkerboard.
SIMULIA
Tosca Structure
7. The setting of FILTER_TYPE has no impact upon the optimization results

and history if the mass is the objective to be minimized.
8. The setting of FILTER_TYPE has no impact upon the optimization results if
casting constraints are defined.
9. Setting FILTER_TYPE =LOW will lead to less optimization iterations.
10.The minimum member size restriction might not be completely enforced
when applying FILTER_TYPE = LOW.
11.Changing the filter option has no effect when manufacturing constraints
are present.
Examples
OPT_PARAM
ID_NAME
=
OPTIMIZE
=
SCALE
=
BEAD_MIN_STRESS=
optimization_control
bead_optimization
- 1.0
0.01
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END_
SIMULIA
Tosca Structure
REPORT
REPORT
www.3ds.com/tosca
Version 8.1.0 Rev. 1 - 05.2014
Combines optimization results to postprocessing reports. These contain animation sequences of fringe plots of optimization results as well as result plots.
For more detailed information see vol.2 chapter 10.1, Generation of Postprocessing Data.
ID_NAME
= <Id_name_of_report>
Name of the job
MODEL
= <ONF file name>
Name and relative path

of the ONF file, containing the model
First, tosca_report
checks if the file with the
given name exists. If not,
the file <model>_fem.onf
is loaded. The default
value of this parameter is
SAVE.onf/
MODEL_fem.onf.
RESULT
= <ONF result file path

and prefix>
Use this parameter to

specify the path and the
prefix of the result onf
files (one of TP, SHAPE
or BEAD). The default
value of this parameter is
SAVE.onf/TP, SAVE.onf/
SHAPE or SAVE.onf/
BEAD, depending upon
which files out of these
actually exist.
OUTPUT_
FILE
= <name_of_VTFx_file>
Name of the VTFX file to

be created.
If the name ends with
.vtfx, no extension will be
added. If this isnt the
case the extension .vtfx
will be added.
CONTOURPLOT
= <name of contour plot>
Name of contour plot to

be written as separate
case in the vtfx file. More
than one entry is allowed
see also CONTOUR-
PLOT
SIMULIA
Tosca Structure
DEFAULT_G
ROUP
= <name of element group>
Default group for contour

plots, i.e. visualization
model and fringe plot will
be restricted to this
group.
APPEND_
TO_VTFX
=YES
=NO
Appends report to file

specified with parameter
OUTPUT_FILE.
Remarks
1. Note that MODEL, RESULT and OUTPUT_FILE should be specified using
absolute paths or relative paths starting from the job directory (more
precisely, from the directory where tosca_report is started)
2. To add sensitivity plots to your report file, you must first write the sensitivity
information to ONF using a USER_FILE command. Then use the following
command contained in your original parameter file (because Tosca Structure control must know all objective functions and constraint definitions):
REPORT
ID_NAME = sens_plots
SENSITIVITY_PLOT = YES
END_
The procedure in detail is described in vol.2 chapter 10.1.5.6, Sensitivity
plots.
4. Using DEFAULT_GROUP in the REPORT-command the Tosca Structure

control appends the specified group to all referenced CONTOURPLOTs. In
the example below GROUP = MESHSMOOTH is added to the CONTOURPLOTs MODEL, SHAPE_CTRL and SHAPE_DISP if they do not already
reference a group. Thus, the visualization model is restricted to the referenced group which may reduce file size significantly.
REPORT
ID_NAME
RESULT
MODEL
CONTOURPLOT
CONTOURPLOT
CONTOURPLOT
OUTPUT_FILE
=
=
=
=
=
=
=
default_shape
"SAVE.onf/SHAPE"
MODEL
SHAPE_CTRL
SHAPE_DISP
"TOSCA_POST/default_shape"
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3. APPEND_TO_VTFX allows to combine reports with several smooth results

into one vtfx archive. Please note, if APPEND_TO_VTFX=NO and the file
specified with parameter OUTPUT_FILE exists, it is overwritten. Otherwise
a new file is created.
SIMULIA
Tosca Structure
REPORT
DEFAULT_GROUP
= MESHSMOOTH
www.3ds.com/tosca
Version 8.1.0 Rev. 1 - 05.2014
END_
SIMULIA
Tosca Structure
SELECT
Selects subsets of different types of objects (solids, nodes, elements etc).
These subsets can be combined to a group with the command GROUP_DEF.
All commands have only reference to the selected (active) objects. For more
detailed information see vol.2 chapter 3.7, Selection of Objects in Tosca
Structure.gui in the Tosca Structure 8.1.0 user manual.
SELECT, object, type, item, lab1, lab2, lab3
type
Specifies the object type

ALL
All object types
CS
Coordinate systems
ELEM
Elements
ELGR
Element groups
EPROP
Element properties
ETYPE
Element types
MAT
Material types
NDGR
Node groups
NODE
Nodes
NONE
Deactivates all currently

selected objects (unselect)
SOLID
Solids (primitives)
Selection type
S
Selection of a subset from the

total set of this object type
Reselection from the current

subset
Addition to the current subset
Substraction from the current

subset
ALL
Selects all specified objects
NONE
Selects none of the specified

objects (unselect)
INV
Switches the currently

selected objects with the not
selected objects
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object
SIMULIA
Tosca Structure
SELECT
object=ALL
No further specification is possible.
object=CS
SELECT, CS, type, item, lab1
item
CS
Coordinate system
lab1
<cs_name>
Name of the Coordinate system
object=ELEM
SELECT, ELEM, type, item, lab1, lab2, lab3
item
ELEM
The elements between

min_value and
max_value are selected by
increment
lab1
<min_value>
lowest element ID
lab2
<max_value>
highest element ID
lab3
<increment>
increment
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Version 8.1.0 Rev. 1 - 05.2014
SELECT, ELEM, type, item, lab1, lab2

item
LAYER
The elements are selected by

layer starting from the active
elements
lab1
<layer_number>
number of element layers
lab2
The selection of the next layer is realized by common nodes,

edges or faces
POINT
Common nodes
LINE
Common element edges
AREA
Common element faces
SELECT, ELEM, type, item

item
ELGR
Selection of the elements of

the active element groups
EPROP
Selection of the elements with

the active element properties
ETYPE

the active element types
SIMULIA
Tosca Structure
MAT

the active material types
ND_ALL
Selection of the elements in

which all nodes are active
ND_ANY
Selection of the elements in

which at least one node is
active
object=ELGR
SELECT, ELGR, type, item, lab1
item
ELGR
Selection of element groups

by name
lab1
<el_group>
Name of the element group
object=EPROP
SELECT, EPROP, type, item, lab1
ITEM
EPROP
Selection of element properties by number
lab1
<value>
Number of the element property
SELECT, EPROP, type, item, lab1

ITEM
EPROP_NAME
Selection of element properties by name
lab1
<name_of_Eprop>
Name of the element property
SELECT, ETYPE, type, item, lab1

item
ETYPE
Selection of element types by

name
lab1
<name_of_etype>
Name of the element type
object=MAT
SELECT, MAT, type, item, lab1
item
MAT
Selection of materials by number
lab1
<value>
Number of material
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object=ETYPE
SIMULIA
Tosca Structure
SELECT
SELECT, MAT, type, item, lab1

item
MAT_NAME
Selection of materials by
name
lab1
<name_of_mat>
Name of material
object=NDGR
SELECT, NDGR, type, item, lab1
item
NDGR
Selection of node groups by

name
lab1
<name_of_nd_group>
object=NODE
SELECT, NODE, type, item
www.3ds.com/tosca
Version 8.1.0 Rev. 1 - 05.2014
item
ELEM
Selection of the nodes of the

active elements. (including
midside nodes)
ELGR
Selection of the nodes of the

active element groups
FIX_ALL
Selection of all nodes which

are fixed in all translational
degrees of freedom
FIX_ANY

are fixed in at least one translational degree of freedom
FIX_UX

are fixed in X-direction
FIX_UY

are fixed in Y-direction
FIX_UZ

are fixed in Z-direction
CORNER_NODE
Selection of all corner nodes
MIDSIDE_NODE
Selection of all midside nodes
NDGR
Selection of all nodes of the

active node groups
ND_ESF
Selection of the nodes on the

boundary of the active elements (including inner surfaces)
SIMULIA
Tosca Structure
ND_SF
Selection of the active surface

nodes
SOLID
Selection of the nodes in the

active solids
SELECT, NODE, type, item, lab1, lab2, lab3

item
NODE
The nodes between
min_value and
max_value are selected by
increment.
lab1
<min_value>
Lowest node number
lab2
<max_value>
Highest node number
lab3
<increment>
Increment
SELECT, NODE, type, item, lab1, lab2, lab3
item
DISP_DX
Nodes with enforced X-displacement (in cs=lab3)

between min_value and
max_value
DISP_DY
Nodes with enforced Y-displacement (in cs=lab3)

max_value
DISP_DZ
Nodes with enforced Z-displacement (in cs=lab3)

LOC_1 (bzw. LOC_X)
Selection of the nodes with

first coordinate value between
min_value and
max_value in cs=lab3
LOC_2 (bzw. LOC_Y)

second coordinate value
LOC_3 (bzw. LOC_Z)

third coordinate value
lab1
<min_value>
Minimum value
lab2
<max_value>
Maximum value
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max_value
SIMULIA
Tosca Structure
SELECT
lab3
<cs_name>
Name of the coordinate system
object=SOLID
SELECT, SOLID, type, item, lab1, lab2, lab3
item
SOLID
Selection of solids by name
lab1
<name_of_solid>
Name of the solid
Examples
Select all surface nodes. Very useful for shape optimization. See also volume
3: GROUP_DEF:
! Selecting all elements for surface identification
select,elgr,s,elgr,ALL_ELEMENTS
select,elem,s,elgr
SF_IDENT
! select surface nodes
select,node,s,ND_SF
All nodes inside the solid SOL_1 should be selected:

SELECT, SOLID, S, SOLID, SOL_1
SELECT, NODE, S, SOLID
Selection of all surface nodes of the elements in the design area. The elements in the design area have property 4.
SELECT, EPROP, S, EPROP, 4
www.3ds.com/tosca
Version 8.1.0 Rev. 1 - 05.2014
SELECT, ELEM, S, EPROP

SELECT, NODE, S, ELEM
SELECT, NODE, R, ND_SF
Selection of all elements at least with one node of the node group
design_nodes and two layers of elements around that element group.
SELECT, NDGR, S, NDGR, DESIGN_NODES
SELECT, NODE, S, NDGR
SELECT, ELEM, S, ND_ANY
SELECT, ELEM, A, LAYER, 2, POINT
SIMULIA
Tosca Structure
Selection of all surface nodes of the automatically generated mesh smooth

node group except for nodes of the node group no_mesh_smooth
SELECT,NDGR,S,NDGR,MESH_SMOOTH_NODE
SELECT,NODE,S,NDGR
SELECT,NODE,R,ND_SF
SELECT,NDGR,S,NDGR,NO_MESH_SMOOTH
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SELECT,NODE,U,NDGR
SIMULIA
Tosca Structure
SF_IDENT
SF_IDENT
Identification and marking of all surface nodes of the active nodes. The nodes
can be addressed with the command SELECT due to this marking. For example, if shells lie on the surface of solid elements, only the free boundary of the
shell is identified as being a surface. In this case the solid elements have to
be selected with the command SF_IDENT. The following commands may be
used to perform the identification of the surface nodes for 3D elementtypes
only after the finite element model was read in via FEM_INPUT
SELECT,ETYPE,S,ETYPE,SOLID_BRICK_8
SELECT,ETYPE,A,ETYPE,SOLID_TETRA_4
SELECT,ELEM,S,ETYPE
SF_IDENT
For more detailed information see vol.2 chapter 3.4.7.2, Identifying surface
nodes for shape optimization in the Tosca Structure 8.1.0 user manual.
Remarks
www.3ds.com/tosca
Version 8.1.0 Rev. 1 - 05.2014
1. In SHAPE optimization only marked surface nodes can be defined as being

design nodes. The identification of the surface nodes can be done by
setting the command OPTIONS, READ_SF_IDENT = ON already during
loading of the FE model (volume 3: FEM_INPUT).
SIMULIA
Tosca Structure
SMOOTH
ID_NAME
= <ID>
Unique ID name of the

SMOOTH block; is also used
as the default output file name
base; mandatory
TASK
= <option>
Determines the task type;

mandatory
= ISO
Iso-surface of a topology optimization result
= SURFACE
Surface of the initial model or

the result of shape or bead
optimization
= ALL_ITERATIONS
Iso-surfaces for each iteration

of topology optimization
MODEL
= <ONF file name>
Name of the ONF model file;

mandatory
RESULT
= <ONF file name>
ONF result file name containing the material distribution

(for topology optimization with
TASK = iso or
all_iterations) or the
optimization displacement (for
bead or shape optimization)
OUTPUT_
FILE
= <file name base>
Base for the output file name;

the value of ID_NAME
parameter is used by default
ISO_VALUE
= <value>
Isovalue; is used to determine

the positions on the element
edges where the new nodes
are created. Larger values
lead to models with smaller
volume. Not used if TASK =
surface. Value between 0
and 1; default: 0.3
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Contains the parameters that control the generation of (iso)surfaces by Tosca

Structure.smooth. For more detailed information see vol.2 chapter 9.1, Tosca
Structure.smooth in the Tosca Structure 8.1.0 user manual.
SIMULIA
Tosca Structure
SMOOTH_
CYCLES
= <value>
Number of smoothing cycles;

if set to 0, no smoothing is
performed. Larger values lead
to smoother models, but may
cause the narrowing of thin
components. Not used if
TASK = surface. Nonnegative integer value,
default: 5
SHRINKAGE_CO
RRECTION
=YES
=NO
Reduce the shrinkage effects

caused by the laplacian
smoothing
REDUCTION_
RATE
= <value>
Defines the percent of faces

that should be removed during the data reduction; if set to
0, no data reduction occurs. If
set to 100, the data reduction
stops when no faces can be
removed (that is checked
using REDUCTION_ANGLE
parameter). Real value
between 0 and 100; default: 0
REDUCTION_
ANGLE
= <value>
Defines the maximal angle

between adjacent faces at a
node such that the node may
be removed during the data
reduction. Real value in
degrees between 0 and 90;
default: 15
SELF_
INTERSECTION_
CHECK
= <option>
Defines if the self-intersection

checks are to be performed
during the isocut, smoothing
and data reduction
= OFF
No checks
= CHECK
Check once
= RUNTIME
Check always
= ITERATIVE
first run without check, then

rerun if self-intersections are
found; default
www.3ds.com/tosca
Version 8.1.0 Rev. 1 - 05.2014
SMOOTH
MIN_ANGLE
= <value>
Defines the minimal angle of

the triangles that result from
the smoothing and data
reduction; triangles with
smaller angles may be present if they are created during
the isocut. Too large value
may prevent the smoothing;
too small value may lead to
degenerated triangles. Real
value in degrees between 0
and 90; default: 15
MIXED_MESH
= YES
= NO
If set to YES, then the quadrilaterals are formed from adjacent triangles; applies to
VTFX, ONF, IGES and WRL
output formats only. Default:
NO
FORMAT
See the table below
Output file format; one or

more FORMAT entries can be
specified. In case that the isosurfaces for all iterations are
calculated, one file for each
iteration in each mentioned
format (except VTFX) is
saved; additionally, a VTFX
file containing the isosurfaces
for all iterations is generated.
OUTPUT_
SURFACE
= ORIGINAL
= NEW
= BOTH
Specifies what should be

saved to the output files: the
original surface (ORIGINAL),
the surface generated by isocut (NEW), or the complete
surface (BOTH). The parameter has no influence for shell
element models, and is
ignored for the generation of
slices. Default: BOTH
VTF_
ORIGINAL_
MODEL
= YES
= NO
If set to YES, the original FEM

model will be saved to the
VTFX output file in addition to
the (iso)surface. Default: NO
APPEND_TO_
VTFX
=YES
=NO
Appends report to file specified with parameter

OUTPUT_FILE.
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SIMULIA
Tosca Structure
SIMULIA
Tosca Structure
IGES_UNIT
= IN (inches)
= MM (millimeters)
= FT (feet)
= MI (miles)
= M (meters)
= KM (kilometers)
= MIL (mils)
= UM (microns)
= CM (centimeters)
= UIN (microinches)
Unit used for output in IGES

format.
Note that the same unit is
used in the case that the
slices are generated and
saved in IGES format.
Default: MM
SLICE_
NUMBER
= <value>
Number of parallel section

planes that define the slices. If
set to 0, no slices are saved.
Only used for solid models.
Nonnegative integer value,
default: 0
SLICE_
NORMAL
= <x>,<y>,<z>
Normal to the section planes.

The real values x, y, z that are
not all equal to zero should be
separated by commas;
spaces before or after the
commas are allowed. Default:
0, 1, 0
SLICE_
FORMAT
= IGS_POLYGON
Save slices as polygons using

cubic parametric splines for
each segment (IGES block
112). File name:
<name>_slices.igs. Default
= IGS_CURVES
Save slices as curves

obtained by interpolation
using uniform cubic splines
(IGES block 126). File name:
<name>_slices_ipl.igs
= CLI
Save slices as polygons

saved in common layer interface format. File name:
<name>_slices.cli
= ALL
Save slices in all formats

mentioned above
www.3ds.com/tosca
Version 8.1.0 Rev. 1 - 05.2014
SMOOTH
BORDER
= YES
= NO
If set to YES, the border of the

shell element model will be
saved according to the format
defined by SLICE_FORMAT
parameter; the file name is
the same as for slice output,
with slices replaced with border. Only used for shell element models. Default: NO
GROUP_FILE
= <ONF group file

name>
Name of the ONF file containing the groups
GROUP_
EXCLUDE
= <group name>
The elements of the group are

ignored for all operations
GROUP_
INCLUDE
= <group name>
The elements of the group are

marked as normal and are
used for the (iso)surface calculaton
GROUP_
SURFACE
= <group name>
The surface of the elements in

the group will be calculated
even if they would be deleted
or cut otherwise.
TARGET_
VOLUME
= <value>
Defines the target volume that

is to be achieved iteratively by
varying the isovalue. If set to
0, the given isovalue is used
for the generation of the isosurface. Not used if TASK =
surface. Real value
between 0 and 1; default: 0
ISO_VALUE_
GROUP
= <group>,<value>
Defines the isovalue for a

given group. Not used if TASK
= surface. Value is
between 0 and 1
TARGET_
VOLUME_
GROUP
= <group>,<value>
Defines the target volume for

a given group. Not used if
TASK = surface. Value is
between 0 and 1
ISO_
SEQUENCE
= CONST
Use the same isovalue for

each iteration. Only used if
TASK =
all_iterations. Default
= INCR
Use linearly increasing isovalues. Only used if TASK =

all_iterations.
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SIMULIA
Tosca Structure
SIMULIA
Tosca Structure
EXCLUDE_
LOADED
= YES
= NO
If set to YES, the loaded elements will be removed from

the smoothed result. Only
available if <jobname>_fem.onf file is used as
the input model file. If not set,
the entire model is used for
smoothing (Default: NO).
The exclusion of loaded elements is required for the automatic remeshing in Tosca
ANSA environment (Default in
TAE: YES).
ORIGINAL_
SURFACE_
SMOOTHING
= OFF
= SHRINK
= FULL
Defines if the original surface

is to be smoothed or remain
unchanged. OFF means no
changes to the original surface, SHRINK allows its
nodes to be moved towards
the inside only, FULL allows
any modifications of the original surface. Default: OFF
RESULT_
FILTERING
= OFF
= MODERATE
= FULL
Defines if the element material values are to be filtered

(averaged locally) before the
isocut, and to what extent.
Default: NO
KEEP_
CONNECTION_NODES
= YES
= NO
Keep nodes on the border

towards an excluded area
COMPONENT
_LIMITING_
SIZE
= <value>
Default: YES
Defines the minimal allowed
relative size of a connected
component (calculated using
its number of faces). All components with the relative size
below this value are removed.
Default: 0
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Version 8.1.0 Rev. 1 - 05.2014
SMOOTH
SIMULIA
Tosca Structure
The following table describes the options for FORMAT command:

Formats for transfer to Postprocessing
Program
FORMAT
File name, comments
Abaqus/CAE
inp
iges1
<name>.inp
ANSYS
cdb
<name>.cdb
iges3
CATIA
iges3
<name>.stl (STL recommended as design draft)

GLView
Inova
vtfx
<name>.vtfx
MEDINA
stl
<name>.stl
(using FEM formats is also possible)
MSC Nastran
bdf
<name>.bdf
Patran
out
<name>.out (Patran neutral format)
Pro/E
iges1
Rapid Prototyping applications
stl
<name>.stl
Solid Works
iges2
<name>_2.igs (IGES with explicit point information)
vtfx
<name>.vtfx
NX
stl
<name>.stl
Graphic
(animation)
programs
obj
<name>.obj (Wavefront .obj file for 3D model

exchange)
Other pre/
postprocessors
See above
Use out, inp, bdf, cdb; see above for file

names.
Table 2
stl
Output parameters for Tosca Structure.smooth
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parameter
SIMULIA
Tosca Structure
SMOOTH
Remarks
1. The parameter file may contain any number of SMOOTH blocks. In order to
avoid the output files to be overwritten, different values of OUTPUT_FILE
parameter for each SMOOTH block should be used, in case that this
parameter is defined. If OUTPUT_FILE parameter is omitted, the value of
ID_NAME parameter (that should be unique) is used and the files do not
get overwritten.
2. If TARGET_VOLUME parameter is set to a non-zero value, ISO_VALUE
parameter is ignored. In this case, the calculations will only result in an
isosurface if the relative volume can be attained for some isovalue between
0 and 1. Moreover, for some models, the dependence of the relative
volume on the isovalue has "jumps", therefore a certain target volume
cannot be attained even if it lies between the minimal and maximal relative
volumes. If this happens, it is recommended to choose another target relative volume, or run the calculation with a fixed isovalue instead.
3. Group name "all" representing all elements of the model can be used
alongside actual group names loaded from an ONF group file. Group
names are case-insensitive.
www.3ds.com/tosca
Version 8.1.0 Rev. 1 - 05.2014
4. APPEND_TO_VTFX allows to combine reports with several smooth results

into one vtfx archive. Please note, if APPEND_TO_VTFX=NO and the file
specified with parameter OUTPUT_FILE exists, it is overwritten. Otherwise
a new file is created.
SIMULIA
Tosca Structure
SOLID
Defines geometric SOLIDS For more detailed information see vol.2 chapter
3.9, Solids (Geometric Primitives) in the Tosca Structure 8.1.0 user manual.
ID_NAME
= <Id_name_of_solid>
Name of the solid
SOLID_
PROP
= NEUTRAL
Defines a neutral area
= VARIATION
Defines an area of variation
= RESTRICTED
Defines a restriction area
CS
Name of the reference

coordinate system
VAL_1_MIN
= <lowest_value_coord_1>
VAL_1_MAX
= <highest_value_coord_1>
VAL_2_MIN
VAL_2_MAX
VAL_3_MIN
VAL_3_MAX
END_
Remarks
1. All coordinate axes must have: val_min < val_max.
2. It is necessary that all operators are entered.
SOLID
ID_NAME
SOLID_PROP
CS
VAL_1_MIN
VAL_1_MAX
VAL_2_MIN
VAL_2_MAX
VAL_3_MIN
VAL_3_MAX
END_
=
=
=
=
=
=
=
=
=
UNIT_CUBE
RESTRICTED
CS_0
0.0
1.0
0.0
1.0
0.0
1.0
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Examples
SIMULIA
Tosca Structure
STOP
STOP
Definition of STOP conditions. For more detailed information see vol.2 chapter 5.9.2, Global Stop Criterion (Number of iterations), vol.2 chapter 6.11,
Stop Condition and vol.2 chapter 7.10, Stop Condition in the Tosca Structure
8.1.0 user manual.
ID_NAME
= <Id_name_of_
stop_condition>
LOGICAL
= <name_of_
logical_variable>
ITER_MAX
Name of the STOP condition

Name of a logical variable
= <value>
maximum number of iterations
MOD_NDGR
Node group for which the

comparison is made
MOD_TYPE
= [ MAX | MIN | SUM | COUNT ],

[ MOVE | MOVE_GROWTH |
MOVE_SHRINK | MOVE_TOTAL
|MOVE_GROWTH_TOTAL |
MOVE_SHRINK_TOTAL |
CTRL_INP | CTRL_INP_SHAPE |
CTRL_INP_SHAPE_FIX
|CTRL_INP_SHAPE_FREE |
CTRL_INP_SURFACE ]
The MAX (MIN, SUM,

COUNT) of the variable
specified in the second
parameter is compared to
MOD_REF using the
operator specified in
MOD_OPER
MOVE
amount of optimization
displacement
... only positive
... only negative
optimization displacement referring to initial
model
... only positive
... only negative
controller input value
(equivalent stress)
ctrl_inp of design nodes
ctrl_inp of restricted
design nodes
ctrl_inp of free design
nodes
ctrl_inp of surface nodes
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Version 8.1.0 Rev. 1 - 05.2014
The following
parameters
are only available in combination
MOVE_GROWTH
MOVE_SHRINK
MOVE_TOTAL
MOVE_GROWTH_TOTAL
MOVE_SHRINK_TOTAL
CTRL_INP
CTRL_INP_SHAPE
CTRL_INP_SHAPE_FIX
CTRL_INP_SHAPE_FREE
CTRL_INP_SURFACE
SIMULIA
Tosca Structure
MOD_OPER
= [ LT | LE | EQ | GE | GT ]
comparison operater
(less than, less or
equal,...)
MOD_REF
= <real>, [ MULT | ADD | SUB | DIV ],

[ PREV | FIRST ]
MULT: <real>*Value of
MOD_TYPE in
PREV|FIRST iteration
ADD: <real>+ Value of
MOD_TYPE in
PREV|FIRST iteration
etc.
OPTIMIZE
= <name_of_
optimization_group>

task
Remarks
1. Using the parameter ITER_MAX a global stop condition can be set. In the
optimization system a number of 40 iterations is set by default.
2. If a global STOP condition is defined no other parameters can be defined in
the STOP command. If an additional logical STOP condition has to be
defined, another STOP definition has to be defined.
Examples
The optimization should stop, when the maximum equivalent stress of the
node group all_nodes is smaller than 1% of the maximum equivalent stress of
the first iteration:
ID_NAME
= STOP_COMMAND
MOD_NDGR
= ALL_NODES
MOD_TYPE
= MAX, CTRL_INP_SHAPE
MOD_OPER
= LE
MOD_REF
= 0.01, MULT, FIRST
OPTIMIZE
= RUN
END_
The optimization should stop when the equivalent maximum von Mises stress
in the design area is smaller than 200 MPa.
VARIABLE
ID_NAME
DEF_TYPE
TYPE
= var_sig
= SYSTEM
= SIG_MISES
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STOP
SIMULIA
Tosca Structure
STOP
ND_GROUP
GROUP_OPER
= design_nodes
= MAX
END_
LOGICAL
ID_NAME= logi_1
DEF_TYPE
OPER
VAR_A
FIX_VAL
=
=
=
=
BASE
LT
var_sig
200
END_
STOP
ID_NAME
LOGICAL
OPTIMIZE
= my_stop_condition
= logi_1
= my_optimization_problem
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Version 8.1.0 Rev. 1 - 05.2014
END_
SIMULIA
Tosca Structure
TEST_BEAD
Defines a test displacement for bead optimization. For more detailed information see vol.2 chapter 7.9, Check run (TEST_BEAD) in the Tosca Structure
8.1.0 user manual.
OPTIMIZE
= <Name_of_optimize>

task
FORMAT
= ONF
Output in optimization
neutral file (ONF) format
= USER_FILE
Output of virtual test

information in format
specified in user file command (e.g. table of displacement values,...)
FILE_NAME
= <Name_of_output_file>
Name of the output file
DIRECTION
= GROW
= SHRINK
= RANDOM
Direction of the test displacements (standard

growth, standard shrinkage or non-standard
nodal random displacement)
DISPLACEMENT
= <value_of_
max_displacement>

test displacement
INCREMENT
= <Number_of_increments>
Number of increments
START_
MODEL
= NO
= YES
Output of the start model

(no displacement)
USER_FILE
= <id_of_userfile>
Userfile definition for user

specific output of virtual
optimization results
Remarks
1. TEST_BEAD is carried out immediately after entering the command as
long as the user entries are correct.
2. Test displacements are always carried out with reference to a defined optimization task (OPTIMIZE).
3. A given file name for naming the results file (Default = TEST_BEAD).
4. DIRECTION: There are three possibilities to define the direction of
displacement: standard growth out of the component (GROW) for all
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Items for FORMAT = USER_FILE
SIMULIA
Tosca Structure
TEST_BEAD
design nodes in the optimization group, standard shrinkage into the

component (SHRINK) for all design nodes in the optimization group or nonstandard 'random' displacement of the design nodes in the optimization
group (RANDOM). The default setting is GROW.
5. DISPLACEMENT: Maximum amount of displacement for the test displacements. If no value is set a mesh-dependent amount of displacement is
automatically determined.
6. INCREMENT: Number of increments in which the maximum absolute value
of displacement of the test displacement is applied (Default is INCREMENT=1).
7. Procedure: In increments (INCREMENT) a maximum absolute displacement value (DISPLACEMENT) for a given direction (DIRECTION) is
applied to the design variables which have been allocated to the optimization problem (OPTIMIZE, see operator DV). All restrictions of the design
variables (DVCON_BEAD entries) that have been allocated to the optimization problem (OPTIMIZE, see operator DVCON) are executed. For each
increment a result file (FILE_NAME) in the given format (FORMAT) is
produced.
Examples
TEST_BEAD
OPTIMIZE
FORMAT
FILE_NAME
DIRECTION
DISPLACEMENT
INCREMENT
=
=
=
=
=
=
MY_OPT_TASK
ONF
TEST_BEAD
GROW
3.67
5
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Version 8.1.0 Rev. 1 - 05.2014
END_
SIMULIA
Tosca Structure
TEST_SHAPE
Defines a test displacement for shape optimization. For more detailed information see vol.2 chapter 6.9, Check run (TEST_SHAPE) in the Tosca Structure 8.1.0 user manual.
OPTIMIZE
= <Name_of_optimize>

task
FORMAT
= ONF
Output in optimization
neutral file (ONF) format
= USER_FILE
Output of virtual test

information in format
specified in user file command (e.g. table of displacement values,...)
FILE_NAME
= <Name_of_output_file>
Name of the output file.

Caution: The automatic
creation of the vtfx report
requires the use of the
default file name
"TEST_SHAPE".
DIRECTION
= GROW
= SHRINK
= RANDOM
Direction of the test displacements (standard

growth, standard shrinkage or non-standard
nodal random displacement)
DISPLACEMENT
= <value_of_
max_displacement>

test displacement
INCREMENT
= <Number_of_increments>
Number of increments
USER_FILE
= <id_of_userfile>
Userfile definition for user

specific output of virtual
optimization results
Remarks
1. TEST_SHAPE is carried out immediately after entering the command as
long as the user entries are correct.
2. Test displacements are always carried out with reference to a defined optimization task (OPTIMIZE).
3. A given file name for naming the results file (Default = TEST_SHAPE).
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Items for FORMAT = USER_FILE
SIMULIA
Tosca Structure
TEST_SHAPE
4. DIRECTION: There are three possibilities to define the direction of

displacement: standard growth out of the component (GROW) for all
design nodes in the optimization group, standard shrinkage into the
component (SHRINK) for all design nodes in the optimization group or nonstandard 'random' displacement of the design nodes in the optimization
group (RANDOM). The default setting is GROW.
5. DISPLACEMENT: Maximum absolute displacement value for the test
displacements. If no value is set a mesh-dependent absolute displacement
value is automatically determined.
6. INCREMENT: Number of increments in which the maximum absolute
displacement value of the test displacement is applied (Default is INCREMENT=1).
7. Procedure: In increments (INCREMENT) a maximum absolute displacement value (DISPLACEMENT) for a given direction (DIRECTION) is
applied to the design variables which have been allocated to the optimization problem (OPTIMIZE, see operator DV). All restrictions of the design
variables (DVCON_SHAPE entries) that have been allocated to the optimization problem (OPTIMIZE, see operator DVCON) are executed. For each
increment a results file (FILE_NAME) with an increment number is created.
8. Because with DIRECTION=GROW or SHRINK standard displacements
can be applied, it can be that LINK_SHAPE conditions cannot be fully
tested because the LINK_SHAPE condition (determined by standard
displacements) have already been fulfilled. If the optimization task contains
LINK_SHAPE conditions it is recommended to use DIRECTION=RANDOM
to apply non-standard displacements. In this way the correct function of the
LINK_SHAPE conditions can be tested.
www.3ds.com/tosca
Version 8.1.0 Rev. 1 - 05.2014
Examples
TEST_SHAPE
OPTIMIZE
FORMAT
FILE_NAME
DIRECTION
DISPLACEMENT
INCREMENT
=
=
=
=
=
=
MY_OPT_TASK
ONF
TEST_SHAPE
GROW
3.67
5
END_
SIMULIA
Tosca Structure
USER_FILE
Defines which data of the FE model, the FE calculation or the optimization
should be saved in a specified file. For more detailed information see vol.2
chapter 10.5.4, User defined output files (USER_FILE) in the Tosca Structure
8.1.0 user manual.
ID_NAME
<id_name_of_user_file>
Name of the USER_FILE

definition
FILE_NAME
<file_name>
Name of the file
FILE_
OPTION
Specification of file attributes
EL_GROUP
File is created only once.

With a new written statement this file is overwritten
= ADD
New written statement is

added to the end of the
file
= VAR
File name is extended

with a numerator (iteration number)
= VAR2
File name is extended

with a numerator (iteration number-1)
Determining the written format of the file

= ASCII
File is created as an
ASCII file
= ONF
Output is in optimization
Neutral File (ONF) format.
= STL
Output is in Standard
Transformation Language (STL)
= VRML
Output is in VRML 2.0

format
= HTML
Output is in HTML
Name of the element

group which is used to
define the USER_FILES.
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FORMAT
= FIX
SIMULIA
Tosca Structure
USER_FILE
ND_GROUP
TYPE
Type of data that is to be written.

Depends on the FORMAT

which is used to define
the USER_FILES.
for FORMAT= ASCII

= TABULAR
Output of variables in
tables
= CATIA_RSO
Output of geometry modifications by shape optimization for transfer to

CATIA RSO module.
= DMIG
Node displacements are

written as DMIG cards
= DVGRID
Node displacements are

written as DVGRID cards
= GROUPS
Definition of node groups

and element groups
= SHAPE_DATA
Specific data for shape

ptimization
= BEAD_DATA
Specific data for bead

optimization
= TOPO_DATA
Specific data for topology optimization
= SIZING_DATA
Specific data for sizing

optimization
= TEST_SHAPE_LEVEL
Output for TEST_SHAPE

command
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Version 8.1.0 Rev. 1 - 05.2014
for FORMAT = ONF
SIMULIA
Tosca Structure
= FINITE_MODEL,
<coordinate_system_option>
Output of node and element information of the

FE model. If the
<coordinate_system_opti
on> is set at LOCAL the
node coordinates are distributed in the local coordinate system. Using the
option GLOBAL the node
coordinates are in the
global cartesian coordinate system
= SHAPE_NEXT_DATA
Optimization displacement of next iteration
= BEAD_NEXT_DATA
Optimization displacement of next iteration
= FINITE_MODEL
Output of the Finite Element Mesh in the given

EL_GROUP
= TOPO_MAT_ALL
Areas with material in the

complete model
(HARD+TRANS+NON_D
ESIGN)
= TOPO_MAT_DES
Areas with material in the

design space
(HARD+TRANS)
= TOPO_MAT_NO
Areas with no material

(SOFT)
for FORMAT = HTML
= TABULAR
SEPARATOR
Output of variables in
tables
Separation character between columns

= SPACE
Blank
= BLANK
Blank
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for FORMAT = VRML
SIMULIA
Tosca Structure
USER_FILE
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Version 8.1.0 Rev. 1 - 05.2014
DATA_TAB
= TAB
Tabulator
= COMMA
Comma (default)
= EXCLAM
Exclamation mark
= <xx>
Any kind of character

separator, maximum two
characters
for TYPE=TABULAR
= <var_name>
Determines which variables <var_name> are

written.
TITLE_1
= <Title_1>
Title 1 for ASCII-file
TITLE_2
= <Title_2>
Title 2 for ASCII-file
ISO_VALUE
for TYPE = ISO_MODEL
VRML_RES
= REL_DENS, <value>
Material distribution is
used as the basis for iso
surface calculations. The
given relative density
value must lie between 0
(minimum density) and 1
(maximum density).
= ABS_DENS, <value>
Material distribution is
used as the basis for iso
surface calculations. The
given density value is an
absolute density value.
= SIG, <value>
Stress distribution is used

as the basis for iso surface calculations. The
given value is an absolute stress value
for FORMAT = VRML not for TYPE = ISO_MODEL

= <res_type>, <min_val>,
<max_val>
<res_type>
= CTRL_INP_ND
Nodal controller input
= CTRL_INP_EL
Element controller input
SIMULIA
Tosca Structure
VRML_
START
WRITE
= OPT_DISP
Optimization node displacement (absolute

value)
= MP_VALUE
Material property value

(topology optimization)
<min_val>
Minimum user-defined
fringe value
<max_val>
Maximum user-defined
fringe value
NO
The start model is not

written
YES
The start model is written

as line plot
When the file should be created

= EVER
File will be written in each

design cycle
= NOW
The file is created immediately in TOSCA_PREP

upon entering the SAVE
option for the
USER_FILE. This occurs
only when it is necessary
and permitted.
1. The data can be generated in different formats. The following entries are
necessary in order to obtain a complete definition of the file to be generated using the command USER_FILE:
- Name of the file in which the results are to be shown
- Type of file
- Output format
- Type of results
- When the file should be created
- Nodes and elements for which the data should be generated
Pre-settings already exist in the system for many of these settings. By
entering a relevant value, these are overwritten. The settings are done
using the command END_ and the active default values are checked for
consistency of entries, to check if the written command can be executed. If
the file cannot be generated due to entries cancelling each other (e.g. an
attempt to generate data referring to elements for a node group), the
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Remarks
SIMULIA
Tosca Structure
USER_FILE
system shows a warning and the write command is not activated. Only
when all entries are consistent, the file can be activated for writing.
2. A maximum of 20 columns can be defined in a table.
3. A total of maximum 200 columns can be defined.
4. One variable can be in several columns at the same time and different variables cannot exist in one column.
5. Columns not fully occupied and lying between the first column and the
highest occupied column, are filled with zeros.
6. The output of results done via a VRML mesh are automatically scaled
between the minimum and maximum result value of the start model when
no explicit minimum and maximum value is given.
7. When entering the file name, it is necessary to know that files can be
deleted or saved in sub-directories at the end of the optimization. This can
be controlled using "wildcards". Which files are to be moved or deleted can
be set in the initialization file (see Bd.1, Chapter 8.1.3). Using the system
settings, all files that end in ".txt" are moved to the directory TOSCA_POST
after optimization has been completed.
Examples
uf_shape_onf
USER_FILE
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Version 8.1.0 Rev. 1 - 05.2014
ID_NAME
FILE_NAME
FORMAT
EL_GROUP
DATA_TYPE
WRITE
=
=
=
=
=
=
uf_shape_onf
SHAPE
ONF
=
=
=
=
=
=
uf_seset
SESET.INP
ASCII
senas_nodes
SESET, 1
NOW
all_elements
SHAPE_DATA
EVER
END_
uf_seset
USER_FILE
ID_NAME
FILE_NAME
FORMAT
ND_GROUP
DATA_ TYPE
WRITE
END_
SIMULIA
Tosca Structure
Example for a table output

USER_FILE
ID_NAME
FILE_NAME
FILE_OPTION
FORMAT
WRITE
TYPE
SEPARATOR
DATA_TAB
DATA_TAB
DATA_TAB
DATA_TAB
=
=
=
=
=
=
=
=
=
=
=
tab1
freq_tab.dat
ADD
ASCII
EVER
TABULAR
EXCLAM
ITERATION
=
=
=
=
=
=
=
results_1
vrmlresults
VRML
=
=
=
=
=
=
=
UF_MODEL_ONF
MODEL_fem
FIX
ONF
freq_1
freq_2
freq_3
END_
VRML-Resultsfile
USER_FILE
ID_NAME
FILE_NAME
FORMAT
EL_GROUP
TYPE
VRML_RES
WRITE
all_elements
TOPO_MAT_ALL
CTRL_INP_ND
EVER
END_
uf_model_onf.mac
ID_NAME
FILE_NAME
FILE_OPTION
FORMAT
EL_GROUP
TYPE
WRITE
all_elements
FINITE_MODEL
NOW
END_
Result transfer to CATIA RSO module (uf_shape_catia_rso.mac)

The results of the shape optimization can be transfered to the CAD model in
will be applied.
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USER_FILE
SIMULIA
Tosca Structure
USER_FILE
USER_FILE
ID_NAME
FILE_NAME
FILE_OPTION
FORMAT
ND_GROUP
TYPE
WRITE
SEPARATOR
=
=
=
=
=
=
=
=
UF_RSO
RSO_OUTPUT.TXT
VAR
ASCII
TITLE_1
= x(mm) # y(mm) # z(mm) #

C1(mm) # C2(mm) # C3(mm)
all_nodes
CATIA_RSO
EVER
TAB
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Version 8.1.0 Rev. 1 - 05.2014
END_
SIMULIA
Tosca Structure
VARIABLE
Defines numerical variables. The command VARIABLE defines fixed or
numerical variables that change from iteration to iteration. The following
parameters are used to define variables regardless of their type (For more
detailed information see vol.2 chapter 10.5.1, Numerical variables (VARIABLE) in the Tosca Structure 8.1.0 user manual):
ID_NAME
= <id_name_of_variable>
Name of the variable
DEF_TYPE
= SYSTEM
Variable is determined
from a load case dependent or a loadcase independent value
= FIX
Value of the variable is

determined and remains
unchanged to a fixed
value
= OPER
OPER Value of the variable is determined from

other predefined variables that are linked with
the help of an operator
LIST
UPDATE
Output format determined for the variable

= NO_LIST
No output of value
= LIST
Output of value
When to determine the value of the variable

= FIRST
In the first design cycle
= EVER
In each design cycle
VALUE
= <value>
Fixed value of the variable (real number
Definition of the selection area
EL_GROUP
Name of an element
of the variable is to be
determined.
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Items for DEF_TYPE FIX
SIMULIA
Tosca Structure
VARIABLE
ND_GROUP

variable is to be determined.
The specification of a group is not necessary when the TYPE of variable is a

scalar, area-independent variable (e.g. iteration number)
GROUP_OPER: Operator to determine the value of the variable that is used
within the selection area. In cases of variable types without selection areas,
this entry can remain blank
GROUP_
OPER
= MAX
Maximum value from the

selection area
= AVERAGE
Average value from the

selection area
= MIN
Minimum value from the

selection area
= SUM
Sum of all values from

the selection area
= COUNT

of values from the selection area
Items for DEF_TYPE SYSTEM

Types of variables:
E: Element based value
S: Scalar value
N E : Node with additional element information
www.3ds.com/tosca
Version 8.1.0 Rev. 1 - 05.2014
N: Node based value
AREA
Area of the selected elements (only for 2d and shell

elements)
BEAD_HEIGHT
Height of the bead
Buckling frequency
CENTER_GRAVITY_X
Center of gravity for the xdirection
CENTER_GRAVITY_Y
Center of gravity for the ydirection
CENTER_GRAVITY_Z
Center of gravity for the zdirection
DAMAGE
Damage value from durability analysis without loadcase

information
BUCK_FREQ
DAMAGE_LC
Damage value from durability analysis with loadcase

information
DISP_ABS
absolute nodal displacement
DISP_X
nodal displacement in xdirection
DISP_Y
nodal displacement in ydirectionn
DISP_Z
nodal displacement in zdirection
DISP_X_ABS
absolute nodal displacement in x-direction
DISP_Y_ABS
absolute nodal displacement in y-direction
DISP_Z_ABS
absolute nodal displacement in z-direction
DYN_FREQ
Eigenfrequence from modal

analysis
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Description
Type of
variable
Loadcase
dependent
TYPE
SIMULIA
Tosca Structure
SIMULIA
Tosca Structure
Loadcase
dependent
Type of
variable
DYN_FREQ_KREISSEL
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Version 8.1.0 Rev. 1 - 05.2014
ELEMENT
Description
TYPE
VARIABLE
Eigenfrequency calculated
with Kreisselmaier-Steinhauser formula
Number of elements in a
group (only with operator
COUNT)
Stiffness measure for

simultaneous handling of
external loading and prescribed displacement in
stiffness optimization
FS_ACCEL_X
Acceleration in x-direction for

frequency response
FS_ACCEL_Y
Acceleration in y-direction for

frequency response
FS_ACCEL_Z
Acceleration in z-direction for

frequency response
FS_DBA_PRESSURE
Sound Pressure Level [dBA]
FS_DB_PRESSURE
Sound Pressure Level [dB]
FS_DISP_ABS
Absolute amplitude for frequency response
FS_DISP_X_ABS
Amplitude in x-direction for

frequency response
FS_DISP_Y_ABS
Amplitude in y-direction for

frequency response
FS_DISP_Z_ABS
Amplitude in z-direction for

frequency response
FS_PHASE_X
Phase in x-direction for frequency response
FS_PHASE_Y
Phase in y-direction for frequency response
FS_PHASE_Z
Phase in z-direction for frequency response
Loadcase
dependent
Type of
variable
FS_PRESSURE
Instantaneous Sound Pressure [Pa]
FS_RMS_PRESSURE
Effective Sound Pressure(RMS)[Pa]
FS_VELOCITY_X
Velocity in x-direction for frequency response
FS_VELOCITY_Y
Velocity in y-direction for frequency response
FS_VELOCITY_Z
Velocity in z-direction for frequency response
INERTIA_XX
Moment of inertia around xx-direction
INERTIA_XY
Moment of inertia around xy-direction
INERTIA_XZ
Moment of inertia around xz-direction
INERTIA_YY
Moment of inertia around yy-direction
INERTIA_YZ
Moment of inertia around yz-direction
INERTIA_ZZ
Moment of inertia around zz-direction
INTERNAL_FORCE_ABS
NE
absolute nodal internal force
INTERNAL_FORCE_X
NE
nodal internal force in xdirection for global coordinate system or in an user

defined coordinate system
INTERNAL_FORCE_X_ABS
NE

in x-direction for global coordinate system or in an user
INTERNAL_FORCE_Y
NE
nodal internal force in ydirection for global coordinate system or in an user

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TYPE
Description
SIMULIA
Tosca Structure
SIMULIA
Tosca Structure
Loadcase
dependent
Type of
variable
Description
TYPE
www.3ds.com/tosca
Version 8.1.0 Rev. 1 - 05.2014
VARIABLE
INTERNAL_FORCE_Y_ABS
NE

in y-direction for global coordinate system or in an user
INTERNAL_FORCE_Z
NE
nodal internal force in zdirection for global coordinate system or in an user

NE

in z--direction for global
coordinate system or in an
user defined coordinate system
INTERNAL_MOMENT_ABS
NE
absolute nodal internal

moment
INTERNAL_MOMENT_X
NE
nodal internal moment

around x-direction for global
INTERNAL_MOMENT_X_ABS
NE

moment around x-direction
for global coordinate system
or in an user defined coordinate system
INTERNAL_MOMENT_Y
NE

around y-direction for global
INTERNAL_MOMENT_Y_ABS
NE

moment around y-direction
Loadcase
dependent
Type of
variable
INTERNAL_MOMENT_Z
NE

around z-direction for global
NE

moment around z-direction
MOVE
Node displacement caused

by optimization
MOVE_GROWTH
Deformation by addition of
material
MOVE_GROWTH_TOTAL
Deformation by addition of
material
MOVE_SHRINK
Deformation by removal of
material
MOVE_SHRINK_TOTAL
Deformation by reduction of
material
MOVE_TOTAL
Node displacement referring

to the initial model
NODE
Number of Nodes in the FEmodel (only with operator

COUNT)
REACTION_FORCE_ABS
absolute reaction force
REACTION_FORCE_X
reaction force in x-direction
REACTION_FORCE_Y
reaction force in y-direction
REACTION_FORCE_Z
reaction force in z-direction
REACTION_MOMENT_ABS
absolute reaction moment
REACTION_MOMENT_X
reaction moment around xdirection
REACTION_MOMENT_Y
reaction moment around ydirection
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TYPE
Description
SIMULIA
Tosca Structure
SIMULIA
Tosca Structure
www.3ds.com/tosca
Loadcase
dependent
Type of
variable
Description
TYPE
Version 8.1.0 Rev. 1 - 05.2014
VARIABLE
REACTION_MOMENT_Z
reaction moment around zdirection
REACTION_FORCE_X_ABS
absolute reaction force in xdirection
REACTION_FORCE_Y_ABS
absolute reaction force in ydirection
absolute reaction force in zdirection
REACTION_MOMENT_X_ABS

around x-direction
REACTION_MOMENT_Y_ABS

around y-direction

around z-direction
RHO_DELTA_REL
relative change of element

density from actual iteration
to previous iteration
RHO_DELTA
change of element density

from actual iteration to previous iteration
RHO_REL
relative element density

(quotient of actual density
over initial element density)
RHO
element density (actual)
ROT_X
nodal rotation via x-axis from

FE analysis
ROT_X_ABS
absolute nodal rotation

around x-axis for global
ROT_Y
nodal rotation via y-axis from

FE analysis
Loadcase
dependent
Type of
variable
ROT_Y_ABS

around y-axis for global
ROT_Z
nodal rotation via z-axis from

FE analysis
ROT_Z_ABS

around x-axis for global
SF_LEN_FIX
Total length of the free surface
SF_LEN_FREE
Total length of the fixed surface
SF_LEN
Total length of the surface
CTRL_INP_SHAPE_FIX
Equivalent stress of the

restricted design nodes
CTRL_INP_SHAPE_FREE
Equivalent stress of the free

design nodes
CTRL_INP_SHAPE
Equivalent stress of the

design nodes
CTRL_INP
E/N
Equivalent stress
CTRL_INP_SURFACE
Equivalent stress of the surface nodes
SIG_1
E/N
Maximum principal stress
SIG_2
E/N
2nd. principal stress
SIG_3
E/N
Minimum principal stress
SIG_ABS_123
E/N
Maximum of the absolute

value of the principal
stresses
SIG_ABS_3
E/N
absolute value of the minimum principal stress
SIG_CONTACT_PRESSURE
Contact stress pressure
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TYPE
Description
SIMULIA
Tosca Structure
SIMULIA
Tosca Structure
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TYPE
Loadcase
dependent
Type of
variable
Description
Version 8.1.0 Rev. 1 - 05.2014
VARIABLE
SIG_CONTACT_SHEAR
Total Shear Contact stress
SIG_CONTACT_SHEAR_X
Shear X Contact stress
SIG_CONTACT_SHEAR_Y
Shear Y Contact stress
SIG_CONTACT_TOTAL
Total Contact stress
SIG_KUHN
E/N
Kuhn stress hypothesis
SIG_DRUCKER_PRAGER
E/N
Drucker-Prager stress
hypothesis
SIG_SANDEL
E/N
Sandel stress hypothesis
SIG_BELTRAMI
E/N
Beltrami stress hypothesis
SIG_MARIOTTE
E/N
Mariotte stress hypothesis
SIG_MISES
E/N
Mises stress hypothesis
SIG_SAUTER
E/N
Sauter stress hypothesis
SIG_GALILEI
E/N
Galilei stress hypothesis
SIG_TRESCA
E/N
Tresa stress hypothesis
SIG_TOPO_MISES
E/N
Mises stress as constraint
STRAIN_ELASTIC
elastic Strain
STRAIN_PLASTIC
plastic Strain
STRAIN_TOTAL
Total Strain (elastic + plastic)
STRAIN_ENERGY_DENS
E/N
Strain energy density
STRAIN_ENERGY
E/N
Strain energy
VOLUME
volume of element
WEIGHT
weight of element
Items for loadcase dependent variables

LC_SET: Load case combination that is used to determine the variable (can
be entered several times)
LC_SET = <approach>, <loadcase>, <substep>, <shell_layer>
SIMULIA
Tosca Structure
<approach>
Definition of the type

of calculation
ALL
ALL Calculation of variables for all types of

applied calculations
STATIC
Linear static analysis
MODAL
Modal analysis
NONLINEAR
Non-linear static analysis
<loadcase>
Load case definition
ALL
Calculation for all load

cases
<no_of_loadcase>
Number of load case

from which the value
should be calculated
<substep>
Definition of the intermediate step
ALL
Calculations for all intermediate steps
<no_of_substep>
> Number of the intermediate step from which the

value should be calculated
<shell_layer
>
TOP
Upper layer of shell
MID
Mid-layer of shell (membrane)
BOT
Bottom layer of shell
MAX
max (TOP, MID, BOT)
MIN
min (TOP, MID, BOT)
Load case selection

= MAX
Maximum value for all

load cases chosen with
LC_SET
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LC_SEL
Definition of position
where the shell stress
should be evaluated
SIMULIA
Tosca Structure
VARIABLE
= MIN
Minimum value for all

load cases chosen with
LC_SET
= SUM
Sum all load cases chosen with LC_SET
Items for non-scalar variables

Nodegroup or elementgroup can be specified for these variables
EL_GROUP
Name of an element
of the variable is to be
determined.
ND_GROUP

variable is to be determined.
ELEM
= <number of element>
Number of element to be
used for the design
EL_GROUP)
NODE
= <number of node>
Number of node to be
used for the design
ND_GROUP)
The specification of a group is not necessary when the TYPE of

variable is a scalar, area-independent variable (e.g. iteration
number).
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GROUP_OP
ER
Operator to determine the value of the variable that is used within

the selection area. In cases of variable types without selection
areas, this entry can remain blank
= MAX
Maximum value from the

selection area
= AVERAGE
Average value from the

selection area
= MIN
Minimum value from the

selection area
= SUM
Sum of all values from

the selection area
SIMULIA
Tosca Structure
= COUNT

of values from the selection area
Items for DEF_TYPE OPER
VAR_OPER
Operator linking the variables VAR_A to VAR_D

Operators with 2 to 4 operands
= ADD
Addition
A+B+C+D
= MULT
Multiplication
A*B*C*D
= MIN
Minimun
min(A,B,C,D)
= MAX
Maximum
max(A,B,C,D
)
= SUB
Subtraction
A-B
= DIV
Division
A/B
= ABS
absolute value
abs(A)
= SIN
Sinus
sin(A)
= COS
Cosinus
cos(A)
= CUT_OFF
Cutoff Operator to
remove peaks
(parameters are
specified with additional settings)
max(CUT_O
FF_LOW,mi
n(A,CUT_O
FF_HIGH))
= TAN
Tangens
tan(A)
= LOG
Common logarithm
log(A)
= EXP
Exponential function
exp(A)
= FILTER
Filter function for

vectors used as
terms for the controller based algorithms
(parameters are
specified with additional settings)
filter(A)
= LN
Nat. Logarithm
ln(A)
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Operators with 1 operand
SIMULIA
Tosca Structure
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VARIABLE
= NORM
Norm for vectors

used as terms for the
controller based
algorithms (parameters are specified
with additional settings)
= NPOWER
N-th power to A
(parameter is specified with EXPONENT
Item)
= NROOT
N-th root (parameter

is specified with
EXPONENT Item)
= SQRT
Square root
sqrt(A)
= INT
Integer
int(A)
= NINT
Nearest integer number
nint(A)
= SIGN
Sign function
sign(A)
= DELTA_1
Difference between 2
iterations A(i) - A(i-1)
= DELTA_2
= DELTA_3
= DELTA_4
= DELTA_5
= DELTA_6
Operators with up to 10 operands
operands defined by
item VARIABLE
= COMBINE
weighted addition
w1*VAR1 +
w2*VAR2 ...
Specifying the operands with their ID_NAME
VAR_A
= <var_id_a>
VAR_B
= <var_id_b>
SIMULIA
Tosca Structure
VAR_C
= <var_id_c>
VAR_D
= <var_id_d>
Additional settings for the operators
NPOWER, NROOT and FILTER
EXPONENT
= <exponent value>
real value
Additional settings for the operator

FILTER
RADIUS
= <radius value>
real value
The radius
defines the
maximum
distance for
influencing
neighbour
nodes
SIGMA
= <value>
real value
Sigma
defines the
reduction of
the radius
depending
on the surface bending
(default: 0.2)
CUT_OFF_LOW
= <value>
real value
lower bound
of the vector
value. All values under
this value will
be treated as
zero.
CUT_OFF_HIGH
= <value>
real value
upper bound
of the vector
value. All values higher
than this
value will be
set to the cut
off value.
Operands for VAR_OPER = COMBINE
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Additional settings for the operator

CUT_OFF
SIMULIA
Tosca Structure
VARIABLE
VARIABLE
= <var_id_1>, <weight1>
ID_NAME of variable VAR1 with

weight factor w1
(default 1) for combination
up to 10 different variables can be

specified
Remarks
1. Definition can be done by direct allocation of a number or a database entry
or by linking several numerical variables. Variables make different
commands (e.g. STOP, OBJ_FUNC) much more flexible.
A numerical variable can have the following status:
- NOT_CHECK: The variable is not yet determined
- UNSET: The variable cannot be determined
- SET: The value of the variable is determined and has been saved.
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2. Only variables of TYPE DISP_X, DISP_Y, DISP_Z and ROT_X, ROT_Y,

ROT_Z and REACTION_FORCE_X, REACTION_FORCE_Y,
REACTION_FORCE_Z and REACTION_MOMENT_X,
REACTION_MOMENT_Y, REACTION_MOMENT_Z and
INTERNAL_FORCE_X, INTERNAL_FORCE_Y, INTERNAL_FORCE_Z
and INTERNAL_MOMENT_X, INTERNAL_MOMENT_Y,
INTERNAL_MOMENT_Z are admitted for COMBINE using SUB,
SUB_ABS or VAR_OPER . Absolute displacements are not allowed for
combination. Mean values of displacements can be calculated using this
option.
3. The parameter VARIABLE can also be used to define operands for other
VAR_OPER items. In this case only two (or 2-4) entries are admitted,
weights are not admissible and their order is significant.
4. Plastic strain values (TYPE = STRAIN_PLASTIC) are calculated by Tosca
Structure and may differ from your solver results.
Examples
VARIABLE
ID_NAME
DEF_TYPE
VALUE
= var_01
= FIX
= 10.5
END_
SIMULIA
Tosca Structure
VARIABLE
ID_NAME
DEF_TYPE
TYPE
UPDATE
=
=
=
=
var_02
SYSTEM
ITER
EVER
=
=
=
=
=
=
var_03
SYSTEM
SIG_MISES
my_el_group
MAX
EVER
=
=
=
=
=
=
DISP_TIP_RIGHT
DISP_Z
SYSTEM
STATIC,1
MAX
517
=
=
=
=
=
=
=
MAX_VAL_11_14
OPER
MAX
var_11
var_12
var_13
var_14
=
=
=
=
=
MEAN_VALUE_11_12
OPER
COMBINE
var_11,0.5
var_12,0.5
END_
VARIABLE
ID_NAME
DEF_TYPE
TYPE
EL_GROUP
GROUP_OPER
UPDATE
END_
VARIABLE
ID_NAME
TYPE
DEF_TYPE
LC_SET
GROUP_OPER
NODE
END_
ID_NAME
DEF_TYPE
VAR_OPER
VAR_A
VAR_B
VAR_C
VAR_D
END_
VARIABLE
ID_NAME
DEF_TYPE
VAR_OPER
VARIABLE
VARIABLE
END_
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VARIABLE
SIMULIA
Tosca Structure
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VARIABLE
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SIMULIA
Tosca Structure
Volume IV
Examples Manual
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SIMULIA
Tosca Structure
SIMULIA
Tosca Structure
Preface
Preface
This manual lists and describes examples of topology, shape, bead and sizing optimization using Tosca Structure. The description covers the initial
model with its boundary conditions and loads, as well as the most important
attributes of the optimization model.
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The examples found in this manual are available in the example directory of
the Tosca Structure distribution and can be executed by the user at any time.
The shown models normally have a low number of elements and nodes so
the optimization of the examples is easily done and with little calculation
efforts.
The examples are found in the following directories:
$tosca/<fe_solver>/examples/bead
$tosca/<fe_solver>/examples/shape
$tosca/<fe_solver>/examples/topo
$tosca/<fe_solver>/examples/sizing
$tosca/<life_solver>/examples/<fe_solver>/
The parameter file of the optimization (*.par), the analysis model for the FE
analysis (*.bdf, *.inp, ...) and all other necessary files that are important for
defining the optimization problem can be found in each individual model
directory. Specific files used for vol.1 chapter 3, Getting Started with Tosca
Extension for ANSYS/WB can be found in
$tosca/ansys/TS_Ext_for_WB.
Examples Manual 4 - 3
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SIMULIA
Tosca Structure
4 - 4 Examples Manual
SIMULIA
Tosca Structure
Topology optimization is a tool to generate a new design proposal and is often
used within the concept phase for a determining a new conceptual design for
a component. In this section, typical topology optimization examples are
described.
Example overview
Steering arm
Plate min. max.
Cranehook
Picker Arm
Control Arm
Booster
Examples
Airbeam
Keywords
Airbeam symm.
1.1
Geometric Restrictions
Casting
X
Maximum
member size
Minimum
member size
Symmetry:
cyclic
Symmetry:
planar
Symmetry:
rotational
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Frozen
SIMULIA
Tosca Structure
Airbeam
1.2
Airbeam
Task
Maximize Stiffness under volume constraint
Keywords
Design variables, Objective function, Constraint, Frozen elements
Commands
DV_TOPO, OBJ_FUNC, STRAIN_ENERGY, CONSTRAINT, VOLUME, DVCON_TOPO, FROZEN
The actual model shows the main parts of a topology optimization task: Definition of design variables, constraints and objective function. The standard
task will be defined using Tosca ANSA environment or Tosca Structure.gui.
1.2.1
Model
Fig. 1
1.2.2
Design space of the bending beam with boundary conditions
Optimization Task
The topology optimization task is to maximize the stiffness using only 45% of
the initial volume. For manufacturing reasons the outer element layer should
remain unmodified during optimization. This means that only the internal elements are permitted to be used as changeable elements for the optimization
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In this model, a bending beam is fixed on the left side with a corresponding
force on the right side. All nodes on the left side of the model are fixed in the
x-axis direction. The node on the bottom left side is also fixed in the y-axis
direction. A force of 40N is applied in the right side in a negative direction of
the y-axis.
SIMULIA
Tosca Structure
1.2.3
Procedure: Summary
Model: airbeam.ext from the examples directory for your optimization task
Design area: all elements
Design variable constraint: a layer of one element on the surface is frozen
(elements fixed during optimization)
Objective: maximize stiffness
Constraint: relative volume of 45 % (equality constraint)
1.2.4

Choose a topology_optimization_controller Task in Tosca ANSA environment.
Create the model_link:
Definition of the design area and fixed areas
In the optimization task choose the group ALL_ELEMENTS as your design
area (DESIGN_AREA | EDIT). Define a frozen area as design variable constraint (DV_CONSTRAINT|NEW | FROZEN_AREA) and choose all elements
on the outer surface for this constraint (for details about group definition and
choice of elements see (vol.1 chapter 1.1.13, Managing Groups).
Definition of the optimization task
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The objective function is to maximize stiffness. This corresponds to minimizing the compliance (sum of strain energy, a measure of flexibility). Thus,
choose COMPLIANCE for the group ALL_ELEMENTS as term for optimization (OBJ_FUNC_ITEM_1 | NEW | COMPLIANCE) and set the target to
MINMAX (OBJ_FUNC_ITEM_1 | EDIT).
Next, a relative target volume of 45 % has to be defined. Choose CONSTRAINTS | NEW | VOLUME_CONSTRAINT and set a relative value of 0.45
in the dialogue window for the group ALL_ELEMENTS.
1.2.5

Definition of the design area and fixed areas
Two material definitions are added and two groups are defined during preprocessing of the analysis model in the FE preprocessor in order to permit a simple selection of elements that represent the design space. One material
group and one element set is defined as being a fixed area.
The element groups defined in the analysis model can be directly addressed.
If the element numbers of the group members are known they can be added
in a list and placed together in one group.
SIMULIA
Tosca Structure
Airbeam
GROUP_DEF
ID_NAME
= frozen_elements
TYPE
= ELEM
FORMAT
= LIST
LIST_BEGIN
1-109, 218-3815:109, 3816-3924
END_
In this example, the chosen optimization elements constitute the predefined

group ALL_ELEMENTS that contains all elements of the model.
DV_TOPO
ID_NAME
EL_GROUP
= design_variables
= ALL_ELEMENTS
END_
In order to define the group of elements, frozen_elements as being fixed, the

design variable constraint must be activated.
DVCON_TOPO
ID_NAME
EL_GROUP
CHECK_TYPE
= dvcon_frozen
= frozen_elements
= FROZEN
END_
The objective function is to maximize stiffness. This corresponds to minimizing the compliance (sum of strain energy, a measure of flexibility). A design
response (DRESP) must therefore be defined for the compliance of the structure:
DRESP
ID_NAME
DEF_TYPE
TYPE
UPDATE
EL_GROUP
GROUP_OPER
=
=
=
=
=
=
DRESP_SUM_ENERGY
SYSTEM
STRAIN_ENERGY
EVER
ALL_ELEMENTS
SUM
END_
This response is to be minimized and thereby maximizing stiffness:
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Tosca Structure
OBJ_FUNC
ID_NAME
DRESP
TARGET
= DRESP_SUM_ENERGY
= MINMAX
END_
A maximum of 45% of the initial volume may be used in this optimization.

Therefore, a volume constraint must be defined that refers to the elements in
the design space. A design response must therefore be defined which contains the sum of the total volume of the optimization group.
DRESP
ID_NAME
DEF_TYPE
TYPE
UPDATE
EL_GROUP
GROUP_OPER
=
=
=
=
=
=
DRESP_VOL_TOPO
SYSTEM
VOLUME
EVER
ALL_ELEMENTS
SUM
END_
This value is afterwards referenced in the constraint that enforces the maximal volume usage.
CONSTRAINT
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ID_NAME
DRESP
MAGNITUDE
EQ_VALUE
=
=
=
=
volume_constraint
DRESP_VOL_TOPO
REL
0.45
END_
At last the optimization task is compiled, i.e. the design variables are linked
with the objective function and the constraints. Furthermore, additional
parameters for the optimization can be entered which can improve the convergence of the controller.
OPTIMIZE
ID_NAME
DV
OBJ_FUNC
DVCON
CONSTRAINT
=
=
=
=
=
design_variables
maximize_stiffness
dvcon_frozen
volume_constraint
SIMULIA
Tosca Structure
Airbeam
END_
OPT_PARAM
ID_NAME
OPTIMIZE
SPEED
START_DELETE
=
=
=
=
optimization_parameters
SLOW
PERC,0.2
END_
For postprocessing, Tosca Structure automatically writes files in ONF format.

After the optimization run, these can be changed to postprocessing reports in
Tosca Structure.report or can be used to prepare the optimization results for
being transferred to a CAD system (Tosca Structure.smooth) or for a validation run.
1.2.6
Results
The optimization results created after 15 design cycles is illustrated in Fig. 2.
Optimization result "airbeam_topo"
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SIMULIA
Tosca Structure
1.3
1.3.1
Picker_arm
Task
Maximize the stiffness with a volume constraint
Keywords
Tosca Structure.smooth, Frozen
Commands
SMOOTH, FROZEN
Model
The model in this example refers to a robotic picker arm. The functional surfaces of the picker arm are loaded with pressure. The picker arm is fixed radially in the middle cross-bored area.
Fig. 3
1.3.2
Optimization Task
Minimize compliance (maximize the stiffness) using only 50% of the initial volume. Because the optimization task is nearly identical to the example in vol.4
chapter 1.2, Airbeam only the group of frozen elements and the target volume
must be changed.
Postprocess your result regarding the material distribution during the optimization progress. Create an isosurface of the optimization result for further
processing in the design process.
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Analysis model of the "picker arm"
1.3.3
Procedure: Summary
Model: picker_arm.ext from the examples directory for your optimization task
SIMULIA
Tosca Structure
Picker_arm
Design variable constraint: Fix elements of group frozen_elements

Settings: 15 iterations (default)
Smooth run with target volume 0.5
Postprocessing: optimization progress (element density)
1.3.4

This optimization task is a standard topology optimization task as described in
the example in vol.4 chapter 1.2, Airbeam or in vol.1 chapter 1.2, Topology
Optimization with Tosca ANSA environment. The set-up including starting a
TOPO_CONTROLLER task, loading the model and definition of design area,
objective function and constraint can be done as described in the Getting
Started Manual. In the following, several postprocessing possibilities are discussed.
Tosca Structure.smooth and output for postprocessing
Fig. 4
An intermediate iteration represented in Tosca Structure.view
Navigating through the iterations the change of material distribution can be

seen. The resulting "hard" structure forms a rough "building block" model
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After the optimization has finished, the optimization progress can be visualized.
To create postprocessing data, choose POST-PROCESSING
|
GENERATE_REPORT_FILE | CONTOUR_PLOT | [EDIT] in the task manager. Choose the result sequence to be visualized (ELEMENT FILL FILTER
in this case to visualize material distribution). The FILTER MIN value
defines the limit for the soft elements (i.e. elements with a relative material
value lower than FILTER MIN are not shown). After creating the VTFX file
with the optimization sequence (UPDATE) it can be visualized using the following entry VTF_VISUALIZATION in the task manager tree (UPDATE).
SIMULIA
Tosca Structure
which cannot be easily used for further processing in the design process.
Thus, a smooth run (SMOOTH | SMOOTH_INSTANCE | RUN_SMOOTH |
[EDIT] to define the settings) is the next step to prepare the result for CAD
transfer or validation run (Fig. 5). Enter the relative value of your target volume (in this case 0,5). The default ISO_VALUE is ignored automatically when
a TARGET_VOLUME is specified. If you have asked for VTFX output in your
smooth run, the isosurface created by Tosca Structure.smooth can be shown
with Tosca Structure.view (SMOOTH
|
SMOOTH_INSTANCE
|
VTF_VISUALIZATION | [UPDATE]). How to set up a validation run is
described in detail in vol.1 chapter 1.2.9, Result Transfer and Validation Run
(Smooth).
Fig. 5
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1.3.5
Set-up for Tosca Structure.smooth

the example in vol.4 chapter 1.2, Airbeam. The set-up can be done easily
using the wizard included in Tosca Structure.pre. In the following, several
postprocessing possibilities are discussed.
Tosca Structure.smooth and output for postprocessing
The results of the topology optimization can be converted automatically into
report files for postprocessing using Tosca Structure.report.For a quick visualization using Tosca Structure.view, choose the result type(s) to be visualized
(Material Distribution in this case). Filter(min) value defines the
limit for the soft elements (i.e. elements with a relative material value lower
than Filter(min)are not shown). After starting Tosca Structure.report, the
VTFX file with the optimization sequence can be visualized (View Report).
SIMULIA
Tosca Structure
Picker_arm
If the results of the topology optimization need to be further processed with

the smoothing and surface reduction module Tosca Structure.smooth, either
define a smooth command in the parameter file before starting the optimization or start the smooth run in the corresponding window in Tosca Structure.gui. Choose your settings and get a quick view of your smoothed result
with Tosca Structure.view (VTFX output required).
Setup for Tosca Structure.smooth
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Fig. 6
SIMULIA
Tosca Structure
1.3.6
Fig. 7
1.4
Illustration of the non smoothed final result (material distribution

of last iteration) and the smoothed result
Crane Hook
Task
Maximizing the stiffness with a volume constraint
Keywords
Casting restrictions, Symmetry: planar
Commands
DVCON_TOPO, FROZEN, DEMOLD_CONTROL
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This simple model of a crane hook clearly shows the difference of an optimization with and without manufacturing restrictions. The initial model of the
hook is stressed by the forces of a cable as shown in Fig. 8. The crane hook
is being supported by the upper bore hole. As the model here is to be kept
SIMULIA
Tosca Structure
Crane Hook
very simple, no other contacts or swinging motions in the bore hole are to be
described or taken into account.
Fig. 8
Load cases of the model "crane hook"
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The surface elements in the area of the tip of the crane hook are defined as
being FROZEN, in order for it to remain as such during optimization. In addi-
SIMULIA
Tosca Structure
tion, a force is applied in a second load case which illustrates a load case of
misuse.
Fig. 9
Optimization Model with FROZEN elements
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If the part is optimized without manufacturing restrictions (Fig. 10), the resulting structure is one with inner hollows that can not be easily manufactured. In
many cases such optimization suggestions are modified depending on the
SIMULIA
Tosca Structure
Crane Hook
designers experience. This can cause the final structure to become unreliable. Changes made manually seldom provide the best solutions.
Fig. 10
Procedure: Summary
Model: cranehook.ext from the examples directory for your optimization task
Design variable constraint: demold restriction on all elements with middle
plane
Objective: maximize stiffness (minimize compliance)
1.4.2

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1.4.1
Optimization results of the structure without manufacturing

restrictions
SIMULIA
Tosca Structure

Started Manual. In the following, only the definition of the manufactoring
restriction is described.
Setting up a demold restriction
To define a demold restriction choose the item PRE_PROCESSING |
DV_CONSTRAINT | NEW | DEMOLD_CONTROL in the task manager. In the
DEMOLD_CONTROL item, specify the global positive z-axis as demold direction (vector 0,0,1) and select point with coordinates (0,0,-20) to define a middle plane. The restrictions is applied to all elements (Fig. 11).
Fig. 11
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1.4.3
Definition of demold restriction

Using the command DVCON_TOPO a manufacturing restriction can be
defined in addition to that of the frozen areas. This guarantees the optimized
structure be castable or forgeable.
DVCON_TOPO
ID_NAME
EL_GROUP
CHECK_TYPE
PULL_DIR
ANGLE
CHECK_GROUP
MID_PLANE
=
=
=
=
=
=
=
dvcon_cast
ALL_ELEMENTS
CAST
0, 0, 1
0.
ALL_ELEMENTS
POINT,0,0,-20
END_
SIMULIA
Tosca Structure
Crane Hook
The element group to which the restrictions refer is to be entered along with
the direction of deformation (with a vector), the deformation angle, the control
group and the middle plane.
The control group is the group of elements that need to be considered for the
deformation. The group must contain at least the elements given in the element group with the command (EL_GROUP). Should more elements be contained here than in the optimization group, the elements outside the
optimization group are regarded as being a barrier, i.e. the elements in the
optimization may not be removed under these elements.
For example, an engine bracket is optimized and a part of the engine block is
still retained in the analysis model. The check group should be reduced to the
engine bracket because the manufacture of the engine block does not affect
the manufacturing of the engine bracket. If the engine bracket is connected to
the motor, the engine block has to be taken into the CHECK_GROUP. Otherwise, the elements from the optimization area will be removed by the optimization ("pulled" by the engine block).
This must be referenced in the command Optimize in order to activate the
restrictions.
OPTIMIZE
ID_NAME
DV
OBJ_FUNC
DVCON
=topology_optimization
= design_variables
= dvcon_frozen
DVCON
= dvcon_cast
CONSTRAINT
= volume_constraint
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Tosca Structure
Fig. 12
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1.5
Optimization results with manufacturing restrictions (smoothed

with Tosca Structure.smooth)
Beam with Symmetry Restrictions

(airbeam_sym)
Task
maximization of the stiffness with a volume constraint

and a symmetry constraint
Keywords
Symmetry: planar, cyclic, rotational
Commands
LINK_TOPO, DVCON_TOPO
This model is identical to the model show in vol.4 chapter 1.2.

Symmetry conditions should be introduced in the optimization as an addition
to the previous examples. The definition of the symmetry plane, of the symmetry point or of cyclic symmetry needs to include a reference coordinate
system. This definition can be made with the CS_DEF command. If the coor-
SIMULIA
Tosca Structure
Beam with Symmetry Restrictions (airbeam_sym)
dinate system is defined in the model it can be imported. The origin of the
coordinate system is in the middle of the design area.
center_cs
center_cs
Fig. 13
1.5.1
Coordinate system in the center of the beam (frozen_elements in

red color)
Procedure: Summary
Model: airbeam_sym.ext from the examples directory for your optimization
task
Design variable constraint: symmetry restriction

Started Manual. In the following, only the definition of the symmetry restriction
is described.
Setting up a symmetry restriction
To define a symmetry restriction choose the item PRE_PROCESSING |
DV_CONSTRAINT | NEW | SYMMETRY_CONTROL in the task manager. In
the SYMMETRY_CONTROL item, specify for this case a plane symmetry
regarding the XZ-plane (direction vector 0,1,0). Choose the beam center as
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1.5.2
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Tosca Structure
origin of the symmetry by typing its coordinates (43.5, 14.5, 0) as shown in

Fig. 14.
Fig. 14
Definition of plane symmetry restriction
Further you can define more different symmetry restrictions. For example,
rotation symmetry can be defined. Edit the SYMMETRY_CONTROL item and
change the symmetry type to ROTATION_SYM. Specify a 60 angle and the zaxis direction while leaving the origin unchanged.
To define cyclic symmetry choose CYCLIC_SYM in the SYMMETRY_CONTROL
item and specify a translation value of 21. The origin should be the same as
in the previous definitions. The new direction is the x-axis.
Point symmetry can be defined like the rotation symmetry with 180 angle.
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1.5.3

!COORDINATE SYSTEM IN THE CENTRE OF THE BEAM
CS_DEF
ID_NAME
CS_TYPE
DEF_TYPE
CS_REF
ORIGIN_123
ROTATION_321
=
=
=
=
=
=
center_cs
RECTANGULAR
LOCAL
CS_0
43.5,14.5,0
0,0,0
END_
The symmetry condition is defined using the command LINK_TOPO. This

definition specifies the type of symmetry (point, plane, cyclic,...), the refer-
SIMULIA
Tosca Structure
Beam with Symmetry Restrictions (airbeam_sym)
ence to the applied coordinate system and the type of coupling. The masterelement group and the child-coordinate system are referenced. The
LINK_TOPO command is referenced in the DVCON_TOPO command which
completes the assignment of the element group.
For example, plane symmetry regarding the XZ-plane is defined with the
command:
!DEFINE PLANE SYMMETRY
!SYMMETRY PLANE: X-Z PLANE OF CENTER_CS
LINK_TOPO
ID_NAME
TYPE
CS
= link_topo2
= PLANE_SYM, AXIS_2
= center_cs
END_
In the DVCON_TOPO command the LINK_TOPO definition is referenced

with:
DVCON_TOPO
ID_NAME
EL_GROUP
CHECK_TYPE
CHECK_LINK
=
=
=
=
dvcon_plane
ALL_ELEMENTS
LINK_TOPO
link_topo2
To activate the restriction the DVCON_TOPO command must be referenced

in the OPTIMIZE command.
Several definitions of symmetry restrictions are given in the example file in
the installation manual but only the plane symmetry definition is activated. All
other types of symmetries can be activated by changing the parameter file,
but only one symmetry condition can be activated at the same time.
OPTIMIZE
!
!
!
!
ID_NAME
= topology_optimization
DV
= design_variables
OBJ_FUNC
DVCON
= dvcon_frozen
CONSTRAINT
= volume_constraint
Link Topo Constraint
DVCON
= dvcon_link
Plane Symmetry
DVCON
= dvcon_plane
Point Symmetry
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SIMULIA
Tosca Structure
! DVCON
= dvcon_point
! Rotation Symmetry
! DVCON
= dvcon_rotation
! Cyclic Symmetry
! DVCON
= dvcon_cyclic
END_
Optimization results with a plane symmetry restriction
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Fig. 15
SIMULIA
Tosca Structure
Minimum und Maximum Member Size (plate_min_max)
1.6
Minimum und Maximum Member Size

(plate_min_max)
Task
Maximization of stiffness with a volume constraint and

a maximum or a minimum member size control.
Keywords
Minimum/Maximum member size control
Commands
MIN_MEMBER, MAX_MEMBER
The model of the plate used for this example has a u-shaped nut that is
stressed by two opposing forces on its edges. The aim of the optimization is
to maximize the stiffness.
Fig. 16
1.6.1
Design area of the plate with boundary conditions
Procedure: Summary
Model: plate_min_max.ext from the examples directory for your optimization
task
Design variable constraint: minimal member size 6 mm or maximal member
size 5.1 mm
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Tosca Structure
1.6.2

Started Manual. In the following, only the definition of the membersize restriction is described.
Setting up a member size restriction
To define a member size restriction choose the item PRE_PROCESSING |
DV_CONSTRAINT | NEW | MEMBERSIZE_CONTROL in the task manager.
In the MEMBERSIZE_CONTROL item, specify for this case a minimum thickness of 6 mm (Fig. 17).
Fig. 17
Definition of minimal member size restriction
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Additionally you can create another member size constraint for a maximum
thickness. Choose a maximal thickness of 5.1 mm (Fig. 18).
Fig. 18
Definition of maximal member size restriction
SIMULIA
Tosca Structure
In the optimization task only one of the member size restrictions can remain
active. Choose one of the member size restrictions, right click on the item and
select Disable. The item appears crossed out. Run the optimization with the
chosen restriction. Further rerun the optimization by activating the other
restriction and disable the primary active one.
1.6.3

The additional maximum or minimum member size control is introduced in
this optimization example. The restriction should be active for all elements of
the design area. The definition of these geometrical restrictions is done with a
DVCON_TOPO definition:
DVCON_TOPO
ID_NAME
EL_GROUP
CHECK_TYPE
THICKNESS
=
=
=
=
dvcon_min
ALL_ELEMENTS
MIN_MEMBER
7.0
=
=
=
=
dvcon_max
ALL_ELEMENTS
MAX_MEMBER
5.1
END_
DVCON_TOPO
ID_NAME
EL_GROUP
CHECK_TYPE
THICKNESS
For the minimum and maximum member size control the thickness specified
by the user should be at least twice the average element edge length. Undesirable conditions may appear for smaller values.
The definition has to be referenced in the OPTIMIZE command:
OPTIMIZE
ID_NAME
DV
OBJ_FUNC
!insert this line
! DVCON
!insert this line
DVCON
CONSTRAINT
END_
= DV_DESIGN_ELEM
= USER_OBJ_FUNC
for minimum member size constraint
= dvcon_min
for maximum member size constraint
= dvcon_max
= VOLUME_CONSTRAINT
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SIMULIA
Tosca Structure
Different results can be seen depending on the chosen restriction:

no restriction
minimum membersize
Optimization result without restriction, with minimum member

size control and with maximum member size control
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Fig. 19
maximum membersize
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Tosca Structure
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Tosca Structure
Sensitivity Based Topology

Optimization
Sensitivity based topology optimization offers high flexibility in objective and
constraint definition for determining a new conceptual design for a component. In this section, typical sensitivity based topology optimization examples
are described.
Example overview
Temperature load
Mechanism
Stress constraint
Internal forces
Plate symm. freq.
Crank shaft
Plate frequency
Cranehook stat
Cranehook sen
Cranehook dyn stat
Examples
Bonnet
Keywords
Airbeam vol.
2.1
Analysis Type
STATIC
FREQUENCY
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Objective
Displacement
Frequency
(KreisselmaierSteinhauser)
Compliance
Volume
X
X
X
X
Target
MAX
MIN
MINMAX
X
X
X
X
SIMULIA
Tosca Structure
Crane hook
Temperature load
Stress constraint
Plate symm. freq.
Plate frequency
Mechanism
Internal forces
Crank shaft
Cranehook stat
Cranehook sen
Cranehook dyn stat
Bonnet
Examples
Airbeam vol.
Keywords
Constraints
Center of
gravity
Displacement
X
X
Frequency
Internal force
Rotation
von Mises
stress
Volume
Geometric Restriction
Casting
Frozen
X
X
Minimum
member size
2.2
Crane hook
Task
Minimize the volume of the structure with 2 displacement constraints and 2 frequency constraints
Keywords
Casting restriction, Frozen elements
Commands
FEM_INPUT, DRESP, CONSTRAINT, OBJ_FUNC,

OPTIMIZE
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SIMULIA
Tosca Structure
The initial model of the hook is stressed by the forces of a cable as shown in
Fig. 20 a). In addition, a force is applied in a second load case which illustrates a load case of misuse Fig. 20 b). The crane hook is being supported by
the upper bore hole. As the model here is to be kept very simple, no other
contacts or swinging motions in the bore hole are to be described or taken
into account.
Fig. 20
Load cases of the model "crane hook"
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The surface elements in the area of the tip of the crane hook are defined as
being FROZEN, in order for it to remain as such during optimization. Target of
SIMULIA
Tosca Structure
Crane hook
the optimization is the minimization of the volume of the cranehook for given
constraints of displacements and frequencies.
Fig. 21
Optimization model with FROZEN elements
2.2.1
Procedure: Summary
Model: cranehook_dyn_stat.ext from the examples directory for your optimization task
Design variable constraint: demold restriction on all elements using a middle
plane
Objective: minimize volume
Constraint: maximal absolute displacement of node 7166 (Fig. 22) in both
static loadcases should be 1.3 mm (two less or equal constraints)
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Depending on the used solver the analysis can be performed in one or two
solver runs. If the solver supports the combined modal and static analysis the
static loadcases are the loadcases with number 1 and 2. The frequency loadcase is then number 3. For the case that two analysis files are used, the referenced loadcase numbers of the second file are shifted by 10.000. Therefore
the modal analysis has to be referenced with the loadcase number (boundary
conditions set number) 10.001.
SIMULIA
Tosca Structure
Constraint: first eigenfrequency from the modal loadcase should not be less
than 200 Hz, the second eigenfrequency should be minimum 500 Hz (two
greater or equal constraints)
Settings: 50 iterations (default).
Fig. 22

Choose a TOPOLOGY_OPTIMIZATION_SENSITIVITY task in Tosca ANSA
environment and create the model link. Create the design area of all elements
and fix the element group frozen_elements. Define a demold restriction on
all elements using a middle plane through the point with coordinates 0, 0, -20
and the global positive z-axis as pull direction. Set up the objective function to
minimize the crane hook volume. In the following, the definition of displacement and eigenfrequency constraints is described.
Setting up the displacement constraints
To define a displacement constraint choose the item PRE_PROCESSING |
CONSTRAINTS | NEW | DISPLACEMENT_CONSTRAINT in the task manager. In the CONSTRAINT item, switch the MAGNITUDE to ABS and enter the
maximal value for the displacement, 1.3. Switch the TARGET to NODE and
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2.2.2
Node 7166 for displacement constraints
SIMULIA
Tosca Structure
Crane hook
specify the node number 7166. Specify the loadcase number 1 for this constraint as shown in Fig. 23.
Fig. 23
Definition of displacement constraint
Create an identical displacement constraint for loadcase number 2.

Setting up the eigenfrequency constraints
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To define a displacement constraint choose the item PRE_PROCESSING |

CONSTRAINTS | NEW | EIGENFREQUENCY_CONSTRAINT in the task
manager. In the CONSTRAINT item, switch the MAGNITUDE to ABS, select a
GE_VALUE to and enter the minimum value for the first eigenfrequency, 200.
Specify the loadcase number 3 and additionally the substep number 1 for this
SIMULIA
Tosca Structure
constraint as shown in Fig. 24. In this case the selected substep number will
refer to the eigenfrequency with the same order number.
Fig. 24
2.2.3
Definition of eigenfrequency constraint

The corresponding FEM_INPUT command is then:
FEM_INPUT
ID_NAME = READ_BLOCK
FILE=CRANEHOOK_SEN.BDF
END_
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If the solver does not support the combined analysis the FEM_INPUT command contains two entries for the FILE item.
FEM_INPUT
ID_NAME = READ_BLOCK
FILE=CRANEHOOK_SEN.CDB
FILE=CRANEHOOK_SEN_DYN.CDB
END_
For the following definition, the number of analysis files within the
FEM_INPUT command influences the definition of the design responses
because the referenced loadcase numbers of the second file are shifted by
SIMULIA
Tosca Structure
Crane hook
10.000. Therefore the modal analysis has to be referenced with the loadcase
number (boundary conditions set number) 10.001.
Fig. 25
Initial model of the cranehook
The design response for the volume design response and the objective function are defined via the following commands:
DRESP
ID_NAME
DEF_TYPE
TYPE
UPDATE
EL_GROUP
GROUP_OPER
=
=
=
=
=
=
DRESP_VOL_TOPO
SYSTEM
VOL_FILL
EVER
ALL_ELEMENTS
SUM
OBJ_FUNC
ID_NAME
DRESP
TARGET
= min_vol
= DRESP_VOL_TOPO
= MIN
END_
The design response for the second frequency constraint is (for the
FEM_INPUT with two files):
DRESP
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SIMULIA
Tosca Structure
ID_NAME
TYPE
DEF_TYPE
LC_SET
=
=
=
=
DRESP_FREQ_2
DYN_FREQ
SYSTEM
Modal,10001,2
END_
The constraint definitions limit the frequencies to be greater than 200 Hz for
the first mode and the greater than 500 Hz for the second mode. As example
the definition of the constraint for the second mode is shown below.
CONSTRAINT
ID_NAME
DRESP
MAGNITUDE
GE_VALUE
=
=
=
=
DRESP_FREQ_2_CON
DRESP_FREQ_2
ABS
500.0
END_
In addition to the frequency constraints the two displacement constraints are

defined in a similar way. First, a node group with the node for the constraint is
defined:
GROUP_DEF
ID_NAME
TYPE
FORMAT
LIST_BEGIN
7166
= DISP_NODES
= NODE
= LIST
END_
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The node is referenced in the design responses for the displacement of the
first static and the second static loadcase (here only the first static loadcase is
shown):
DRESP
ID_NAME
TYPE
DEF_TYPE
LC_SET
ND_GROUP
=
=
=
=
=
DRESP_DISP1_ABS_1
DISP_ABS
SYSTEM
STATIC,1,
DISP_NODES
END_
Now one of the two displacement constraint can be defined as absolute constraint:
CONSTRAINT
ID_NAME
DRESP
MAGNITUDE
LE_VALUE
=
=
=
=
DISP_constraint_1
DRESP_DISP1_ABS_1
ABS
1.3
END_
SIMULIA
Tosca Structure
Crane hook
The last step is to combine all the definitions in the OPTMIZE command. Only
the objects (like constraints, objective function, design variables,...) referenced in the OPTIMIZE command are used for the optimization.
OPTIMIZE
ID_NAME
DV
OBJ_FUNC
DVCON
DVCON
CONSTRAINT
CONSTRAINT
CONSTRAINT
CONSTRAINT
=
=
=
=
=
=
=
=
=
design_variables
min_vol
dvcon_frozen
dvcon_cast
DISP_constraint_1
DISP_constraint_2
DRESP_FREQ_1_CON
DRESP_FREQ_2_CON
END_
For avoiding checkerboard effects the smoothing filter can be activated with
the OPT_PARAM command.
OPT_PARAM
ID_NAME
= OPT_PARAMS
OPTIMIZE
FILTER_RADIUS = 9.0
END_
For getting an impression of the quality of the optimization it is necessary to
check the values of the constraints and the objective at the end of the optimization. If Tosca Structure stops the problem has converged or the maximum
number of iterations (by default 50) is reached. If no convergence is
achieved, it can be possible that the constraints are too strict meaning that
they can not be reached because of the mechanical boundary conditions of
the model. The model plot does not give any information about the quality of
the result.
A converged model shows the following characteristics:
The change of the objective function is very small so that the plot of the
value of the objective shows a nearly horizontal line
All the constraints are fulfilled or inactive (fulfilled but not near to the constraints value)
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2.2.4
SIMULIA
Tosca Structure
The changes of the constraint are very small so that the plot of the constraint value shows a nearly horizontal line.
Convergence plot for objective function (Volume)
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Fig. 26
SIMULIA
Tosca Structure
Crane hook
Convergence plot for Frequency constraint
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Fig. 27
SIMULIA
Tosca Structure
Convergence plot for displacement constraint
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Fig. 28
SIMULIA
Tosca Structure
Symmetric Plate (plate_sym_freq)
2.3
Optimization result

Task
Maximization of the first natural frequency with a volume constraint.
Keywords
Frequency (Kreisselmaier-Steinhauser)
Commands
DYN_FREQ_KREISSEL
For the optimization of the first natural frequency a symmetric plate is generated in the FE-preprocessor. The plate is fixed at the corners and in the mid-
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Fig. 29
SIMULIA
Tosca Structure
dle a mass element is connected to the structure.
500.0
800.0
Fig. 30
Start model for the natural frequency optimization
The definition of the optimization problem is done using the definition of a

variable (design response variable) which contains the first natural frequency.
This definition is referenced in the objective function.
By maximizing the first natural eigenfrequency is the danger that the modes
may switch, i.e., that the original first eigenfrequency becomes greater than
the original second. This can be avoid buy the Kreisselmeier-Steinhauser criterion that creates a weighting of the eigenfrequencies causing the lowest
eigenfrequency to stay the lowest.
2.3.1
Model: plate_sym_freq.ext from the examples directory for your optimization

task
Objective: maximize first eigenfrequency (using the Kreisselmeier-Steinhauser criterion)
Constraint: relative volume of 30 % (less or equal constraint)
Settings: filter radius 25 mm
Version 8.1.0 Rev. 1 - 05.2014

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Procedure: Summary
2.3.2

the example in vol.4 chapter 2.2, Crane hook or in vol.1 chapter 1.2, Topology
SIMULIA
Tosca Structure

TOPO_SENSITIVITY task, loading the model and definition of design area,
Started Manual. In the following, only the objective function described.
Setting up an eigenfrequency maximization
To define the objective function as the maximization of an eigenfrequency,
choose the item PRE_PROCESSING | OBJ_FUNC_ITEM_1 | NEW |
EIGENFREQUENCY in the task manager. In the OBJFUNC_TERM item, choose
the DYN_FREQ_KREISSEL type. To select the eigenmodes, activate the
LC_SET field and press "?". In the LC_SET dialog, choose the first 5 eigenmodes as shown in Fig. 31. To add loadcase definitions, use the button MORE.
It is not absolute necessary to change the APPROACH to MODAL, if there is
only a modal analysis defined in the input deck. If only one loadcase exists,
the LOADCASE fields can be left empty.
Fig. 31
Selecting the first 5 eigenfrequencies
Choose PRE_PROCESSING | TOPOLOGY_OPTIMIZATION_SENSITIVITY

| NEW | SETTINGS in the task manager and specify a 25 mm filter radius.
2.3.3

The design response is defined as described:
DRESP
ID_NAME
DEF_TYPE
TYPE
LC_SEL
LC_SET
LC_SET
LC_SET
=
=
=
=
=
=
=
DRESP_FREQ
SYSTEM
DYN_FREQ_KREISSEL
MAX
Modal, 1, 1
Modal, 1, 2
Modal, 1, 3
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Setting a filter radius
SIMULIA
Tosca Structure
LC_SET
LC_SET
= Modal, 1, 4
= Modal, 1, 5
END_
OBJ_FUNC
ID_NAME
DRESP
TARGET
= maximize_first_eigenfrequency
= DRESP_FREQ
= MAX
END_
The volume constraint declaration is similar to the one in the static optimization problem.
DRESP
ID_NAME
DEF_TYPE
TYPE
UPDATE
EL_GROUP
GROUP_OPER
=
=
=
=
=
=
DRESP_VOL_TOPO
SYSTEM
VOL_FILL
EVER
ALL_ELEMENTS
SUM
=
=
=
=
volume_constraint
DRESP_VOL_TOPO
REL
0.3
END_
CONSTRAINT
ID_NAME
DRESP
MAGNITUDE
LE_VALUE
END_
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The FILTER_RADIUS item is the filter radius of the smoothing filter which
eliminates the checkerboard effects. The radius has to be chosen in such a
SIMULIA
Tosca Structure
way that the value is about twice the average element edge length in the
model (approx. 12.5). A value of 25 has been used in this example.
Fig. 32
OPT_PARAM command in Tosca Structure.gui
The corresponding OPT_PARAM command is then:

OPT_PARAM
ID_NAME
= KREISSELMEIER_FREQ_SETTINGS
OPTIMIZE
END_
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FILTER_RADIUS = 25.
SIMULIA
Tosca Structure
Fig. 33
Optimization result with a filter radius of r=25
Fig. 34
Frequency diagram for the iterations
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2.3.4
SIMULIA
Tosca Structure
Bonnet with Minmax Formulation
2.4

Task
Maximize stiffness of the structure with relative volume

of 40 %
Keywords
Volume constraint
Commands
MINMAX
With this example the difference between the MINMAX formulation and the
MIN formulation of an optimization problem is shown. A simple example of a
bonnet is used as finite element model. There are three different loadcases
applied to the model.
2.4.1
Initial model of a bonnet with 3 different loadcases applied.
Procedure: Summary
Model: bonnet.ext from the examples directory for your optimization task
Settings: filter radius 0.8 mm
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Fig. 35
SIMULIA
Tosca Structure
2.4.2

Started Manual. In the following, only the objective function is described.
Setting up the objective function
Choose the item PRE_PROCESSING | OBJ_FUNC_ITEM_1 | NEW |
COMPLIANCE in the task manager. In the COMPLIANCE_TERM item, specify
the first loadcase. Repeat the step for the second and third loadcase. Finally
there are three COMPLIANCE items in the objective function area. Set the
objective function target to MIN. In a second optimization run set the objective
function target to MINMAX. Compare the optimization results from both runs.
Are there differences?
Setting a filter radius
Choose PRE_PROCESSING | TOPOLOGY_OPTIMIZATION_SENSITIVITY
| NEW | SETTINGY in the task manager and specify a 0.8 mm filter radius.
2.4.3

For defining the problem the compliance of each loadcase is written into a
design response.
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DRESP
ID_NAME
TYPE
DEF_TYPE
LC_SET
EL_GROUP
GROUP_OPER
=
=
=
=
=
=
COMPL_1
STRAIN_ENERGY
SYS
STATIC,1,
ALL_ELEMENTS
SUM
=
=
=
=
=
=
COMPL_2
STRAIN_ENERGY
SYS
STATIC,2,
ALL_ELEMENTS
SUM
END_
DRESP
ID_NAME
TYPE
DEF_TYPE
LC_SET
EL_GROUP
GROUP_OPER
END_
SIMULIA
Tosca Structure
DRESP
ID_NAME
TYPE
DEF_TYPE
LC_SET
EL_GROUP
GROUP_OPER
=
=
=
=
=
=
COMPL_3
STRAIN_ENERGY
SYS
STATIC,3,
ALL_ELEMENTS
SUM
END_
As first variant the formulation of the optimization problem is done in the classic way, which means that the compliances of all three loadcases are added
and the the sum of the compliances of the three loadcases is minimized.
The formulation of the objective for this looks like:
OBJ_FUNC
ID_NAME
DRESP
DRESP
DRESP
TARGET
=
=
=
=
=
MIN_COMP
COMPL_1, 1.0, 0.0
COMPL_2, 1.0, 0.0
COMPL_3, 1.0, 0.0
MIN
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END_
SIMULIA
Tosca Structure
2.4.4
As result the following structure is determined:
Fig. 36
Final structure of the bonnet with MIN COMPLIANCE formulation.
With the second formulation, the MINMAX formulation, the objective function
definition looks like:
ID_NAME
DRESP
DRESP
DRESP
TARGET
=
=
=
=
=
MIN_MAX_COMP
COMPL_1, 1.0, 0.0
COMPL_2, 1.0, 0.0
COMPL_3, 1.0, 0.0
MIN_MAX
END_
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OBJ_FUNC
SIMULIA
Tosca Structure
In this case the sum of the compliance is not minimized. Instead the maximum compliance of the three defined design responses is minimized. As
result the optimization system ends up with the following structure:
Final structure of the bonnet with MINMAX formulation.
The resulting structure looks totally different compared to the standard formulation. The reason for these differences becomes obvious if the compliances
of the different loadcases are compared.
The MIN formulation ends up with a lesser total compliance of the sum of all
loadcases but the loadcases with the smaller loads have a compliance which
is lesser (higher stiffness) than the loadcase with the doubled load in the middle of the structure (Fig. 38).
The result of the MINMAX formulation shows a higher total compliance but
the compliances of all loadcases are equal which means that the structure
can handle all loadcases in the same effective way. It is not possible to
reduce the compliance for one loadcase without increasing the compliance
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Fig. 37
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Tosca Structure
for another loadcase. This solution represents one point on a Pareto optimality front (Fig. 39).
Compliance for MIN formulation.
Fig. 39
Compliance for MINMAX formulation.
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Fig. 38
SIMULIA
Tosca Structure
Crankshaft
2.5
Crankshaft
Task
Minimize the volume
Keywords
Center of gravity, rotation constraint
Commands
CENTER_GRAVITY_Y
This example illustrates sensitivity based topology optimization of a crankshaft where following demands are considered: low weight, certain bending
and torsional stiffness as well as good behavior under centrifugal loading.
The latter can be achieved via optimized location of the gravity center (balanced design). In this example a constraint is set on the y-coordinate of the
center of gravity. Further constraints are used for the rotational displacements
of node 2. Both load cases are shown in Fig. 40
2.5.1
Load cases of the model "crankshaft"
The model
The model is a simplified model of a crankshaft using shell elements for the
design area. The shafts are modeled with beam elements. The coupling
between shells and beams is done with RBE2. The coupling elements are
therefore defined as frozen elements and are not considered by the optimization. Boundary conditions are set to both outer nodes of the shaft beams
(nodes 1 and 2).
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Fig. 40
SIMULIA
Tosca Structure
2.5.2
Optimization task
The goal of the optimization is to reduce the weight of the crankshaft by minimizing the volume. Further two rotational displacement constraints are considered. An additional constraint is set on the location of the center of gravity.
For better convergence the initial volume of the structure is set to 90 percent.
2.5.3
Optimization task definition in Tosca ANSA environment

1. Start Tosca ANSA environment to define the optimization task.
2. Select a new TOPO_SENSITIVITY task in the Task Manager.
3. Import the analysis model crank_shaft_env.ext (ext=inp, bdf, dat...).
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4. Create an element group DESIGN_ELEMENTS which contains the design

elements and set the group as design area. The group should contain all
shell elements except elements on the coupling spots as shown in Fig. 41.
Fig. 41
Contents of group DESIGN_ELEMENTS
5. Define the objective function to minimize the design volume.

6. Define a rotation constraint to maintain the torsional stiffness by selecting
the item ROTATION_CONSTRAINT. In the CONSTRAINT_ITEM dialog, set
the magnitude to ABS and specify a less or equal value of 2.0e-6. Switch
the TARGET item to NODE and type the node number 2 in the NID field. Set
SIMULIA
Tosca Structure
Crankshaft
the constraint type to ROT_Z and specify the first load case in the LC_SET
field below as shown in Fig. 42.
Fig. 42
Definition of the rotation constraint for torsional stiffness
7. Define a second rotation constraint on the same node to maintain the

bending stiffness. Specify a maximal rotational value of 1.2e-6 along the x
axis and assign the second load case to the constraint definition.
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8. Define a constraint for the y location of the center of gravity of the whole
model by selecting the item CENTER_OF_GRAVITY_CONSTRAINT. In the
CONSTRAINT_ITEM dialog, set the magnitude to ABS and specify a less or
SIMULIA
Tosca Structure
equal value of -18. Set the constraint type to CENTER_OF_GRAVITY_Y

(Fig. 43).
Fig. 43
Definition of the center of gravity constraint
9. Define an initial density of 0.9 by adding the SETTINGS item to the optimization task.
10.Set up the generation of VTFX visualization and start the Tosca Structure
optimization.
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2.5.4
Optimization task definition in Tosca Structure.gui

1. Start Tosca Structure.pre to define the optimization task.
2. Import the analysis model crank_shaft.ext (ext=inp, bdf, dat...). If no
groups are defined in the analysis input (e.g. for MSC Nastran input) import
the groups from the file groups.bdf which can be found in the same directory as the analysis input. For more details please refer to the Tosca Structure Getting Started manual.
3. Create the design variable area. The group DESIGN_ELEMENTS contains
the design elements.
4. Add a design response for the volume as a sum of all design elements
volumes.
SIMULIA
Tosca Structure
Crankshaft
5. Create a design response for the rotational displacement on node 2 along

the z axis. Select the first load case to refer the design response to (Fig.
44).
Fig. 44
Definition of the rotation constraint for torsional stiffness
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6. Create a second design response for rotational displacement on node 2

similar to the previous one. Select the rotation along the x axis and the
assign the second load case to the design response.
SIMULIA
Tosca Structure
7. Create a design response for the y location of the center of gravity of the
whole model as shown in Fig. 45. Make sure to switch the Group Oper to
Sum.
Fig. 45
Definition of the center of gravity constraint
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8. Define the objective function to minimize the design volume.

9. Define constraints to maintain the torsional and bending stiffness as well as
to set the y location of the gravity center. In the first constraint set the
maximal value of 2.0e-6 for the z rotation of node 2. In the second
constraint set the maximal value of 1.2e-6 for the x rotation of node 2. In
the third constraint set a maximal value of -18 for the y coordinate of the
center of gravity. All constraint types should be less or equal and the
magnitude values should be set to ABS.
10.Compose the optimization task (OPTIMIZE) and select the predefined
definitions. Choose the TOPO_SENSITIVITY optimization strategy. Make
sure to reference all defined CONSTRAINT items in the OPTIMIZE
command.
11.Define some additional optimization parameters via the OPT_PARAM
command. Increase the initial density from 0.5 to 0.9.
12.Start the complete Tosca Structure optimization using the start option type
= all.
SIMULIA
Tosca Structure
Crankshaft
2.5.5
Result discussion and validation run

The optimization is finished after approx. 20 design cycles. The results in
form of material distribution are shown in Fig. 46.
Optimization result crankshaft, material distribution
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Fig. 46
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Additionally you can create smooth surfaces using Tosca Structure.smooth or

the related function in Tosca ANSA environment. The results of the smoothing are shown in Fig. 47.
Fig. 47
Optimization result crankshaft, smooth surfaces
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Using Tosca ANSA environment you can generate a new mesh and apply the
initial boundary conditions on the new design model (Fig. 48). After that you
can perform a validation run.
Fig. 48
Reconstructed model (new design)
SIMULIA
Tosca Structure
Mechanism
Check the analysis results. Are both rotation constraints still maintained?
Slight differences can occur due to the smoothing process. The results of the
validation run (here for the solver Abaqus) are shown in Fig. 49.
Fig. 49
Mechanism
Task
Maximization of the displacement of one node under a

volume constraint.
Keywords
Displacement
Commands
DISP
The present example shows that the topology optimization by Tosca Structure
is also capable of performing a mechanism design. The object function is now
different, actually opposite, from the classic compliance formulation. The
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Rotation displacements results of the validation run (load cases 1

and 2)
SIMULIA
Tosca Structure
objective is now to maximize the displacement of a node for a given actuator

force.
Fig. 50
Concept drawing of mechanism design
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Fig. 50 displays the design problem. The symmetry of the structure and optimization problem is used in the input model; note that the input model as well
as the optimization results shows one half of the model (the upper rectangle)
only, however the complete model (the rectangle plus its reflection around the
lower side) are used in the finite element analysis and the optimization. In the
optimized model, the middle point of the right side (the point where the spring
is attached) is displaced towards the inside of the model, i.e., in negative x
direction, therefore the absolute value of the displacement is maximal if the
displacement itself (that is negative) is minimal. Thus, the objective function is
the minimization of the displacement of the node.
The upper left corner and the lower right corner of the half of the model (corresponding to the both left corners and the middle of the right side of the
SIMULIA
Tosca Structure
Mechanism
entire model) are the frozen areas. The elements at these points constitute
the group support:
Fig. 51
2.6.1
Frozen group of the mechanism model
Procedure: Summary
Model: mechanism.ext from the examples directory for your optimization task
Design variable constraint: the group support is marked as frozen
Objective: minimize the displacement in x direction of the node with ID = 2.
Constraint: relative volume is less than 25% (inequality constraint)
Settings: no more than 150 iterations, FILTER_RADIUS = 0.04.

Optimization with Tosca ANSA environment. The set-up including the definition of a new TOPO_SENSITIVITY task, loading the model and definition of
the design area, the objective function, the constraint and the design variable
constraint can be done as described in the Getting Started Manual.
The objective should be defined as displacement in x-direction in node 2. The
target of the objective is to minimize this displacement (as it is negative, the
absolute displacement will be maximized). The volume should be restricted
by 25% of the original volume.
In order to modify the maximal number of iterations, apply Edit command on
GLOBAL_STOP_CONDITION_1 item and modify ITER_MAX value. In order
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2.6.2
SIMULIA
Tosca Structure
to set FILTER_RADIUS to 0.04, first create SETTINGS item using New ->
SETTINGS command of the context menu of TOPOLOGY_OPTIMIZATION_
SENSITIVITY item, then enter the value of the filter radius. Also,
AUTO_FROZEN should be set to LOAD in this dialog (this is the default value
in case that no SETTINGS item is present).
2.6.3

The design response and the objective function are to be defined as follows:
DRESP
ID_NAME = DRESP_NODE_X
TYPE = DISP_X
DEF_TYPE = SYSTEM
LC_SET = STATIC,1,ALL
NODE = 2
END_
OBJ_FUNC
ID_NAME = MIN_DISP
DRESP = DRESP_NODE_X, 1.0, 0.0
TARGET = MIN
END_
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With the constraint that the volume is less or equal to 25% of the original
model (LE_VALUE = 0.25 with MAGNITUDE = REL) and the condition that
the elements at the supports are defined as frozen, the topology optimization
results in the structure shown in Fig. 52. In this figure, the complete model
(consisting of the model that has been actually optimized and its reflection
SIMULIA
Tosca Structure
Internal Forces
around x-axis) is shown. This inverter mechanism is a well-known example

that is found in the academic literature.
Fig. 52
Internal Forces
Task
Stiffness optimization considering internal forces.
Keywords
Internal force constraint, Reaction force constraint
Commands
INTERNAL_FORCE, REACTION_FORCE
can also use the internal forces as the design response. See also vol.2 chapter 4.4.5, Internal force.
This example can be done using the CAE solvers Abaqus, ANSYS, MSC
Nastran and Msc Marc.
A model of a beam structure loaded with a single offset load and fully
clamped at the sides is shown in vol.4 chapter 2: First approach: a constraint
defined by internal forces. The beam structure should be optimized for stiffness but then at the same time each of the sides should only carry half of the
applied force P. That each of the clamped set of boundaries on the side
should be carrying P/2 can be ensured using two different approaches. In the
following, both approaches will be applied.
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Topology optimization result (inverter mechanism)
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Tosca Structure
In both approaches all the elements are defined as design elements and the
top layer of elements in the beam model at vol.4 chapter 2: First approach: a
constraint defined by internal forces is defined as frozen.
Fig. 53
Initial model of a beam structure loaded with a single offset load

and fully clamped at the sides. The beam structure should be
optimized for stiffness but then at the same time each of the sides
should only carry half of the applied force P.
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In the first approach, a constraint is defined for the sum of internal forces
through a cut in the y-direction of the beam structure as shown in Fig. 54a.
For summing up the internal forces in the y-direction an element group
(EL_INTERNAL_GROUP) and a node group (ND_INTERNAL_GROUP) is
defined. In the second approach a constraint is defined for the sum of reaction forces in the y-direction for all the nodes on left side of the beam structure
SIMULIA
Tosca Structure
Internal Forces
as shown in Fig. 54b. For summing up the reaction forces in the y-direction a
node group (ND_REACTION_GROUP) is defined.
2.7.1
a) Determining the internal forces through the beam using a node

set and an element set. b) Determining the reaction forces
through the beam using an element set.
Procedure: Summary
Model: internal_forces.ext from the examples directory for your optimization
task
Design variable constraint: Fix elements of group TOP_FROZEN
Constraint: In approach 1 the sum of the internal forces in y-direction in the
section cut is at least 0.0015 (greater or equal constraint)
Constraint: In approach 2 the sum of the reaction forces in y-direction on the
left side should not exceed 0.0015 (less or equal constraint)
Settings: DENSITY_UPDATE is set to CONSERVATIVE and a 0.1
DENSITY_MOVE value is specified for stabilizing the optimization
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Fig. 54
SIMULIA
Tosca Structure
2.7.2

objective function and volume constraint can be done as described in the
Getting Started Manual. In the following, only the internal and reaction forces
constraints for both approaches are described.
First define the groups needed for the topology optimization. Create an element group TOP_FROZEN for the fix elements as shown in Fig. 53. The
group should contain the top layer of the shell elements. Create the cross
section groups ND_INTERNAL_GROUP and EL_INTERNAL_GROUP
needed for the calculation of the internal force in approach 1. Refer to Fig. 54.
The position of the cross section is not important, however place it somewhere in the middle of the beam. Additionally create the node group
ND_REACTION_GROUP containing all outer nodes on the left side of the
beam (Fig. 54) for the reaction force calculation in approach 2.
First approach: a constraint defined by internal forces
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Choose the item PRE_PROCESSING | CONSTRAINTS | NEW |

INTERNAL_FORCE_CONSTRAINT in the task manager. In the CONSTRAINT
item, switch the magnitude to ABS and enter a minimum value 0.0015 for this
constraint (GE_VALUE). Set the target to NODE_AND_ELEMENT_GROUP and
select
the
predefined
groups
ND_INTERNAL_GROUP
and
EL_INTERNAL_GROUP. Specify an INTERNAL_FORCE_Y constraint type.
The constraint definition is shown in Fig. 55.
Fig. 55
Definition of internal forces constraint
To define some additional optimization settings, choose the item

PRE_PROCESSING | TOPOLOGY_OPTIMIZATION_SENSITIVITY | NEW
| SETTINGS in the task manager. For stabilizing the optimization a more
SIMULIA
Tosca Structure
Internal Forces
strict update of design variables is defined. Switch the DESITY_UPDATE to

CONSERVATIVE and specify a 0.1 value for DENSITY_MOVE.
Second approach: a constraint defined by reaction forces
REACTION_FORCE_CONSTRAINT in the task manager. In the CONSTRAINT
item, switch the magnitude to ABS and enter a maximal value 0.0015 for this
constraint (LE_VALUE). Set the target to NODE_GROUP and select the predefined group ND_REACTION_GROUP. Specify a REACTION_FORCE_Y
constraint type. The constraint definition is shown in Fig. 56.
Fig. 56
2.7.3
Definition of reaction forces constraint

DV_TOPO
ID_NAME
EL_GROUP
END_
= DESIGN_VARIABLES
= ALL_ELEMENTS
and
GROUP_DEF
ID_NAME
TYPE
FORMAT
LIST_BEGIN
9801-10000
END_
DVCON_TOPO
ID_NAME
= TOP_FROZEN
= ELEM
= LIST
= DVCON_FROZEN
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Define design and frozen area like the following:
SIMULIA
Tosca Structure
EL_GROUP
CHECK_TYPE
END_
= TOP_FROZEN
= FROZEN
First approach: a constraint defined by internal forces
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In the first approach a constraint is defined for the sum of internal forces
through a cut in the y-direction of the beam structure as shown in Fig. 54a.
For summing up the internal forces in the y-direction an element group and a
node group is defined like the following:
GROUP_DEF
ID_NAME
= ND_INTERNAL_GROUP
TYPE
= NODE
FORMAT
= LIST
LIST_BEGIN
149,476,751,1078,1353,1680,1955,2282,2557,2884,3159,3486,
3761,4088,4363,4690,4965,5292,5567,5894,6169,6496,6771,
7098,7373,7700,7975,8302,8577,8904,9179,9506,9781,10108,
10383,10710,10985,11312,11587,11914,12189,12516,12791,
13118,13393,13720,13995,14322,14597,14924,15199,
15526-20551:201,
20826,21153,21428,21755,22030,22357,22632,22959,23234,
23561,23836,24163,24438,24765,25040,25367,25642,25969,
26244,26571,26846,27173,27448,27775,28050,28377,28652,
28979,29254,29581,29856,30183,30458,30785,31060,31387,
31662,31989,32264,32591,32866,33193,33468,33795,34070,
34397,34672,34999,35274,35601,35876,36604,36879,37206,
37481,37808,38083,38410,38685,39012,39287,39614,39889,
40216,40491,40818,41093,41420,41695,42022,42297,42624,
42899,43226,43501,43828,44103,44430,44705,45032,45307,
45634,45909,46236,46511,46838,47113,47440,47715,48042,
48317,48644,48919,49246,49521,49848,50123,50450,50725,
51052,51327
END_
GROUP_DEF
ID_NAME
TYPE
FORMAT
LIST_BEGIN
75-9875:200
END_
= EL_INTERNAL_GROUP
= ELEM
= LIST
In this approach the internal forces is summed up in the y-direction for the
previously defined node and element group yielding
SIMULIA
Tosca Structure
Internal Forces
DRESP
ID_NAME
TYPE
DEF_TYPE
GROUP_OPER
ND_GROUP
EL_GROUP
END_
=
=
=
=
=
=
DRESP_INT_Y_SUM
INTERNAL_FORCE_Y
SYSTEM
SUM
ND_INTERNAL_GROUP
EL_INTERNAL_GROUP
Note, that GROUP_OPER=SUM is extremely important because default is

GROUP_OPER=MAX. Please, see also vol.2 chapter 4.5.1, Group operations for design responses.
Afterwards, the DRESP for the sum of internal forces are applied in a constraint enforcing that more than half of the applied force P (P/2=0.00015)
should be transferred to the boundaries on the right side like to the following
constraint
CONSTRAINT
ID_NAME
DRESP
MAGNITUDE
GE_VALUE
END_
=
=
=
=
CON_INT_Y_SUM
DRESP_INT_Y_SUM
ABS
0.0015
Afterwards, the sum of strain energy is minimized in the objective function for
obtaining a stiff structure in the following way
=
=
=
=
=
DRESP_SUM_ENERGY
SYSTEM
STRAIN_ENERGY
ALL_ELEMENTS
SUM
= DRESP_SUM_ENERGY
= MIN
Additionally, the material volume of the structure is only allowed to be 15%

compared to the existing model which leads to the following constraint
DRESP
ID_NAME
DEF_TYPE
TYPE
EL_GROUP
GROUP_OPER
END_
CONSTRAINT
ID_NAME
=
=
=
=
=
DRESP_VOL_TOPO
SYSTEM
VOL_TOPO_FILL
ALL_ELEMENTS
SUM
= VOLUME_CONSTRAINT
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DRESP
ID_NAME
DEF_TYPE
TYPE
EL_GROUP
GROUP_OPER
END_
OBJ_FUNC
ID_NAME
DRESP
TARGET
END_
SIMULIA
Tosca Structure
DRESP
MAGNITUDE
LE_VALUE
END_
= DRESP_VOL_TOPO
= REL
= 0.15
Then all the design commands are added to the optimization in OPTIMIZE
commands yielding
OPTIMIZE
ID_NAME
DV
OBJ_FUNC
DVCON
CONSTRAINT
CONSTRAINT
END_
=
=
=
=
=
=
DESIGN_VARIABLES
MAXIMIZE_STIFFNESS
DVCON_FROZEN
VOLUME_CONSTRAINT
CON_INT_Y_SUM
For stabilizing the optimization a stricter update of design variables are

defined leading to the following
OPT_PARAM
ID_NAME = SPECIAL
OPTIMIZE = TOPOLOGY_OPTIMIZATION
DENSITY_MOVE
= 0.1
END_
The result of the optimization is shown in Fig. 57a.

Second approach: a constraint defined by reaction forces
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In the second approach a constraint is defined for the sum of reaction forces
in the y-direction for all the nodes on left side of the beam structure as shown
in Fig. 54b. For summing up the reaction forces in the y-direction a node
group for is defined like the following:
GROUP_DEF
ID_NAME
= ND_REACTION_GROUP
TYPE
= NODE
FORMAT
= LIST
LIST_BEGIN
1,402,603,1004,1205,1606,1807,2208,2409,2810,
3011,3412,3613,4014,4215,4616,4817,5218,5419,
5820,6021,6422,6623,7024,7225,7626,7827,8228,
8429,8830,9031,9432,9633,10034,10235,10636,
10837,11238,11439,11840,12041,12442,12643,13044,
13245,13646,13847,14248,14449,14850,15051,
15452-20678:201,
21079,21280,21681,21882,22283,22484,22885,23086,
23487,23688,24089,24290,24691,24892,25293,25494,
25895,26096,26497,26698,27099,27300,27701,27902,
28303,28504,28905,29106,29507,29708,30109,30310,
30711,30912,31313,31514,31915,32116,32517,32718,
SIMULIA
Tosca Structure
Internal Forces
33119,33320,33721,33922,34323,34524,34925,35126,
35527,35728,36530,36731,37132,37333,37734,37935,
38336,38537,38938,39139,39540,39741,40142,40343,
40744,40945,41346,41547,41948,42149,42550,42751,
43152,43353,43754,43955,44356,44557,44958,45159,
45560,45761,46162,46363,46764,46965,47366,47567,
47968,48169,48570,48771,49172,49373,49774,49975,
50376,50577,50978,51179
END_
In this approach the reaction forces is summed up in the y-direction for the
previously defined node yielding
DRESP
ID_NAME
TYPE
DEF_TYPE
GROUP_OPER
ND_GROUP
END_
=
=
=
=
=
DRESP_REAC_Y_SUM
REACTION_FORCE_Y
SYSTEM
SUM
ND_REACTION_GROUP
Note, that GROUP_OPER=SUM is extremely important because default is

GROUP_OPER=MAX. Please, see also vol.2 chapter 4.5.1, Group operations for design responses.
Afterwards, the DRESP for the sum of reaction forces are applied in a constraint enforcing that that more than half of the applied force P (P/2=0.00015)
should be transferred to the boundaries on the left side like to the following
constraint
=
=
=
=
CON_REAC_Y_SUM
DRESP_REAC_Y_SUM
ABS
0.0015
Then the OPTIMIZE command is modified to include the constraint for the
sum of reaction forces like the following instead of the constraint for internal
forces
OPTIMIZE
ID_NAME
DV
OBJ_FUNC
DVCON
CONSTRAINT
CONSTRAINT
END_
=
=
=
=
=
=
DESIGN_VARIABLES
MAXIMIZE_STIFFNESS
DVCON_FROZEN
VOLUME_CONSTRAINT
CON_REAC_Y_SUM
The result of the optimization is shown in Fig. 57b.
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CONSTRAINT
ID_NAME
DRESP
MAGNITUDE
LE_VALUE
END_
SIMULIA
Tosca Structure
2.7.4
Optimization results when considering force constraints
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The results of three different optimizations are shown in Fig. 57. Fig. 57a
shows the stiffness optimization including the internal force constraint define
in vol.4 chapter 2: First approach: a constraint defined by internal forces. Fig.
57b shows the result of the optimization when the reaction force constraint
given in vol.4 chapter 2: Second approach: a constraint defined by reaction
forces is applied instead of the internal force constraint. Fig. 57c shows the
stiffness optimization with only the volume constraint.
Fig. 57
a) Stiffness optimization including the internal force constraint

define in vol.4 chapter 2: First approach: a constraint defined by
internal forces and volume constraint on the material. b) Stiffness
optimization including the reaction force constraint define in vol.4
chapter 2: Second approach: a constraint defined by reaction
forces and volume constraint on the material. c) Stiffness optimization with only a volume constraint on the material.
SIMULIA
Tosca Structure
Temperature Loading
2.8
Temperature Loading
Task
Stiffness optimization under temperature loading.
Keywords
Temperature loading, Casting restriction
Commands
Fig. 58
a) Load case 1 is combined of a static external force and a constant temperature loading. b) Load case 2 consists strictly of
external static forces. c) Load case 3 consists strictly of a constant temperature loading.
Firstly, stiffness optimization with respect to STRAIN_ENERGY of Load case

2 (see figure Fig. 58) is considered. Initially, a traditionally stiffness optimization is defined where the STRAIN_ENERGY is minimized.
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is also able to consider the temperature loading.
This example can be done using the CAE solvers Abaqus and MSC Nastran.
Fig. 58 displays the design problem considering three load cases.
SIMULIA
Tosca Structure
Remark
a wrong principle.
2.8.1
Procedure: Summary
Model: temperature.ext from the examples directory for your optimization task
Objective: maximize stiffness (minimize compliance) in the first approach. In
the next approaches the objective function is to minimize the absolute displacement in y-axis direction of the load introduction nodes.
Settings: AUTO_FROZEN is set to OFF for the first approach, then to LOAD for
the next approaches.
2.8.2

objective function and volume constraint can be done as described in the
Getting Started Manual.
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First approach: minimize strain energy of load case 3

Choose the item PRE_PROCESSING | OBJ_FUNC_ITEM_1 | NEW |
COMPLIANCE in the task manager and assign the third loadcase to the item.
Define
some
additional
parameters
(PRE_PROCESSING
|
TOPOLOGY_OPTIMIZATION_SENSITIVITY | NEW | SETTINGS) and
make sure the AUTO_FROZEN option is set to OFF for the elements around
the load introduction nodes should be free for the optimization.
Check the results after the optimization run (Fig. 59). One sees that basically
all material is removed from design domain. By removing all the material the
loading through the temperature loading is also removed. Thereby, the
STRAIN_ENERGY is also close to zero. Try to rerun the optimization by
changing the target in the objective function to MAX (maximize the strain
energy). Check the results (Fig. 59). One sees that the structure is stiff in
axial compression and thereby the solution leads to high reaction forces at
the clamped boundary conditions and high stresses.
SIMULIA
Tosca Structure
Temperature Loading
Second approach: minimize global displacement of load introduction

nodes considering load cases 1 and 2
The results of the first approach have revealed that the stiffness optimization
aim is unclear using STRAIN_ENERGY when having temperature loading.
Consequently, one can define the stiffness optimization using displacements
instead of STRAIN_ENERGY. Secondly, the absolute displacements at the
loaded nodes for load case 1 (a) and for load case 2 (b) in Fig. 58 are minimized, respectively.
First define a node group containing three of the loaded nodes (node numbers 3442, 3443 and 3444). To create the new aim, choose the item
PRE_PROCESSING | OBJ_FUNC_ITEM_1 | NEW | DISPLACEMENT in
the task manager and add the new node group. Make sure the displacement
type is set to absolute in y-axis direction (DISP_Y_ABS). Specify loadcase
number 2. Go to the optimization settings and change the AUTO_FROZEN
option to LOAD to fix the loaded nodes. Start the optimization. After the optimization is finished, repeat this step for loadcase number 1.
Check the optimization results (Fig. 60).
2.8.3

First approach: minimize strain energy of load case 3
Define the objective function as following;
=
=
=
=
=
=
SUM_ENERGY_LOADCASE_3
STRAIN_ENERGY
SYSTEM
STATIC,3,
ALL_ELEMENTS
SUM
and
OBJ_FUNC
ID_NAME
DRESP
TARGET
END_
= TEMP_OBJ
= SUM_ENERGY_LOADCASE_3
= MIN
Furthermore, the elements attached to the nodes where the static external
load is applied should not be frozen by default. Therefore, AUTO_FROZEN is
deactivated for the purely temperature load case 3 using the OPT_PARAM
command
OPT_PARAM
ID_NAME
= MY_PARAMETERS
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DRESP
ID_NAME
TYPE
DEF_TYPE
LC_SET
EL_GROUP
GROUP_OPER
END_
SIMULIA
Tosca Structure
OPTIMIZE
AUTO_FROZEN = OFF
END_
The result of the optimization is shown in Fig. 59a. One sees that basically all
material is removed from design domain. By removing all the material the
loading through the temperature loading is also removed. Thereby, the
STRAIN_ENERGY is also close to zero. Alternatively, one might maximize
the STRAIN_ENERGY like the following
OBJ_FUNC
ID_NAME
DRESP
TARGET
END_
= TEMP_OBJ
= STRAIN_ENERGY_LOAD_3
= MAX
The result of the optimization is shown in Fig. 59b. One sees that the structure is stiff in axial compression and thereby the solution leads to high reaction forces at the clamped boundary conditions and high stresses.
Remarks
a wrong principle.
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Therefore, the stiffness optimization aim is unclear using STRAIN_ENERGY

when having temperature loading. Consequently, one can define the stiffness
optimization using displacements instead of STRAIN_ENERGY. Secondly,
the absolute displacements at the loaded nodes for load case 1 (a) and for
load case 2 (b) in Fig. 58 are minimized, respectively.
First a node group is defined containing some of the nodes where the external forces are applied,
GROUP_DEF
ID_NAME
= MY_GROUP
TYPE
= NODE
FORMAT
= LIST
LIST_BEGIN
3442,3443,3444
END_
Afterwards, the absolute displacements are defined for load case 2 and minimized in the objective,
DRESP
ID_NAME
TYPE
DEF_TYPE
LC_SET
=
=
=
=
DISP_LOADCASE_2
DISP_Y_ABS
SYSTEM
STATIC,2,
SIMULIA
Tosca Structure
Temperature Loading
ND_GROUP
END_
OBJ_FUNC
ID_NAME
DRESP
TARGET
END_
= MY_GROUP
= TEMP_OBJ
= DISP_LOADCASE_2
= MIN
Additionally, the OPT_PARAM command is not applied in the displacement

optimization and thereby the elements attached to the nodes where the static
external load is applied are by default frozen.
The result of the optimization is shown in Fig. 60a.
Afterwards, the absolute displacements are defined for load case 1 and minimized in the objective,
DRESP
ID_NAME
TYPE
DEF_TYPE
LC_SET
ND_GROUP
END_
OBJ_FUNC
ID_NAME
DRESP
TARGET
END_
=
=
=
=
=
DISP_LOADCASE_1
DISP_Y_ABS
SYSTEM
STATIC,1,
MY_GROUP
= TEMP_OBJ
= DISP_LOADCASE_1
= MIN
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THE RESULT OF THE OPTIMIZATION IS SHOWN IN Fig. 60B
SIMULIA
Tosca Structure
Fig. 59
Minimizing (a) and maximizing (b) the sum of strain energy for
load case 3 in Fig. 57, respectively.
Fig. 60
Minimizing the absolute displacements at the loaded nodes for

load case 2 (a) and for load case 1 (b) in Fig. 58, respectively.
Comparing the optimization results in Fig. 60 shows that the temperature field
has a significant impact on the designs.
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2.8.4
SIMULIA
Tosca Structure
Stress Constraint
2.9
Stress Constraint
Task
Minimization of the volume considering stress restrictions
Keywords
von Mises stress constraint
Commands
SIG_TOPO_MISES_CONSTRAINT
This chapter shows the minimization of the volume with restrictions on the
maximum von Mises stress illustrated with the example of a beam as seen in
Fig. 61.
Initial beam model for stress constraint optimization
Maximizing the stiffness for a given target volume forms a standard optimization setup in topology optimization - applied, e.g., when a certain weight shall
not be exceeded. Initially a possible "target stiffness" can often not be determined, but the material parameters and thus the maximum admissible stress
for the structure is known. Thus, another optimization setup could be to minimize the volume for a specified stress constraint.
An example is seen in Fig. 62: The stiffness of the beam has been optimized
for a specified target volume. The result shows a stress concentration in the
upper horizontal bar. To reduce that stress it is helpful to specify a stress constraint and to minimize the volume.
Fig. 62
2.9.1
Stress concentration in the upper horizontal bar of a beam optimized for the stiffness and a volume constraint
Procedure: Summary
Model: stress_constraint.ext from the examples directory
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Fig. 61
SIMULIA
Tosca Structure

Objective: minimize volume
Constraint: von Mises stress of 70kPa
Settings: 80 iterations (set per default for this type of optimization setup)
2.9.2
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This optimization setup is a standard topology optimization setup as

described in the example in vol.4 chapter 2.2, Crane hook or in vol.1 chapter
1.2, Topology Optimization with Tosca ANSA environment. Loading the model
and definition of the design area can be done as described in the Getting
Started Manual.
The CONSTRAINT command is defined as follows: CONSTRAINT | NEW |
SIG_TOPO_MISES_CONSTRAINT. Enter the absolute stress value and select
your group using the group selection dialogue.
Fig. 63
Stress constraint definition in Tosca ANSA environment
Define an objective function to minimize the volume of your design area: Edit
your OBJ_FUNC_ITEM (right click on the item) and set the target to MIN.
SIMULIA
Tosca Structure
Stress Constraint
Then OBJ_FUNC_ITEM | NEW | VOLUME (as shown in Fig. 66) and selection of your group.
Fig. 64
Objective function for minimizing volume
Remember
to
increase
the
number
(GLOBAL_STOP_CONDITION | ITER_MAX).
2.9.3
of
iterations
to
80
Fig. 65
DRESP and CONSTRAINT command for stress constraint
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This optimization setup is a standard topology optimization setup as

described in the example in vol.4 chapter 2.2, Crane hook or in vol.1 chapter
2.2, Topology Optimization with Tosca Structure.gui. Loading the model and
definition of the design area can be done as described in the Getting Started
Manual.
The CONSTRAINT command is defined in two steps: First define a design
response (DRESP) with Stress/Strain as Category and select
SIG_TOPO_MISES as Type. Then select in CONSTRAINT command the
defined DRESP and enter the absolute stress value. This is also shown in Fig.
65.
SIMULIA
Tosca Structure
The stress constraint is defined as following:

DRESP
ID_NAME
TYPE
DEF_TYPE
EL_GROUP
=
=
=
=
SIG_TOPO_MISES
SYSTEM
DESIGN_AREA
=
=
=
=
CON_STRESS
ABS
70000.
END_
CONSTRAINT
ID_NAME
MAGNITUDE
LE_VALUE
DRESP
END_
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Define a design response (DRESP) for the objective function with Volume as
Type of Category Base. Then define an OBJECTIVE_FUNCTION with the
minimized DRESP as shown in Fig. 66
Fig. 66
DRESP and OBJECTIVE_FUNCTION command for minimizing

volume
The objective function is defined as following:

DRESP
ID_NAME
TYPE
DEF_TYPE
GROUP_OPER
EL_GROUP
=
=
=
=
=
DRESP_VOL_TOPO
VOLUME
SYSTEM
Sum
DESIGN_AREA
END_
SIMULIA
Tosca Structure
Stress Constraint
OBJ_FUNC
ID_NAME
TARGET
DRESP
= MY_OBJ_FUNC
= MIN
= DRESP_VOL_TOPO
END_
2.9.4
Fig. 67 shows the result of two optimization setups: the upper beam with minimized volume and restricted stress, the lower one with minimized stress and
restricted volume. Both models have the same volume.
Beam with minimized volume and stress constraint (upper one)

Beam with minimized stress and volume constraint (lower one)..
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Fig. 67
SIMULIA
Tosca Structure
Shape Optimization
Shape Optimization
In this section, typical shape optimization examples are described.
Example overview
Clip
Conrod
Holeplate
Hub
Rim
Shaft
Shaft drill
Shaft turn
Threehole
Twohole
Cranehook morph
Check el. group
Examples
Carrier stamp
Keywords
Carrier
3.1
Strategy
Controller
Morph
Analysis Type
STATIC
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FREQUENCY
Objective
von Mises
stress
v. Mises stress
on reference
nodes
Frequency
Target
MAX
MIN
X
X
SIMULIA
Tosca Structure
Example overview
Cranehook morph
Twohole
Threehole
Shaft turn
Shaft drill
Shaft
Rim
Holeplate
Hub
MINMAX
Conrod
Clip
Check el. group
Carrier stamp
Examples
Carrier
Keywords
Constraints
Volume
Automatic
node selection
Displacement
direction (DOF)
X
X
Node fixation
Penetration
check (solid)
X
X
Symmetry:
rotational
Symmetry:
cyclic and
planar
Demolding
(casting)
Drilling
X
X
X
X
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Turning
Displacement
amount
Stamping
Penetration
check (el.
group)
Symmetry:
planar
SIMULIA
Tosca Structure
Shape Optimization
3.2
Holeplate
Task
Minimize the maximum stress
Keywords
Design variables, Displacement direction (DOF), Node

fixation
Commands
DVCON_SHAPE, CHECK_DOF, CHECK_BC
This example illustrates shape optimization of a hole in a plate placed under

bi-axial tension. Only a quarter of the plate is modeled due to a symmetric
configuration.
100.0
Fig. 68
Model of "holeplate"
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The goal of the optimization is to minimize the maximum stresses under the
constraint. Fig. 70 illustrates the von Mises stress and the FE displacement
for both load cases.
loadcase 1
Fig. 70
loadcase 2
Two load cases for model "holeplate"
SIMULIA
Tosca Structure
Holeplate
The nodes on the surface of the drilled hole are to be kept free for modification in shape optimization. The nodes on the symmetry edges should not
move in relation to the symmetry plane. Design variable constraints
(DVCON_SHAPE) must be defined for the nodes on the symmetrical edges
for keeping them fixed during optimization. In this case, the nodes on the
symmetry edges are fixed with respect to the symmetrical planes.
3.2.1
Procedure: Summary
Model: holeplate.ext from the examples directory for your optimization task
Design area: node group design_nodes
Design variable constraint: apply boundary conditions for all nodes
Mesh smooth: mesh smoothing of all elements, while free surface nodes
remain fixed
Objective: minimize the von Mises stresses in the design area
Options: read boundary conditions for all nodes
Stop condition: the global stop condition is set to 5 iterations
3.2.2
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Choose a SHAPE_OPTIMIZATION_CONTROLLER task in Tosca ANSA environment and create the model link. Add the node group containing the design
nodes to the design area. The group design_nodes contains all surface
nodes on the quarter hole.
Choose the item PRE_PROCESSING | DESIGN_AREA | NEW |
MESH_SMOOTH in the task manager to set the mesh smoothing. In the
SIMULIA
Tosca Structure
Shape Optimization
MESH_SMOOTH item, define a mesh smoothing area of all elements with fixation of all free surface nodes, LAYERS = 0 (Fig. 72).
Fig. 72
Definition of mesh smoothing area
Choose the item PRE_PROCESSING | DV_CONSTRAINTS | NEW |

CHECK_BC in the task manager to apply boundary conditions to all nodes.
Set the CHECK_BC option to YES to activate the restriction.
To define the objective function choose the item PRE_PROCESSING |
OBJ_FUNC_ITEM_1 | NEW | EQUIVALENT_STRESS. Set the function type
to define von Mises stress for the design node group. Set the objective function to minimize the selected stresses.
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3.2.3

This fixation of the nodes on the symmetry edges is simply and easily applied
for the optimization:
OPTIONS
READ_BC
= ALL
END_
This command must be defined prior to the FEM_INPUT command. All

defined fixations in the FE model are loaded into Tosca Structure during
model loading.
The command DVCON_SHAPE is used to activate the FE fixations for the
optimization:
SIMULIA
Tosca Structure
Two Hole (Relief Notch)
DVCON_SHAPE
ID_NAME
ND_GROUP
CHECK_BC
= dvcon_fix_spc
= ALL_NODES
= YES
END_
By activating CHECK_BC = YES all nodes of the node group ALL_NODES,

which contain fixations in the FE model and which are in the area
MESH_SMOOTH, are restricted in the same degrees of freedom as defined
by the fixations of the analysis model. The parameter FREE_SF = FIX is set
in the command MESH_SMOOTH to avoid any surface changes outside this
area.
By using this definition, all nodes on the surface area of MESH_SMOOTH are
completely fixed. These nodes should also not contain restrictions defined by
DVCON_SHAPE.
Fig. 73
3.3

Task
Minimize the deviation to a variable value of reference
Keywords
Penetration check, Displacement direction (DOF), v.

Mises stress on reference nodes
Commands
CHECK_SOLID, CHECK_DOF, REF_NODE_STRESS
This example uses the principle of a relief notch and demonstrates how the
optimization task should be defined. High stresses are found in a notch (primary notch) of a component. A second notch (secondary notch) having a
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3.2.4
SIMULIA
Tosca Structure
Shape Optimization
short distance to the primary notch should work to relieve the stresses on the
primary notch. The optimal shape of the secondary notch should be obtained
using shape optimization in order to achieve as low a stress factor as possible in the primary notch. Fig. 74 shows the stresses in the two hole model.
Fig. 74
stresses in the initial model
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The stress in the primary notch is only minimal when the maximum stresses
in the secondary notch and the primary notch are the same. A distribution of
the notch effect takes place at both positions. In order to optimize this effect,
a definition must be made using a variable reference value.
The definition of following groups is required for the optimization task (Fig.
75).
Fig. 75
3.3.1
Groups for optimization
Procedure: Summary
Model: twohole.ext from the examples directory for your optimization task
Design variable constraint: solid body boundaries for the design nodes
SIMULIA
Tosca Structure
Design variable constraint: fixation of the displacement along the global yaxis for node group fix_y
Mesh smooth: mesh smoothing of element group ms_elgr, while free surface
nodes remain free
Objective: minimize the deviation of the maximal von Mises stresses in the
primary and secondary notch
Settings: average nodal displacement, nodal displacements are scaled by
factor 2 additionally
3.3.2

This optimization task represents an advanced example. The optimization
task definition using only the task manager in Tosca ANSA environment is not
possible. This makes the use of the Modules Buttons necessary.
3.3.3

The first step is to define a numerical variable that contains the maximum
stress value of the nodes in the primary notch.
VARIABLE
ID_NAME
DEF_TYPE
UPDATE
TYPE
ND_GROUP
GROUP_OPER
=
=
=
=
=
=
REF_NODE_STRESS
SYSTEM
EVER
SIG_MISES
REFERENCE_NODES
MAX
The variable stress value is updated in each iteration.

The second step is to define the maximum von Mises Stress in the design
area:
DRESP
ID_NAME
DEF_TYPE
TYPE
ND_GROUP
GROUP_OPER
=
=
=
=
=
DRESP_VON_MISES
SYSTEM
SIG_MISES
design_nodes
Max
END_
The objective function of the optimization problem is to minimize the deviation

of the stress values in the design area from the variable reference values.
That means the maximum stress value in the design area (secondary notch)
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END_
SIMULIA
Tosca Structure
Shape Optimization
is closer to the stress level found in the reference area (primary notch)
whereby the stress level in the primary notch is lowered.
OBJ_FUNC
ID_NAME
DRESP
TARGET
= minimize_deviation
= DRESP_VON_MISES, ,REF_NODE_STRESS
= MINMAX
END_
3.3.4
Fig. 76
optimization results (initial left, result right)
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The stresses at the reference nodes in the design area are drastically minimized through the optimized relief notch.
Fig. 77
The von Mises equivalent stress in the primary and secondary

notches
SIMULIA
Tosca Structure
Shaft
3.4
Shaft
Task
Minimize maximum stress
Keywords
Automatic node selection, Displacement direction

(DOF), Rotational symmetry
Commands
GROUP_AUTO_DEF, CHECK_DOF, ROTATION_SYM
During the optimization of rotary symmetrical components, the rotational symmetry is to be maintained. During restriction-free optimization a non-symmetrical stress distribution will create a non-rotational symmetrical structure.
Using the functionality LINK_SHAPE symmetrical requests are guaranteed. A
shaft that has been manufactured by turning is optimized in this example. The
rotational symmetry must be maintained during optimization. Fig. 78 represents the initial model with boundary conditions and the deformed structure.
Initial model "shaft"
In order to maintain the rotational symmetry the nodes on the surface of the
shaft must have the same z-coordinates as those in the global cylindrical
coordinate system. These nodes must be selected as a group and link conditions are arranged that couples the absolute displacement. The command
GROUP_AUTO_DEF is used in Tosca Structure to define the respective
node groups. This command allows a simple, automatic definition of these
node groups.
3.4.1
Procedure: Summary
Model: shaft.ext from the examples directory for your optimization task
Design area: node group surface_nodes
GROUP_AUTO_DEF: automatic definition of node group using the node
group parent (contains all nodes in the length of the shaft)
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Fig. 78
SIMULIA
Tosca Structure
Shape Optimization
Design variable constraint: left and right faces of the shaft (node groups
left_nodes and right_nodes) are fixed in global z-axis direction
Design variable constraint: nodal displacements of all surface nodes on one
diameter are the same in order to guarantee a turnable structure.
remain free
Objective: minimize the maximal von Mises stresses in the design area
3.4.2

possible. This makes the use of the Modules Buttons necessary. Another way
to define this task using the task manager represents the example shaft_turn.
3.4.3

Definition of node groups
Using the command GROUP_AUTO_DEF, nodes can be automatically
searched for, starting with a parent group of nodes. This is described below:
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parent node group
direction of search
for link node group
Fig. 79
Definition of link node groups
First, a parent node group is defined that contains all nodes in the length of
the shaft.
GROUP_DEF
ID_NAME
= parent
SIMULIA
Tosca Structure
Shaft
TYPE
= NODE
FORMAT
= LIST
LIST_BEGIN
16, 177-1717:140
END_
From here, the command GROUP_AUTO_DEF is used for each node of the
parent group to find all nodes in a circumferential direction (360 of the global
cylindrical coordinate system CS_1) and to define new groups with the name
of the parent group as name prefix. For every node of the parent group a new
group is defined with indices (parent_1, paren_2,.., parent_13).
GROUP_AUTO_DEF
ND_GROUP
CS
TOL
SEARCH_TYPE
SEARCH_DIR
=
=
=
=
=
parent
CS_1
0.1,0.1,0.1
CONTINUOUS
+2
SEARCH_LEN
= 360
END_
-----------------------------------------------------------| Data output of GROUP_AUTO_DEF comand |

-----------------------------------------------------------GROUP_AUTO_DEF (temporary data) :
ND_GROUP
: PARENT
CS
: CS_1
TOL
: 0.1000
, 0.1000
, 0.1000
SEARCH_TYPE
: CONTINUOUS
SEARCH_DIR
: +2
(positive second coordinate of CS)
SEARCH_LEN
: 360.0
Remark :
Only the selected nodes will be considered (see SELECT
command).
----------------------------------------------------------| Begin execution of GROUP_AUTO_DEF command |
----------------------------------------------------------NODE_GROUP NAME: PARENT_1
Number of Nodes: 30
Min_No.: 1
Max_No.: 30
----------------------------------------------------------1 -> 30
-----------------------------------------------------------
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A record of the processing of the commands GROUP_AUTO_DEF is written

to TOSCA.OUT file. A check can be made here to see if the processing was
done correctly.
SIMULIA
Tosca Structure
Shape Optimization
NODE_GROUP NAME: PARENT_2

Number of Nodes: 30
Min_No.: 147
Max_No.: 205
----------------------------------------------------------147 148 151 153 155 157 159 161 163 165 167 169 171 173 175
177 179 181
183 185 187 189 191 193 195 197 199 201 203 205
-----------------------------------------------------------
NODE_GROUP NAME: PARENT_3

Number of Nodes: 30
Min_No.: 287
Max_No.: 345
----------------------------------------------------------287 288 291 293 295 297 299 301 303 305 307 309
311 313 315
317 319 321 323 325 327 329 331 333 335 337 339
341 343 345
----------------------------------------------------------.....
Definition of the link conditions

In order to maintain the rotational symmetry each node of a link group
(parent_*) must have the same absolute displacement (in the cylindrical coordinate system CS_1) as the master nodes of the link group. The master node
is determined by the MAX-criterion, i.e. the node with the largest stress is
the master node.
LINK_SHAPE
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ID_NAME
MASTER
CLIENT
CS
TOL
=
=
=
=
=
link_length
MAX
LENGTH
CS_1
0.1,0.1,0.1
END_
Assigning link conditions

The link conditions must be assigned to the individual node groups using the
command DVCON_SHAPE. As the definition of node groups occurs automatically and a lot of node groups are generated in large models, Tosca Structure
also has the functionality to provide automatic generation. The command
DVCON_AUTO_SHAPE allows the automatic definition of DVCON_SHAPE
entries for all groups that have a certain name prefix (in this case parent_).
DVCON_AUTO_SHAPE
ID_NAME
= dvcon_link_*
ND_GROUP_FAMILY = parent_*
CHECK_LINK
= link_length
SIMULIA
Tosca Structure
Shaft
END_
All internal definitions are also written in a TOSCA.OUT file as a protocol

using this command
-----------------------------------------------------------| Information about the command DVCON_AUTO_SHAPE
|
----------------------------------------------------------In the following some DVCON_SHAPE commands will be submitted
automatically.
The syntax of these commands will be as follows:
DVCON_SHAPE
ID_NAME
ND_GROUP
CHECK_LINK
= DVCON_LINK_*
= PARENT_*
= LINK_LENGTH
The strings * result from the complements to

the full names of the existing node groups.
----------------------------------------------------------| Data output of DVCON_SHAPE entries
|
----------------------------------------------------------DVCON_SHAPE (database extraction):
ID_NAME
: DVCON_LINK_1
ND_GROUP
: PARENT_1
CHECK_LINK
: LINK_LENGTH
ID_NAME
: DVCON_LINK_2
ND_GROUP
: PARENT_2
CHECK_LINK
: LINK_LENGTH
ID_NAME
: DVCON_LINK_3
ND_GROUP
: PARENT_3
CHECK_LINK
: LINK_LENGTH
.....
All DVCON_SHAPE definitions must be referenced using the command

OPTIMIZE. This is done by entering the name prefix in the DVCON_SHAPE
entries:
OPTIMIZE
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END_
SIMULIA
Tosca Structure
Shape Optimization
ID_NAME
DV
OBJ_FUNC
DVCON
DVCON
DVCON
MESH_SMOOTH
=
=
=
=
=
=
=
shape_optimization
design_variables
minimize_max_mises
dvcon_left_fix_z
dvcon_right_fix_z
dvcon_link_*
mesh_smooth
END_
3.4.4
The results after optimization are shown below:
Fig. 80
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3.5
Optimization results "shaft" (with/without link conditions)
Carrier
Task
Keywords
Automatic node selection, Symmetry: planar
Commands
GROUP_AUTO_DEF, DVCON_AUTO_SHAPE,
LINK_PLANE_SYM
Both radii are to be optimized in this model. The component has been manufactured through punching and should not have any deflections in its depth.
Both radii should remain identical, i.e. the component should remain symmetrical. In free optimization, the nodes on the left radius will shrink and the
SIMULIA
Tosca Structure
Carrier
nodes on the right radius will grow due to the non-symmetrical stress distribution. Fig. 81 illustrates the initial model and relevant stresses.
Fig. 81
Procedure: Summary
Model: carrier.ext from the examples directory for your optimization task
Design area: node group surface
GROUP_AUTO_DEF: automatic definition of node group using the node
group parent (contains all outer nodes in the radius)
Design variable constraint: design nodes are fixed in global z-axis direction
Design variable constraint: plane symmetry restriction along the global x-axis
on the design nodes
Design variable constraint: nodal displacements of all surface nodes in a row
normal to the radius are the same in order to guarantee a stampable structure.
remain fixed up to the sixth layer
Settings: average nodal displacement
3.5.2

possible. This makes the use of the Modules Buttons necessary. Another way
to define this task using the task manager represents the example
carrier_stamp.
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3.5.1
Model "carrier"
SIMULIA
Tosca Structure
Shape Optimization
3.5.3

Definition of the link conditions
Using the commands GROUP_AUTO_DEF and DVCON_AUTO_SHAPE the
nodes in both radii are coupled over the depth of the structure. Nodes from
the parent group can be found on the front edge.
search
direction
parent node
group right
Fig. 82
Definition of LINK_LENGTH
First the parent group that contains the parent nodes on the right and left
radius is defined.
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GROUP_DEF
ID_NAME
TYPE
FORMAT
LIST_BEGIN
1845-1865:2
853-873:2
= parent
= NODE
= LIST
END_
The link groups are defined from this group using the command for automatic
group definition:
GROUP_AUTO_DEF
ND_GROUP
CS
TOL
SEARCH_TYPE
SEARCH_DIR
SEARCH_LEN
=
=
=
=
=
=
parent
CS_0
0.01,0.01,0.01
CONTINUOUS
-3
40
END_
SIMULIA
Tosca Structure
Carrier
The link condition is defined for assigning the group at a later stage. The
nodes should all be assigned the same absolute optimization displacement
as the master node. The master node is determined using MAX (the largest
absolute displacement) from the relevant coupling group.
LINK_SHAPE
ID_NAME
MASTER
CLIENT
CS
TOL
=
=
=
=
=
link_length
MAX
LENGTH
CS_0
0.01,0.01,0.01
END_
Using DVCON_AUTO_SHAPE, all groups with the name prefix parent_ are
assigned the link condition as defined above.
DVCON_AUTO_SHAPE
ID_NAME
= dvcon_length_*
ND_GROUP_FAMILY = parent_*
CHECK_LINK
= link_length
END_
Defining the plane symmetry

To keep both radii symmetrical, a plane symmetry coupling condition must
also be defined. A coordinate system is used to define the symmetry plane. In
Fig. 83 the symmetry plane is shown where the x-axis of the global coordinate system (CS_0) is the normal to the plane.
CS_0
Fig. 83
Definition of LINK_PLANE_SYM
LINK_SHAPE
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symmetry plane
SIMULIA
Tosca Structure
Shape Optimization
ID_NAME
MASTER
CLIENT
CLIENT_DIR
CS
TOL
=
=
=
=
=
=
link_plane_sym
MAX
PLANE_SYM
1.0, 0.0, 0.0
CS_0
0.01,0.01,0.01
END_
This kind of LINK-coupling is only applicable for a symmetrical mesh. The link
conditions are assigned to the node groups using the command
DVCON_SHAPE. The node group 'surface' contains all nodes on the surface
of both radii that are to be optimized (all design nodes).
DVCON_SHAPE
ID_NAME
ND_GROUP
CHECK_SPC
CHECK_LINK
=
=
=
=
dvcon_plane_sym
surface
NO
link_plane_sym
END_
Definition of the optimization problem

Definitions found in DVCON_SHAPE must now be referenced in the command OPTIMIZE:
OPTIMIZE
ID_NAME
DV
OBJ_FUNC
DVCON
DVCON
DVCON
MESH_SMOOTH
=
=
=
=
=
=
=
shape_optimization
design_variables
minimize_maximum_stress
dvcon_fix_z
dvcon_plane_sym
dvcon_length_*
mesh_smooth
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END_
SIMULIA
Tosca Structure
Carrier_stamp
3.5.4
Fig. 84
3.6
Optimization results model carrier
Carrier_stamp
Task
Minimize maximum stiffness
Keywords
Conserve stampable surface
Commands
LINK_SHAPE, SURF_STAMP
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This is the same model as the previous example and the objective function
and constraints are the same. In this case, the finite element model is built
using a tetrahedral mesh. Further, a constraint which enforces manufacturability by means of stamping (symmetry is also possible but not shown here)
is required.
SIMULIA
Tosca Structure
Shape Optimization
The standard coupling conditions may not be used, as the surface nodes of
the mesh are not lying exactly in the direction of stamping. Fig. 85 illustrates
the mesh, boundary conditions and the stress distribution of the initial model.
Fig. 85
Model carrier_stamp
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For arbitrary meshes, the surface nodes may not be grouped using the standard link conditions. In this case, a geometric and mesh independent
approach has to be used. The user has to specify a surface node group
which describes the stamping surface. In addition, the stamping direction has
to be defined using a coordinate system.
The stamping surface is described by the stamping direction and the nodes
on this surface produce a manufacturing curve. When the manufacturing
curve is moved along the stamping direction, the stamping surface is
described. Tosca Structure automatically determines the producing curve for
a given link domain.
SIMULIA
Tosca Structure
Carrier_stamp
The definition of the following groups is required for the optimization task (Fig.
86).
Fig. 86
Procedure: Summary
Model: carrier_stamp.ext from the examples directory for your optimization
task
Design area: node group design_area
Design variable constraint: stamping restriction for node group geo_area in
direction of the global positive z-axis
Design variable constraint: fixation of the displacement along the global xaxis for node group fix_x
Design variable constraint: fixation of the displacement along the global zaxis for node group fix_z
remain fixed up to the third layer
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3.6.1
SIMULIA
Tosca Structure
Shape Optimization
3.6.2

This optimization task is a standard shape optimization task as described in
the example in vol.4 chapter 3.2, Holeplate or in vol.1 chapter 1.3, Shape
SHAPE_CONTROLLER task, loading the model and definition of design
area, design variable constraint and objective function can be done as
described in the Getting Started Manual.
To fix nodes or node group choose the item PRE_PROCESSING
|
DV_CONSTRAINTS | NEW | DOF_CONTROL in the task manager. To create
a stamping restriction choose the item PRE_PROCESSING
|
DV_CONSTRAINTS | NEW | STAMP_CONTROL in the task manager.
3.6.3

Definition of the link condition
Geometric linking is defined using the LINK_SHAPE command. The
LINK_SHAPE definition is then referenced in a DVCON_SHAPE entry and
thereby assigned to a node group. Determining the manufacturing curve is
influenced by the number of master nodes. The master nodes are determined
using the standard link criteria. If MAX is used, the nodes with the highest
absolute optimization displacement are used as master nodes. The segmentation of the stamping surface is done automatically by the optimization system. In this case, the stamping direction is defined via the z-axis of the global
rectangular coordinate system CS_0.
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LINK_SHAPE
ID_NAME
MASTER
CLIENT
CLIENT_DIR
CS
=
=
=
=
=
geo
MAX
SURF_STAMP
0.0, 0.0, 1.0
cs_0
END_
Assigning the link condition

The DVCON_SHAPE command is used to assign the link condition to a node
group.
DVCON_SHAPE
ID_NAME
ND_GROUP
CHECK_LINK
= dvcon_geo
= geo_area
= geo
END_
SIMULIA
Tosca Structure
Shaft_turn
The DVCON_SHAPE definition has to be referenced in the OPTIMIZE command.

OPTIMIZE
ID_NAME
DV
OBJ_FUNC
DVCON
DVCON
DVCON
DVCON
DVCON
MESH_SMOOTH
=
=
=
=
=
=
=
=
=
shape_optimization
design_variables
min_function
check_spc
dvcon_fix_x
dvcon_fix_y
dvcon_fix_z
dvcon_geo
mesh_smooth
END_
Optimization result
Fig. 87
3.7
Initial and optimized shape of carrier_stamp
Shaft_turn
Task
Minimize maximum stress
Keywords
Conserve turnable surface
Commands
LINK_SHAPE, SURF_TURN
For rotational symmetrical components, a non-symmetrical shape should not

be generated in the optimization. Therefore, the design nodes have to be
linked in a symmetrical way. For rotation symmetrical meshes, the standard
link formulation in Tosca Structure may be used. If the meshes are not rotational symmetrical (what is often the case in tetrahedron meshes) the meshindependent or geometric approach in Tosca Structure has to be used to
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3.6.4
SIMULIA
Tosca Structure
Shape Optimization
maintain symmetrical behavior. Fig. 88 illustrates the boundary conditions

and the stress distribution of the initial model.
Fig. 88
Initial model shaft turn
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Segmentation into link groups is not possible for arbitrary meshes. The
parameter SURF_TURN in the LINK_SHAPE command is used to define the
restriction. This geometric approach allows the definition of turning restrictions for any finite element mesh. The rotation curve is determined automatically by the optimization system. The user only has to define a surface node
group which specifies the turn surface and the rotation axis using a coordinate system.
SIMULIA
Tosca Structure
Shaft_turn
The definition of following groups is required for the optimization task (Fig.
89).
Fig. 89
Procedure: Summary
Model: shaft_turn.ext from the examples directory for your optimization task
Design area: node group design_area
CS_DEF: new cylindrical coordinate system, defined by rotating the global
CS by 270 around the global x-axis
Design variable constraint: turning restriction for node group geo_area1 in
direction of the global positive y-axis
Design variable constraint: fixation of the displacement along the global yaxis for node group fix_area
Design variable constraint: fixation of the first (radial) coordinate (in the new
cylindrical coordinate system) of the displacements for node group
cylinder_circle
remain free
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3.7.1
SIMULIA
Tosca Structure
Shape Optimization
3.7.2

To create a turning restriction choose the item PRE_PROCESSING |
DV_CONSTRAINTS | NEW | TURN_CONTROL in the task manager.
In order to define the constraint for the radial coordinate of the nodes in
cylinder_circle node group, a cylindrical coordinate system is needed sucht
that its z axis is the rotation axis of the model, i.e., the global y axis. In order
to define it interactively (although not precisely), first click an appropriate button in CS_DEF panel of Modules Buttons:
CORD2 -> CORD2R for Nastran;
CORD -> CYLINDRICAL for Abaqus;
LOCAL -> CYLINDRICAL for ANSYS.
Then, select three nodes that define the coordinate system:
the origin at the center of the larger circle (the rear face in Fig. 92; its center
lies on the axis of the model);
the second point (defining the new z axis) at the center of the smaller circle
((the rear face in Fig. 92; its center lies on the axis of the model);
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the third point, e.g., on the border of the smaller circle (the location of the
third point makes no difference, it is only required that it does not lie on the
axis of the model).
In the dialog that opens after three points are chosen, it is possible to correct
the coordinates by editing the fields A1,..., C3, in case that better precision is
needed or if the selection of nodes has presented some difficulties:
A1 = 0, A2 = 0, A3 = 0, B1 = 0, B2 = 5, B3 = 0, C1 = 0.2, C2 = 0, C3 = 0.
Afterwards, this coordinate system should be mentioned in CS_DEF field of
DOF_CONTROL dialog (opened when New -> DOF_CONTROL command is
applied on the item DV_CONSTRAINTS), after CHECK_DOF is set to
CS_DEF in the dialog. Then, DOF_1 = FIXED sets the fixation of r coordinate
(i.e., the distance to the axis of the cylindrical coordinate system), so that all
nodes of the node group (cylinder_circle; choose it in ND_GROUP field) are
not allowed to be displaced radially.
SIMULIA
Tosca Structure
Shaft_turn
3.7.3

The link condition is defined via the LINK_SHAPE command and later
assigned to a node group using the DVCON_SHAPE command. The master
nodes are determined in segments of the rotation surface. Segmentation is
done automatically by the optimization system. The use of MAX means that
the nodes with the highest absolute displacement are used as master nodes
for the link conditions. The y-axis of the global Cartesian coordinate system is
the rotation axis.
LINK_SHAPE
ID_NAME
MASTER
CLIENT
CLIENT_DIR
CS
=
=
=
=
=
link_geo
MAX
SURF_TURN
0.0, 1.0, 0.0
CS_0
END_
Assigning the link condition

The link condition is assigned to a node group in the DVCON_SHAPE command.
DVCON_SHAPE
ID_NAME
ND_GROUP
CHECK_LINK
= dvcon_geo
= geo_area
= link_geo
END_
Finally, the DVCON_SHAPE definition has to be referenced in the OPTIMIZE

command to activate the link condition for the optimization problem.
ID_NAME
DV
OBJ_FUNC
DVCON
DVCON
DVCON
DVCON
MESH_SMOOTH
END_
=
=
=
=
=
=
=
=
shape_optimization
design_variables
min_function
check_spc
fix_y
fix_cylinder_circle
dvcon_geo
mesh_smooth
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OPTIMIZE
SIMULIA
Tosca Structure
Shape Optimization
The optimization results for the model shaft_turn are illustrated in Fig. 90 :
Fig. 90
Shaft_drill
Task
Keywords
Conserve drillable surface
Commands
LINK_SHAPE, SURF_DRILL
The model is a shaft with a transverse drilling. Symmetrical aspects allow for
modeling of only a half model and symmetry boundary conditions are applied
to the symmetry plane. The drilling hole has to be maintained during the optimization procedure. Drilling combines a turning surface which has to be
demoldable against the feed direction of the die. If no restrictions are
enforced, an oval shaped hole would be the result of the optimization as the
stress distribution is not symmetrical.
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3.8
Optimization result shaft_turn without link conditions and with

SURF_TURN definitions
SIMULIA
Tosca Structure
Shaft_drill
Fig. 91 illustrates the boundary conditions and the stress distribution of the
initial model.
Fig. 91
Model shaft_drill: boundary conditions and stress distribution
Fig. 92
3.8.1
Procedure: Summary
Model: shaft_drill.ext from the examples directory for your optimization task
Design area: node group drill
CS_DEF: new cylindrical coordinate system, defined by rotating the global
CS by 90 around the global y-axis and origin with coordinates (0,0,5)
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The definition of following groups is required for the optimization task (Fig. 92)
SIMULIA
Tosca Structure
Shape Optimization
Design variable constraint: drilling restriction for the design nodes in direction
of the global positive z-axis
Design variable constraint: fixation of the displacement along the global xaxis for node group fix_x
Design variable constraint: fixation of the displacement along the x-axis of the
new cylindrical CS for node group shell
remain fixed up to the fourth layer

To define a drilling restriction, create the item PRE_PROCESSING
|
DV_CONSTRAINTS | DRILL_CONTROL in the task manager. The drilling
axis is the z-axis, therefore the origin should be set to (0, 0, 0) and the direction to (0, 0, 1).
One design variable constraint should be defined in order to preserve the
outer cylindrical surface of the model (the node group shell). To do it, a new
cylindrical coordinate system should be defined, such that r = const holds for
all points of the cylindrical surface (when written in this coordinate system);
the constraint is then simply the fixation of the 1st coordinate with respect to
this coordinate system. The easiest way to define such coordinate system is
to choose NODE -> CYLINDRICAL command in CS_DEF panel of Module
Buttons, and then choose the first two nodes on the axis of the cylinder
(e.g., the nodes with IDs 1527 and 1601) and then any node that does not lie
on the axis (e.g., 1582). The design variable constraint is then created using
New
->
DOF_CONTROL command on PRE_PROCESSING
|
DV_CONSTRAINTS item.
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3.8.2
SIMULIA
Tosca Structure
Shaft_drill
3.8.3

The drill restriction is defined on a surface node group. The feed direction is
specified via the z-axis of the global cylindrical coordinate system. The master nodes in the segments are determined via the command MAX.
LINK_SHAPE
ID_NAME
MASTER
CLIENT
CLIENT_DIR
CS
=
=
=
=
=
GEO
MAX
SURF_DRILL
0.0, 0.0, 1.0
cs_0
END_
Assignment of the link condition

The link condition is assigned to a node group via the DVCON_SHAPE command.
DVCON_SHAPE
ID_NAME
ND_GROUP
CHECK_LINK
= dvcon_geo
= drill
= geo
END_
OPTIMIZE
ID_NAME
DV
OBJ_FUNC
DVCON
DVCON
DVCON
MESH_SMOOTH
DVCON
DVCON
END_
=
=
=
=
=
=
=
=
=
optimize
design_variables
min_function
dvcon_spc
dvcon_fix_x
dvcon_fix_y
mesh_smooth
dvcon_geo
dvcon_fix_shell
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Finally, the DVCON_SHAPE definition must be referenced in the OPTIMIZE

command.
SIMULIA
Tosca Structure
Shape Optimization
Defining the remaining DVCON_SHAPE parameters

Apart from DVCON_SHAPE that uses a link defined via LINK_SHAPE, four
other design constraints are required. For
Optimization result
Optimization result shaft_drill
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Fig. 93
SIMULIA
Tosca Structure
Clip
3.9
Clip
Task
Minimize the maximum stress (maximum stress value

outside the design area)
Keywords
Displacement amount, Displacement direction (DOF),

Penetration check (solid)
Commands
CHECK_GROW_SHRINK, CHECK_DOF,
CHECK_SOLID
This example illustrates a plastic clip that is used to fix a variety of objects.
The maximum stress is found on the inner side of the clip
Boundary conditions and stress shown in the initial model
The aim of optimization is to reduce the stresses without changing the contour of the inner side. Only nodes on the outer side are to be designed.
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Fig. 94
SIMULIA
Tosca Structure
Shape Optimization
The stress level is very low at the tips. Therefore, an optimization without
restrictions would result in these low-stressed areas shrinking. Thus, two
cylindrical frozen areas are defined at the tips.
Fig. 95
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3.9.1
Procedure: Summary
Model: clip.ext from the examples directory for your optimization task
Design area: node group DV_NODES
CS_DEF: new rectangular coordinate system, defined by rotating the global
CS by 45 around the global z-axis
CS_DEF: new cylindrical coordinate system, defined by translating the previously defined rectangular CS to origin with coordinates (23,23,0)
CS_DEF: new cylindrical coordinate system, defined by translating the previously defined rectangular CS to origin with coordinates (23,-23,0)
Design variable constraint: two solid body boundaries for the design nodes
Design variable constraint: fixation of all displacements for node group
NODES_FIX_ALL
Design variable constraint: fixation of the displacement along the global zaxis for node group nodes_fix_z
Design variable constraint: maximal growth and shrinkage of 6 mm for the
design nodes
remain free
SIMULIA
Tosca Structure
Clip

The easiest way to define the two coordinate systems is first to define any
two cylindrical coordinate systems by three nodes using a button in CS_DEF
panel of Modules Buttons (see vol.2 chapter 3.8, Coordinate Systems
(CS_DEF)). Then, the three points in the definition of these coordinate systems are to be set as follows:
Coordinate system 1 (CS_CYL_RIGHT) : A1 = 0, A2 = 32.57, A3 = 0, B1 = 0,
B2 = 32.57, B3 = 10, C1 = 10, C2 = 32.57, C3 = 0.
Coordinate system 2 (CS_CYL_LEFT): A1 = 32.57, A2 = 0, A3 = 0, B1 =
32.57, B2 = 0, B3 = 10, C1 = 42.57, C2 = 0, C3 = 0.
The axes of these coordinate systems are parallel to the global x, y and z
axes; the origins are located inside the two tips of the clip. Note that, although
the definition of coordinate systems mentioned in Summary is different, the
coordinate systems have the same origins and directions of z axis, and therefore they result in the definition of geometrically equal SOLIDs.
Then, create a CHECK_SOLID item in Task Manager under
DV_CONSTRAINTS and select the node group DV_NODES (the design
area) consisting of all nodes of the outer surface of the clip. Then, select the
command New -> SOLID of the context menu of the new CHECK_SOLID
item; in the appeared dialog, choose SOLID_PROP = RESTRICTED,
CS_DEF = CS_CYL_RIGHT, VAL_1_MIN = 0, VAL_1_MAX = 7, VAL_2_MIN
= 0, VAL_2_MAX = 360, VAL_3_MIN = -100, VAL_3_MAX = 100. Repeat the
action creating the second SOLID with the same settings except that
CS_DEF = CS_CYL_LEFT should be used now.
The fixation of the nodes of the group NODES_FIX_ALL is done using
DOF_CONTROL item under DV_CONSTRAINTS by setting all three directions (DOF_1, DOF_2, DOF_3) to FIXED.
The fixation of the nodes of the group nodes_fix_z in the direction of z-axis is
done using DOF_CONTROL item under DV_CONSTRAINTS by setting
DOF_3 field to FIXED and the other two (DOF_1 and DOF_2) to FREE.
Using GROW/SHRINK_CONTROL item under DV_CONSTRAINTS, the limits for the optimization displacements (CHECK_GROW = 6,
CHECK_SHRINK = 6) are chosen.
3.9.3

Definition of the coordinate systems
Coordinate system in the center of the clip
CS_DEF
ID_NAME
CS_TYPE
DEF_TYPE
CS_REF
ORIGIN_123
=
=
=
=
=
1
RECTANGULAR
LOCAL
CS_0
0,0,0
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3.9.2
SIMULIA
Tosca Structure
Shape Optimization
ROTATION_321
= 45,0,0
END_
Cylindrical coordinate system in the tip of the left clip

CS_DEF
ID_NAME
CS_TYPE
DEF_TYPE
CS_REF
ORIGIN_123
=
=
=
=
=
CS_CYL_LEFT
CYLINDRICAL
LOCAL
1
23,23,0
END_
Cylindrical coordinate system in the tip of the right clip

CS_DEF
ID_NAME
CS_TYPE
DEF_TYPE
CS_REF
ORIGIN_123
=
=
=
=
=
CS_CYL_RIGHT
CYLINDRICAL
LOCAL
1
23,-23,0
END_
Definition of solids
The coordinate system is now used to define the cylindrical frozen areas in
the tips of the clip
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SOLID
ID_NAME
SOLID_PROP
CS
VAL_1_MIN
VAL_1_MAX
VAL_2_MIN
VAL_2_MAX
VAL_3_MIN
VAL_3_MAX
=
=
=
=
=
=
=
=
=
SOLID_CYL_LEFT
RESTRICTED
CS_CYL_LEFT
0
7
0
360
-100
100
=
=
=
=
=
=
=
SOLID_CYL_RIGHT
RESTRICTED
CS_CYL_RIGHT
0
7
0
360
END_
SOLID
ID_NAME
SOLID_PROP
CS
VAL_1_MIN
VAL_1_MAX
VAL_2_MIN
VAL_2_MAX
SIMULIA
Tosca Structure
Clip
VAL_3_MIN
VAL_3_MAX
= -100
= 100
END_
Fig. 96
Definition of the design nodes in the model "clip"
Defining DVCON_SHAPE
Both solids must now be defined as being frozen areas using a
DVCON_SHAPE definition. During the actual solid definition the solids were
assigned the attribute "RESTRICTED" which function as restricted bodies.
DVCON_SHAPE
=
=
=
=
=
=
dvcon_solid
DV_NODES
SOLID_CYL_LEFT
SOLID_CYL_RIGHT
NO
CS_0,FREE,FREE,FIX
END_
Up to six solids can be referenced in a DVCON_SHAPE definition.

To view the stresses outside the design area the stress in the node group
ALL_NODES must be determined in the design response.
DRESP
ID_NAME
DEF_TYPE
TYPE
UPDATE
ND_GROUP
GROUP_OPER
=
=
=
=
=
=
DRESP_MAX_MISES
SYSTEM
SIG_MISES
EVER
ALL_NODES
MAX
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ID_NAME
ND_GROUP
CHECK_SOLID
CHECK_SOLID
CHECK_SPC
CHECK_DOF
SIMULIA
Tosca Structure
Shape Optimization
END_
3.9.4
Fig. 97
Task
Keywords
Conserve stampable surface, Conserve turnable

surface, Symmetry: rotational
Commands
SURF_STAMP, SURF_TURN, ROTATION_SYM
This example illustrates controller based shape optimization of a rim. The

optimization task is to lower the maximal Mises stresses while keeping the initial volume of the rim. Further several manufacturing restrictions are considered. The new design must show rotational symmetry by 60. The rim holes
must remain stampable after optimization. CHECK_SLIDE restrictions are set
on the inner and outer rim surfaces which prevents them from violation,
caused by the change of the rim holes outlines during optimization. A demold
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3.10 Rim
SIMULIA
Tosca Structure
Rim
restriction is specified for the outer surfaces of the rim holes. The rim model is
shown in Fig. 98
Fig. 98
Model "rim"
3.10.1 The model

The rim is modeled using 3D solid elements. As design nodes only the surface nodes of the rim holes are used. Two load cases are considered. The
loads are applied on the node in the middle of the mounting hole and transfered to the structure via RBE2 elements.
The goal of the optimization is to reduce the maximal stresses considering

both loadcases. The initial volume of the rim remains unchanged. Several
manufacturing restrictions are applied to the rim holes as well as to the inner
and outer rim surfaces.

1. Start Tosca ANSA environment to define the optimization task.
2. Select a new SHAPE_CONTROLLER task in the Task Manager.
3. Import the analysis model rim.ext (ext=inp, bdf, dat...).
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3.10.2 Optimization task
SIMULIA
Tosca Structure
Shape Optimization
4. Create a node group DESIGN_NODES_ALL which contains the design

nodes and set the group as design area. The group should contain all
nodes of the rim holes as shown in Fig. 99
Fig. 99
Contents of group DESIGN_NODES_ALL
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Create six more node groups containing each hole separately (HOLE_1 ...
HOLE_6). This group definitions are needed for the stamp restrictions on the
holes. Create two node groups containig the nodes of the inner
(TURN_INNER) and the outer rim surface (TURN_OUTER), needed for the
CHECK_SLIDE restriction (Fig. 100).
Fig. 100 Inner and outer rim surface
SIMULIA
Tosca Structure
Rim
Further create two more node groups for the demold restriction on the outer
surface of the rim holes (first group DEMOLD). Extend the group by adding
the nodes of the inner turn surface of the rim to create the check group for the
demold restriction (CHECK_DEMOLD).
Fig. 101 Demold group and check group for the demold restriction
Fig. 102 Fix nodes

5. Create a STAMP_CONTROL restriction for the first hole (node group
HOLE_1) and specify the positive global y axis as stamp direction (vector
0,1,0). Repeat this step for the other five holes.
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The MESH_SMOOTH command can cause the undesirable displacement of

some nodes on the outer turn surface of the rim. Therefore some nodes need
to be fixed. Create a group with the fix nodes (FIX_NODES) as shown in Fig.
102.
SIMULIA
Tosca Structure
Shape Optimization
6. Define a SYMMETRY_CONTROL restriction on the design nodes. Specify a

60 rotation symmetry along the global y axis.
7. Create a CHECK_SLIDE restriction on the outer rim surface as shown in
Fig. 103. For some of the design nodes are also part of this surface, the
CHECK_SLIDE definition restricts the displacements of these nodes so that
the surface remains unchanged. The affected nodes can only be moved
along the surface. Repeat this definition for the inner rim surface as well.
Fig. 103 CHECK_SLIDE restriction on the outer rim surface
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8. Create a DOF_CONTROL item and fix the nodes of the group FIX_NODES
in every direction of the global coordinate system CS_0
9. Create a DEMOLD_CONTROL restriction for the outer surfaces of the rim
holes (node group DEMOLD). Specify the positive global y axis as demold
direction and select the group CHECK_DEMOLD as check group.
10.Specify the MESH_SMOOTH area using the MS_LAYER option and add 4
layers starting from the design nodes.
11.Define the objective function as a MINMAX function to minimize the
maximal von Mises stress in the design area from both load cases. For
more details please refer to the Tosca Structure Getting Started manual.
12.Define a volume constraint to keep the initial volume of the rim
unchanged.
13.Set up the generation of VTFX visualization and start the Tosca Structure
optimization.
SIMULIA
Tosca Structure
Rim

1. Start Tosca Structure.pre to define the optimization task.
2. Import the analysis model rim.ext (ext=inp, bdf, dat...). If no groups are
defined in the analysis input (e.g. for MSC Nastran input) import the groups
from the file groups.bdf which can be found in the same directory as the
analysis input. For more details please refer to the Tosca Structure Getting
Started manual.
3. Create the design variable area. The group DESIGN_NODES contains the
design elements.
4. Create a LINK_SHAPE condition with client type SURF_STAMP to set a
stamp restriction to the rim holes. Specify the positive global y axis as client
direction. For each rim hole create a DVCON_SHAPE using the node groups
HOLE_1 ... HOLE_6. Assign the link condition above to the DVCON_SHAPE
items.
5. Create a LINK_SHAPE condition with client type ROTATION_SYM to set a
rotation symmetry to the design area. Specify a 60 symmetry around the
global y axis. Choose a tolerance value of 0.01 for each axis which
matches the Tosca Structure default tolerance value. Assign the link condition to a DVCON_SHAPE item selecting the design group.
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6. Create a LINK_SHAPE condition with client type SURF_TURN which is used

for the definition of the slide surface (Fig. 104). Set the node group
TURN_OUTER as master criterion for the outer rim surface. Specify the
positive global y axis as client direction. Assign the link condition to a
DVCON_SHAPE item selecting the same node group. To specify a slide
surface, activate the link condition in the field CHECK_SLIDE. After that
SIMULIA
Tosca Structure
Shape Optimization
repeat the whole definition for the inner rim surface (node group
TURN_INNER).
Fig. 104 LINK_SHAPE condition for turnable surface
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7. Create a LINK_SHAPE condition with client type SURF_DEMOLD to set a

demold restriction to the outer rim hole surfaces. Specify the global positive
y axis as demold direction. The check group for the demold restriction is
CHECK_DEMOLD. Assign the link condition to a DVCON_SHAPE item
selecting the. The node group containing the outer rim hole surfaces is
named DEMOLD. The restriction is set for this group.
8. Define a DVCON_SHAPE item to fix some nodes on the outer rim turning
surface. The nodes are assembled in the group FIX_NODES. Fix the
displacements of the node group in all global directions.
9. Create the design responses. Add a design response for the volume as a
sum of all design elements volumes. Create design responses for the
maximal von Mises stress in the design area for both load cases.
10.Define the objective function to minimize the maximal von Mises stress
from both load cases (MINMAX).
11.Define a volume constraint with a relative value of 1.0. Thus the initial
weight of the rim remains unchanged.
SIMULIA
Tosca Structure
Rim
12.Define a MESH_SMOOTH area which contains four element layers starting

with the DESIGN_NODES group.
13.Compose the optimization task (OPTIMIZE) and select the predefined
definitions. Choose the SHAPE_CONTROLLER optimization strategy. Make
sure to reference all defined DVCON_SHAPE items in the OPTIMIZE
command.
14.Start the complete Tosca Structure optimization using the start option type
= all.
3.10.5 Result discussion
Fig. 105 Optimization results, stresses.
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Generate both displacement and control plots. Notice the growth and the
shrink areas. How does the shape of the rim holes change? Are all manufacturing restrictions maintained? Depending on the solver the maximal stresses
are reduced by more than 20 percent.
SIMULIA
Tosca Structure
Shape Optimization
3.11 Threehole
Task
Maximize the lowest natural frequency with volume

constraint
Keywords
Displacement direction (DOF)
Commands
CHECK_DOF
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The lowest natural frequency is to be maximized in this example without a

change in volume. Fig. 106 illustrates the initial model along with the first five
eigenmodes.
Fig. 106 Initial model of "threehole" and its 5 first eigenmodes
SIMULIA
Tosca Structure
Threehole

Model: threehole.ext from the examples directory for your optimization task
Design variable constraint: fixation of the displacement along the global xaxis for node group nodes_fix_x
remain free
Objective: maximize the first eigenfrequency


DRESP
ID_NAME
DEF_TYPE
TYPE
LC_SET
LC_SEL
UPDATE
END_
=
=
=
=
=
=
OBJ_FUNC
ID_NAME
DRESP
TARGET
END_
= MAXIMIZE_FREQ
= DRESP_FREQ
= MAX
DRESP_FREQ
SYSTEM
DYN_FREQ
MODAL,ALL,1
MIN
EVER
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The first natural frequency must be defined in the design response and then
maximized as objective function.
SIMULIA
Tosca Structure
Shape Optimization
Definition of constraints
Optimization where natural frequencies are to be maximized generally
causes an increase of mass/volume and thus increasing the natural frequencies. To avoid this from happening a volume constraint needs to be defined:
DRESP
ID_NAME
DEF_TYPE
TYPE
UPDATE
EL_GROUP
GROUP_OPER
=
=
=
=
=
=
DRESP_VOL_SHAPE
SYSTEM
VOLUME
EVER
ALL_ELEMENTS
SUM
=
=
=
=
=
volume_constraint
DRESP_VOL_SHAPE
REL
1.0
0.01
END_
CONSTRAINT
ID_NAME
DRESP
MAGNITUDE
EQ_VALUE
TOL_VALUE
END_
Fig. 107 Optimization result for threehole
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Fig. 107 and Fig. 108 illustrate the optimization results:
SIMULIA
Tosca Structure
Hub
Fig. 108 Frequencies during optimization
Hub
Task
Keywords
Conserve cyclic and plane symm. (non-symm. meshes), Displacement direction (DOF), Symmetry: planar
Commands
SURF_CYCLIC_PLANE_SYM, CHECK_DOF,
ROTATION_SYM
This example illustrates the shape optimization of a hub of a wind turbine system. The optimization task is to lower the maximum von Mises stresses. The
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3.12
SIMULIA
Tosca Structure
Shape Optimization
new design must show rotational symmetry by 120 with plane symmetrical
segments. The assembly of the hub model is shown in Fig. 109:
Fig. 109 Assembly of model "hub"
3.12.1 The model

The hub is modeled using 3D solid elements. As shown in Fig. 110 the model
is loaded with two moments in opposite direction and is fixed at the end of the
shaft.
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two moments in opposite

direction (red arrows)
fixed constraint
Fig. 110 Boundary conditions and loads of model "hub"

Fig. 111 shows the design nodes (coloured in blue) and the non-design nodes
(coloured in green). So, inner and outer surface of the base body can be
SIMULIA
Tosca Structure
Hub
changed individually by the shape optimization. The connections modeled as

non-design nodes have to be fixed.
design nodes
fixed nodes
Fig. 111 Design nodes
Model: hub.ext from the examples directory for your optimization task
Design variable constraint: fixation of all displacements for node group FIX
Design variable constraint: SURF_CYCLIC_PLANE-symmetry condition with
start point (0,0,1),direction (1,0,0) and angle 120 in the global coordinate
system
Mesh smooth: mesh smoothing of all elements in design area, while free surface nodes remain free
Stop condition: 10 iterations

the former examples or in vol.1 chapter 1.3, Shape Optimization with Tosca
ANSA environment. The set-up including starting a SHAPE_CONTROLLER
task, loading the model and definition of design area and objective function
can be done as described in the Getting Started Manual. The fixation of displacements is described in vol.4 chapter 3.9.2, Procedure in detail: Tosca
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SIMULIA
Tosca Structure
Shape Optimization
ANSA environment. The SURF_CYCLIC_PLANE-symmetry can be created

as follows: DESIGN_AREA | DV_CONSTRAINTS |
NEW |
SYMMETRY_CONTROL (Fig. 113).
Fig. 112 Definition of SURF_CYCLIC_PLANE_SYM
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the former examples or in vol.1 chapter 2.3, Shape Optimization with Tosca
Structure.gui. The set-up including starting a SHAPE_CONTROLLER task,
loading the model and definition of design area and objective function can be
done as described in the Getting Started Manual. The fixation of displacements is described in vol.4 chapter 3.9.3, Procedure in detail: Tosca Struc-
SIMULIA
Tosca Structure
Hub
ture.gui. The SURF_CYCLIC_PLANE-symmetry can be created by selecting

SURF_CYCLIC_PLANE_SYM as Client in LINK_SHAPE (Fig. 113).
Fig. 113 Definition of SURF_CYCLIC_PLANE_SYM

In the parameter file the link condition is defined as:
LINK_SHAPE
END_
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ID_NAME = LINK_SHAPE_1_SYMMETRY_CONTROL_3
MASTER = MAX
CLIENT = SURF_CYCLIC_PLANE_SYM
CYCLIC_SYM_START = 0., 0. , 1.
CLIENT_DIR = 1.,0.,0.
CS = CS_0
TOL = 0.1
ANGLE = 120.
SIMULIA
Tosca Structure
Shape Optimization

Fig. 114 and Fig. 115 show the optimization results:
Fig. 115 Optimization results for the front view of hub: von Mises stress of
original (left) and optimized (right) mode
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Fig. 114 Optimization results for hub: von Mises stress of original (left) and
optimized (right) model
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SIMULIA
Tosca Structure
Hub
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SIMULIA
Tosca Structure
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SIMULIA
Tosca Structure
SIMULIA
Tosca Structure
Bead Optimization
Bead Optimization
Tosca Structure.bead supports the engineer in finding the layout of bead stiffeners for sheet metal components. In this section, typical bead optimization
examples are described.
Example overview
Oil pan
Plate
Hood eig. sens.
Hood eig.
Examples
Hood
Keywords
Holder
4.1
Strategy
Controller
Sensitivity
Analysis Type
STATIC
FREQUENCY
X
X
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Objective
Frequency
Frequency
(KreisselmaierSteinhauser)
Compliance
Target
MIN
MAX
Bead height
SIMULIA
Tosca Structure
Plate
Displacement
amount
Mesh
enhancing
Symmetry:
planar
4.2
Hood eig. sens.
Plate
Oil pan
Hood eig.
Hood
Examples
Holder
Keywords
X
X
X
Plate
Task
Minimize compliance
Keywords
Bead height
Commands
DV_BEAD, DVCON_BEAD, BEAD_HEIGHT, DRESP,

OBJ_FUNC, OPTIMIZE
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The Tosca Structure.bead module is used to determine the optimum position

and orientation of stiffeners in a sheet metal structure in order to minimize the
SIMULIA
Tosca Structure
Bead Optimization
compliance. In Fig. 116 the initial model is illustrated. The boundary is fixed
and the center is loaded with a pressure load
Fig. 116 Model plate

All nodes of the model should be used for optimization. The boundary nodes,
which are fixed in the finite element model, should also be fixed during optimization. Therefore, the node fixations of the finite element model are activated
for the optimization procedure.
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4.2.1
Procedure: Summary
Model: plate.ext from the examples directory for your optimization task
Design area: all nodes
Constraint: maximum bead height 20 mm
Settings: 60 mm bead width
4.2.2

Choose a BEAD_OPTIMIZATION_CONTROLLER task in Tosca ANSA environment and create the model link. Add all nodes to the design area.
Choose the item PRE_PROCESSING | DV_CONSTRAINTS | NEW |
CHECK_BC in the task manager to apply boundary conditions to all nodes.
Set the CHECK_BC option to YES to activate the restriction.
SIMULIA
Tosca Structure
Plate
To define the objective function choose the item PRE_PROCESSING |

OBJ_FUNC_ITEM_1 | NEW | COMPLIANCE.
BEAD_HEIGHT_CONSTRAINT in the task manager to set a constraint on the
bead height. In the CONSTRAINT item, switch the magnitude to ABS and
specify 20 mm for the bead height value (Fig. 118).
Fig. 118 Definition of bead height constraint

Choose PRE_PROCESSING | BEAD_OPTIMIZATION_CONTROLLER | NEW
| SETTINGS in the task manager to set some additional options for the optimization task. Specify a width value of 60 mm.
4.2.3

The boundary conditions are imported in Tosca Structure using the OPTIONS
command:
READ_BC
= ALL
END_
This setting has to be set before the FEM_INPUT-statement. All nodal boundary conditions of the finite element model are imported. The fixations may
then be activated via the DVCON_BEAD command.
DVCON_BEAD
ID_NAME
ND_GROUP
CHECK_BC
END_
= dvcon_fix_spc
= ALL_NODES
= YES
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OPTIONS
SIMULIA
Tosca Structure
Bead Optimization
The parameter CHECK_BC = YES ensures that all nodes with a fixation in
the finite element model are also fixed in the corresponding DOFs during the
optimization procedure.
The height of the stiffeners is the constraint to the optimization problem.
Therefore, a design response containing the Type = BEAD_HEIGHT has to
be defined referenced in the CONSTRAINT command:
DRESP
ID_NAME
DEF_TYPE
ND_GROUP
TYPE
GROUP_OPER
UPDATE
END_
=
=
=
=
=
=
DRESP_BEAD_HEIGHT
SYSTEM
ALL_NODES
BEAD_HEIGHT
MAX
EVER
CONSTRAINT
ID_NAME
DRESP
MAGNITUDE
EQ_VALUE
=
=
=
=
dresp_bead_height
ABS
20.0
END_
To maximize the stiffness the compliance is minimized. The design response,

object function (OBJ_FUNC) and OPTIMIZE command will then become:
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DRESP
ID_NAME
DEF_TYPE
EL_GROUP
TYPE
GROUP_OPER
UPDATE
LC_SET
END_
OBJ_FUNC
ID_NAME
DRESP
TARGET
END_
=
=
=
=
=
=
=
DRESP_COMPLIANCE
SYSTEM
ALL_ELEMENTS
STRAIN_ENERGY
SUM
EVER
STATIC,1,ALL
= MINIMIZE_COMPLIANCE
= DRESP_COMPLIANCE
= MIN
OPTIMIZE
SIMULIA
Tosca Structure
Hood
ID_NAME
DV
OBJ_FUNC
DVCON
CONSTRAINT
END_
=
=
=
=
=
BEAD_OPTIMIZATION
DESIGN_VARIABLES
MINIMIZE_COMPLIANCE
DVCON_BC
The bead width may be specified in the OPT_PARAM section. If no user

defined bead width is defined, the system automatically determines a bead
width.
OPT_PARAM
ID_NAME
OPTIMIZE
VECTOR
SCALE
BEAD_WIDTH
=
=
=
=
=
MY_PARAMETERS
BEAD_OPTIMIZATION
FIRST
1.0
60
END
Fig. 119 Optimization result
4.3
Hood
Task
Minimize compliance
Keywords
Bead height, Symmetry: planar

BEAD_HEIGHT, LINK_BEAD
The hood is a simple shell structure that is subjected to two loadcases.

Although one of the loadcases is unsymmetrical, the final design should be
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SIMULIA
Tosca Structure
Bead Optimization
symmetric. The purpose of the exercise is to show Tosca Structures ability to

perform bead optimization with more static loadcases.
Fig. 120 Hood loaded in a vertical pull (left) and a shear force (right).
The hood, shown in Fig. 120 is loaded with a vertical pull and a shear force. It
is fixed in the two upper corners. Dimensions: Height 15.0, width 20.0 and
depth 15.0.
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4.3.1
Procedure: Summary
Model: hood.ext from the examples directory for your optimization task
Design variable constraint: plane symmetry restriction
Objective: maximize stiffness (minimize compliance) considering both loadcases
Constraint: maximum bead height 0.5
Settings:
BEAD_WIDTH
=
3,
BEAD_MIN_STRESS
=
0.005,
BEAD_MAX_MEMBRANE = 2
4.3.2

This optimization task is a standard bead optimization task as described in
the example in vol.4 chapter 4.2, Plate or in vol.1 chapter 1.4, Bead Optimization with Tosca ANSA environment. The set-up including starting a
BEAD_CONTROLLER task, loading the model and definition of design area,
SIMULIA
Tosca Structure
Hood
design variable constraint, objective function, bead height constraint as well

as additional optimization settings can be done as described in the example
in vol.4 chapter 4.2, Plate or in the Getting Started Manual.
To define a symmetry restriction choose the item PRE_PROCESSING |
DV_CONSTRAINT | NEW | SYMMETRY_CONTROL in the task manager. In
the SYMMETRY_CONTROL item, specify for this case a plane symmetry
regarding the XY-plane (direction vector 0,0,1). For origin choose the point
with coordinates (5,0,10).
The target of the objective function should be set to MIN.
4.3.3

First of all we want to make sure that the nodes of the boundary is not a part
of the design variables as in the former plate-example (vol.4 chapter 4.2).
And in the same way we choose the remaining nodes as design variables for
the bead optimization (DV_BEAD) and in this example the bead_height constraint is set to 0.5.
Then we want a design response (DRESP) which includes both loadcases.
This may be done several ways, but the most appropriate way is to define two
design responses:
DRESP
ID_NAME
DEF_TYPE
EL_GROUP
TYPE
GROUP_OPER
UPDATE
=
=
=
=
=
=
dresp_compliance_1
SYSTEM
ALL_ELEMENTS
STRAIN_ENERGY
SUM
EVER
LC_SET
= STATIC,1,ALL
LC_SEL
= MAX
DRESP
ID_NAME
DEF_TYPE
EL_GROUP
TYPE
GROUP_OPER
UPDATE
=
=
=
=
=
=
dresp_compliance_2
SYSTEM
ALL_ELEMENTS
STRAIN_ENERGY
SUM
EVER
LC_SET
= STATIC,2,ALL
LC_SEL
= MAX
END_
Notice especially the LC_SET-command that chooses loadcase 1 and 2,

respectively. The design responses are then to be referenced in the object
function:
OBJ_FUNC
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SIMULIA
Tosca Structure
Bead Optimization
ID_NAME
DRESP
DRESP
TARGET
=
=
=
=
minimize_compliance
MIN
END_
Here the weight fraction for both design responses is 1.0. The optimization
task then is:
OPTIMIZE
ID_NAME
DV
OBJ_FUNC
DVCON
CONSTRAINT
STRATEGY
=
=
=
=
=
=
BEAD_OPTIMIZATION
DESIGN_VARIABLES
minimize_compliance
dvcon_FIX_spc
BEAD_CONTROLLER
END_
The optimization result is shown in Fig. 121. The optimization result is however not symmetric.
To enforce plane symmetry a link condition is created. But in order to create
this link condition, a coordinate system needs to be created somewhere on
the symmetry plane.
CS_DEF
ID_NAME
DEF_TYPE
CS_TYPE
CS_REF
ORIGIN_123
ROTATION_321
=
=
=
=
=
=
MY_CS
LOCAL
RECTANGULAR
CS_0
5.0, 0.0, 10.0
0.0, 0.0, 0.0
END_
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The normal of the symmetry plane is the 3rd axis of the coordinate system.
The link condition is then:
LINK_BEAD
ID_NAME
TYPE
CS
= my_link_plane
= PLANE_SYM, AXIS_3
= MY_CS
END_
The link condition needs to be referenced by a design variable constraint

(DV_CON), which then again is also referenced in the optimization task.
DVCON_BEAD
SIMULIA
Tosca Structure
Hood
ID_NAME
CHECK_LINK
ND_GROUP
= my_dvcon
= my_link_plane
= all_nodes
END_
OPTIMIZE
ID_NAME
DV
OBJ_FUNC
DVCON
=
=
=
=
BEAD_OPTIMIZATION
DESIGN_VARIABLES
minimize_compliance
dvcon_FIX_spc
DVCON
= MY_DVCON
CONSTRAINT
STRATEGY
= bead_height_constraint
= BEAD_CONTROLLER
END_
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The result of this symmetric optimization is also shown in Fig. 121.
SIMULIA
Tosca Structure
Bead Optimization
4.3.4
4.4
Hood_eig and Hood_eig_sens
4.4.1
Eigenfrequency optimization with Tosca Structure.bead
Task
Maximize eigenvalue
Keywords
Controller vs. Sensitivity strategy, Bead height,

Displacement amount
Commands
BEAD_HEIGHT, CHECK_GROW_SHRINK
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Fig. 121 Optimization results without (left) and with symmetry restriction
(right)
SIMULIA
Tosca Structure
Fig. 122 First eigenmode of "hood"-structure

The goal of this optimization is to maximize the first eigenvalue of a simply
bent plate. First eigenmode is shown in Fig. 122 and has the eigenvalue of
0.3098 (Using MSC Nastran, other solvers may differ).
The optimization can be done with both the controller and sensitivity based
bead algorithm. In the following are both approaches shown with a bead
height of 0.5.
4.4.2
Eigenfrequency optimization using controller algorithm

Model: hood_eig.ext from the examples directory for your optimization task
Objective: maximize first eigenfrequency
Settings: BEAD_WIDTH = 1.5
objective function, bead height constraint as well as additional optimization
settings can be done as described in the example in vol.4 chapter 4.2, Plate
or in the Getting Started Manual.
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Procedure: Summary
SIMULIA
Tosca Structure
Bead Optimization

BEAD_CONTROLLER
Using the wizard in Tosca Structure.gui the parameter file for optimizing first
eigenvalue is easily achieved.
1. Start Tosca Structure.gui wizard and choose "Bead optimization "
2. Choose the input deck "hood_eig.ext" as input file
3. Choose "ALL_NODES" as design variables
4. Choose the optimization task "Maximize the lowest eigenfequency"
5. We use a BEAD_HEIGHT of 0.5 and a BEAD_WIDTH of 1.5.
Fig. 123 Bead pattern from eigenvalue optimization with controller

The first eigenvalue is only slightly higher 0.3140 (1.3%) after the controller
based optimization. The eigenvalue will NOT become higher if you change
the number of iterations for the controller approach!
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SIMULIA
Tosca Structure
4.4.3
Eigenfrequency optimization using sensitivity algorithm

Procedure: Summary
Model: hood_eig_sens.ext from the examples directory for your optimization
task
Design variable constraint: CHECK_GROW and CHECK_SHRINK = 0.25
Objective: maximize first eigenfrequency (using the Kreisselmeier-Steinhauser criterion)
Settings: FILTER_RADIUS = 1.5
Global stop condition: 20 iterations
objective function, bead height constraint as well as additional optimization
settings can be done as described in the example in vol.4 chapter 4.2, Plate
or in the Getting Started Manual.
To define maximization of eigenfrequency value as objective function choose
the item PRE_PROCESSING | OBJ_FUNC_ITEM_1 | NEW | EIGENFREQUENCY in the task manager. In the OBJFUNC_TERM item, choose the
DYN_FREQ_KREISSEL type to avoid that the modes switch during optimization and select the first five eigenmodes.
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BEAD_SENSITIVITY
Using Tosca Structure.gui Bead-wizard the parameter file for optimizing first
eigenvalue is also easily achieved for the sensitivity based approach. Instead
SIMULIA
Tosca Structure
Bead Optimization
of choosing a BEAD_HEIGHT of 0.5 we set the maximal shrink and grow to

0.25, respectively (BEAD_HEIGHT = growth + shrinkage = 0.25 + 0.25 = 0.5).
.
Fig. 124 Tosca Structure.gui Bead Wizard choosing sensitivity based

approach
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The default settings from Tosca Structure.gui Wizard only regard the first
eigenmode:
DRESP
ID_NAME
TYPE
DEF_TYPE
LC_SET
END_
=
=
=
=
DRESP_EIGENFREQUENCY
DYN_FREQ
SYSTEM
MODAL,ALL,1
For most applications you want to avoid that the modes switch during optimization. The easiest way to do this is to define a new design response based
on the Kreisselmaier-Steinhauser formulation. Here we assume that the first
mode will never get larger as the 5th mode.
DRESP
ID_NAME
TYPE
DEF_TYPE
LC_SET
END_
=
=
=
=
DRESP_KREIS
DYN_FREQ_KREISSEL
SYSTEM
ALL,ALL,1-5
SIMULIA
Tosca Structure
Fig. 125 Bead pattern from eigenvalue optimization with sensitivity based
approach
4.4.4
Discussion of differences
The sensitivity based algorithm uses many more design cycles to get to a
much better result. This is a typical observation for dynamic problems. The
sensitivity algorithm requires a significantly higher calculation effort (120
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Result is a final eigenvalue of 0.3558 (15%), which may even become higher
if one lets the optimization continue for more than 20 iterations (see Fig. 126).
SIMULIA
Tosca Structure
Bead Optimization
Matrix steps, 20 full analysis compared to 4 analysis in the controller algorithm).
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Fig. 126 Convergence of controller and sensitivity based bead algorithm.

The latter also for pure growth (CHECK_SHRINK = 0.0)
It is interesting to see that beads patterns of both algorithms deliver somewhat similar results for the top of the hood (compare Fig. 123 and Fig. 125).
The beads are in the bending direction to increase bending stiffness. For the
bottom part the controller based algorithm also tries to increase stiffness by
inserting bead stiffeners. This seems to be a wrong approach because the
sensitivity based algorithm does not. The reasoning has to do with the kinetic
energy which is not considered in the controller based algorithm which only
prevents bending. The sensitivity based approach also considers the kinetic
energy and minimizes therefore the distance of the bottom part to the supports. This leads to a decrease of kinetic energy of the structure.
To complete our comparison one can repeat the sensitivity based optimization with CHECK_SHRINK less or equal to 0.0 (still the bead height is 0.5):
DVCON_BEAD
ID_NAME
CHECK_BC
ND_GROUP
CHECK_GROW
=
=
=
=
dvcon_max_disp
NO
ALL_NODES
.5
SIMULIA
Tosca Structure
Holder
CHECK_SHRINK
= .0
END
Fig. 127 Bead pattern from eigenvalue optimization with sensitivity based
approach, but only allowing growth (CHECK_SHRINK=0.0)
4.5
Holder
Task
Minimize compliance
Keywords
Mesh enhancing
Commands
BEAD_NODE_SMOOTH
CURV_SMOOTH
This example illustrates the two mesh enhancing capabilities in Tosca Structure.bead. In most cases the default values should not be changed so this
example is only presented for the sake of completeness.
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The result is seen in Fig. 127. Note that the bead in the middle of the top part
did not develop in this case (compare with Fig. 125). This may well be due to
the fact that the algorithm cannot push the surroundings down
(CHECK_SHRINK = 0.0). But it is interesting to see that the iteration history
of the two sensitivity based optimizations is nearly identical (Fig. 126).
SIMULIA
Tosca Structure
Bead Optimization
Fig. 128 displays the optimization problem, a curved sheet metal structure
with a hole in the middle. Around the hole is a non-design area plotted in
white.
In Fig. 129 is the optimized solution shown using BEAD_WIDTH = 50.0 and
BEAD_HEIGHT = 10.0, but otherwise the standard settings from Tosca Structure.gui. The two areas of interest are circled and marked with "1" and "2" and
will used in the following to explain the function of the two optional
OPT_PARAM: BEAD_NODE_SMOOTH (1) and CURV_SMOOTH(2).
Fig. 128 Holder with a vertical load and simple supported. The white area
is nondesign area
.
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Fig. 129 Optimized design with standard settings for

BEAD_NODE_SMOOTH(1) and CURV_SMOOTH(2).
SIMULIA
Tosca Structure
Holder
a)
b)
c)
Fig. 130 BEAD_NODE_SMOOTH for values 1.0 (a), 12.5 (b) and 24.0 (c)
a)
b)
c)
Fig. 131 CURV_SMOOTH for values 1.0 (a), 5.0 (b) and 10.0 (c)
Fig. 131 shows the effect of CURV_SMOOTH for different values. It is important to notice the different element size in the bead onthe left picture. Fig. 131
(a) the curvature of the initial structure squeezes the nodes together so that
the elements become quite small. For even higher degrees of curvature and
large bead heights it is possible that the nodes "grow together", thus distorting the elements so much that the FE-analysis will fail. For Fig. 131 (c) the
smoothing radius is 10 times the average element edge length. The elements
in the curved area are almost the same size as the elements in the non-opti4 - 166 Examples Manual
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BEAD_NODE_SMOOTH defines a distance which is the lowest possible inplane distance where the optimization displacement is allowed to vary from
0.0 to the defined bead_height. Fig. 130 shows the effect of
BEAD_NODE_SMOOTH for different values. Fig. 130 a) the value 1.0 is
smaller than the element edge length and there no smoothing is enforced
from the non-design to design area (see Fig. 128). In Fig. 128 (b) and (c) the
values are higher and it is seen from the figure that more elements are forced
to be in the transition from non-design to design area. The default value in
Tosca Structure.bead is BEAD_NODE_SMOOTH = 0.25*BEAD_WIDTH and
that is in this case shown in Fig. 128 (b). If BEAD_NODE_SMOOTH >
0.5*BEAD_WIDTH the optimization will stop with an error.
CURV_SMOOTH defines the radius in which mesh effects of a curved surface can be reduced. The value depends on the average element edge
length in the design domain and is default set to 5.0 times this length (Fig.
131 b).
SIMULIA
Tosca Structure
Bead Optimization
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mized areas and thereby keeping a valid mesh. It should be noted that high
values of CURV_SMOOTH will result in a large computational effort.
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SIMULIA
Tosca Structure
Holder
SIMULIA
Tosca Structure
Sizing
Sizing
Tosca Structure.sizing supports the engineer in finding optimal thicknesses
for sheet metal components. In this section, typical sizing examples are
described.
Examples overview
Holder
Examples
Beam symm.
Keywords
Beam 2D
5.1
Strategy
Sensitivity
Analysis Type
STATIC
Objective
Strain energy
Target
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MIN
MINMAX
Constraints
Volume
Minimum
member size
Symmetry:
cyclic
Symmetry:
planar
SIMULIA
Tosca Structure
Beam2D
Symmetry:
rotational
Shell thickness
bounds
5.2
Holder
Beam symm.
Examples
Beam 2D
Keywords
X
X
Beam2D
Task
Minimize compliance with volume constraint
Keywords
Design variables, Design response, Objective function,

Constraint, Shell thickness bounds
Commands
DV_SIZING, DVCON_SIZING, DRESP, OBJ_FUNC,

CONSTRAINT, OPTIMIZE, THICKNESS_BOUNDS
5.2.1
Model
In this model, a bending beam is fixed on the left side with a corresponding
force on the right side. All nodes on the left side of the model are fixed in x-
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The Tosca Structure.sizing module is used to determine the optimum shell

thicknesses in a sheet metal structure in order to minimize the compliance.
The actual model shows the main parts of a sizing optimization task: Definition of design variables, constraints and objective function. The standard task
will be defined using Tosca ANSA environment or Tosca Structure.gui.
SIMULIA
Tosca Structure
Sizing
and y-direction. A force of 10N is applied in the middle node of the right side
in a negative direction of the y-axis.
y
x
Fig. 132 Model of 2D beam for sizing
5.2.2
Optimization Task
The sizing optimization task is to maximize the stiffness using 50% of the initial volume. The shell thicknesses are to be changed during the optimization
and may vary between a lower bound of 0.1 and an upper bound of 2.0.
Two optimization tasks can be run - the first changing with a free change of
the shell sizes, the second clustering element areas with the same shell thickness.
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5.2.3
Procedure: Summary
Model: beam2d.ext from the examples/sizing directory for your optimization
task
Design variable constraint: lower and upper bound for shell thicknesses (0.1
and 2.0, resprectively)
Constraint: relative volume of 50 % (inequality constraint)
5.2.4

A standard sizing optimization task is described in detail in the getting started
manual vol.1 Start Manual. Please refer to this manual regarding the basic
definitions.
SIMULIA
Tosca Structure
Beam2D
Definition of the design area and thickness bounds

group ALL_ELEMENTS that contains all elements of the model. In order to
define thickness bounds for the shell thicknesses, a design variable constraint must be activated. The lower and upper bounds for the shell thicknesses are defined as absolute values (MAGNITUDE = ABS) of 0.1 and 2.0
respectively
(DESIGN_AREA
|
DV_CONSTRAINTS
|
NEW
|
THICKNESS_BOUNDS):
Fig. 133 Definition of thickness bounds

Fig. 134 Definition of the objective function
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The objective function is to maximize stiffness. This corresponds to minimizing the compliance (sum of strain energy, a measure of flexibility). Define your
objective as follows: With OBJ_FUNC_ITEM | NEW | COMPLIANCE click
OK (check if ALL_ELEMENTS is selected as group). With OBJ_FUNC_ITEM
| EDIT set your target to MIN.
SIMULIA
Tosca Structure
Sizing
In this optimization the volume is restricted to 50% of the initial volume.

Therefore define a volume constraint that refers to the elements in the design
space.
Fig. 135 Definition of a volume constraint

Optional definition of cluster groups
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The optimization task above perform a free change of each single shell thickness. If you want to enforce certain areas to obtain the same shell thickness,
you can cluster the elements in these areas. Define an element group
(EL_SET_1, EL_SET_2,... (predefined in the example model)) for each of the
clustering areas and assign them to a cluster group design variable constraint
(one for each group) as follows:
Fig. 136 Definition of cluster groups
5.2.5

Definition of the design area and thickness bounds
group ALL_ELEMENTS that contains all elements of the model.
DV_SIZING
ID_NAME
= design_variables
SIMULIA
Tosca Structure
Beam2D
EL_GROUP
= ALL_ELEMENTS
END_
In order to define thickness bounds for the shell thicknesses, a design variable constraint must be activated. The lower and upper bounds for the shell
thicknesses are defined as absolute values (MAGNITUDE = ABS):
DVCON_SIZING
ID_NAME = DVCON_SIZING
EL_GROUP = P1
CHECK_TYPE = THICKNESS_BOUNDS
MAGNITUDE = ABS
LOWER_BOUND = 0.1
UPPER_BOUND = 2.0
END_

The objective function is to maximize stiffness. This corresponds to minimizing the compliance (sum of strain energy, a measure of flexibility). A design
response (DRESP) must therefore be defined for the compliance of the structure:
DRESP
ID_NAME
DEF_TYPE
TYPE
EL_GROUP
GROUP_OPER
=
=
=
=
=
DRESP_SUM_ENERGY
SYSTEM
STRAIN_ENERGY
ALL_ELEMENTS
SUM
This response is to be minimized and thereby maximizing stiffness:

OBJ_FUNC
ID_NAME
DRESP
TARGET
= DRESP_SUM_ENERGY
= MIN
END_
In this optimization the volume is restricted to 50% of the initial volume.

Therefore define a volume constraint that refers to the elements in the design
space. Assign a design response to the constraint which contains the sum of
the total volume of the optimization group.
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END_
SIMULIA
Tosca Structure
Sizing
DRESP
ID_NAME
DEF_TYPE
TYPE
EL_GROUP
GROUP_OPER
=
=
=
=
=
DRESP_VOL_SIZING
SYSTEM
VOLUME
ALL_ELEMENTS
SUM
END_
This value is afterwards referenced in the constraint that enforces the maximal volume usage.
CONSTRAINT
ID_NAME
DRESP
MAGNITUDE
LE_VALUE
=
=
=
=
volume_constraint
DRESP_VOL_SIZING
REL
0.5
END_
At last the optimization task is compiled, i.e. the design variables are linked
with the objective function and the constraints.
OPTIMIZE
ID_NAME
STRATEGY
DV
OBJ_FUNC
CONSTRAINT
DVCON
=
=
=
=
=
=
SIZING
SIZING
DESIGN_VARIABLES
MAXIMIZE_STIFFNESS
VOLUME_CONSTRAINT
DVCON_SIZING
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END_
Optional definition of clustering

The optimization task above perform a free change of each single shell thickness. If you want to enforce certain areas to obtain the same shell thickness,
you can cluster the elements in these areas. Define an element group
(EL_SET_1, EL_SET_2,... (predefined in the example model)) for each of the
clustering areas and assign them to a clustering design variable constraint as
follows:
DVCON_SIZING
ID_NAME
EL_GROUP
EL_GROUP
= CLUSTERING
= EL_SET_1
= EL_SET_2
SIMULIA
Tosca Structure
Beam2D
EL_GROUP
EL_GROUP
EL_GROUP
CHECK_TYPE
=
=
=
=
EL_SET_3
EL_SET_4
EL_SET_5
CLUSTER
END_
The new design variable constraint must be referenced in the optimization

task:
OPTIMIZE
ID_NAME
...
DVCON
= SIZING
= CLUSTERING
END_
For postprocessing, Tosca Structure automatically writes files in ONF format.

After the optimization run, these files can be used to generate postprocessing
reports in Tosca Structure.report.
5.2.6
Results
Fig. 137 Sizing optimization result with free thickness modification
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The optimization result created with free shell modification shows a variying
shell thickness over the model. This can be used as a hint for clustering, i.e.
where to create borders between single sheets of same thickness.:
SIMULIA
Tosca Structure
Sizing
The optimization result created with clustering shows a very uniform thickness distribution:
Fig. 138 Sizing optimization result with clustering
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5.3
Beam with Symmetry Restrictions

(beam_sym)
Task
maximization of the stiffness with a volume constraint

and a symmetry constraint
Keywords
Symmetry constraints, Shell thickness bounds
Commands
LINK_SIZING, DVCON_SIZING;
THICKNESS_BOUNDS
The beam in this example is more finely meshed than in the previous example. Symmetry conditions should be introduced as an addition to a standard
stiffness optimization. The definition of the symmetry plane, of the symmetry
point or of cyclic symmetry needs to include a reference coordinate system.
This definition can be made with the CS_DEF command. If the coordinate
system is defined in the model it can be imported. The origin of the coordinate
system is in the middle of the design area.
Origin
CS_local
Fig. 139 Coordinate system in the center of the beam
SIMULIA
Tosca Structure
Beam with Symmetry Restrictions (beam_sym)
5.3.1
Procedure: Summary
Model: beam_sym.ext from the examples directory for your optimization task
Design variable constraint: lower (0.1) and upper (2.0) bound for shell thicknesses
Design variable constraint: symmetry restriction
Constraint: relative volume of 120 % (inequality constraint)
5.3.2

The symmetry condition is defined via DESIGN_AREA | DV_CONSTRAINTS
| SYMMETRY_CONTROL. .
Fig. 140 Symmetry control
Fig. 141 Definition of a plane symmetry with respect to the XZ-plane
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This definition specifies the type of symmetry ( plane, rotation or cyclic), and
location of the symmetry plane (point and normal direction) or rotational axis
(point and direction).
For example, plane symmetry with respect to the XZ-plane is defined as follows:.
SIMULIA
Tosca Structure
Sizing
For rotational and cyclic symmetry we recommend the activation of a minimum cluster width (of 20 for this model) to get more discernible effects..
Fig. 142 Minimum cluster width definition

Further, the outer layer of elements (element group FROZEN) can be frozen.
5.3.3

!COORDINATE SYSTEM IN THE CENTRE OF THE BEAM
CS_DEF
ID_NAME
CS_TYPE
DEF_TYPE
CS_REF
ORIGIN_123
ROTATION_321
=
=
=
=
=
=
CS_local
RECTANGULAR
LOCAL
CS_0
125.0, 50.0,0
0,0,0
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END_
The symmetry condition is defined using the command LINK_SIZING. This

definition specifies the type of symmetry (point, plane, cyclic,...), the reference to the applied coordinate system and the type of coupling. The masterelement group and the child-coordinate system are referenced. The
LINK_SIZING command is referenced in the DVCON_SIZING command
which completes the assignment of the element group.
For example, plane symmetry regarding the XZ-plane is defined with the
command:
!DEFINE PLANE SYMMETRY
!SYMMETRY PLANE: X-Z PLANE OF CENTER_CS
LINK_SIZING
ID_NAME
TYPE
= my_link_plane
= PLANE_SYM, AXIS_1
SIMULIA
Tosca Structure
CS
= CS_local
END_
In the DVCON_SIZING command the LINK_SIZING definition is referenced

with:
DVCON_SIZING
ID_NAME
EL_GROUP
CHECK_TYPE
CHECK_LINK
=
=
=
=
dvcon_plane
ALL_ELEMENTS
LINK_SIZING
my_link_plane
END_
To activate the restriction the DVCON_SIZING command must be referenced

in the OPTIMIZE command.
For rotational and cyclic symmetry we recommend the activation of a minimum cluster width (of 20 for this model) to get more discernible effects.Further, the outer layer of elements (element group FROZEN) can be frozen.
!
!
!
!
!
!
!
ID_NAME
= SIZING
DV
= design_variables
OBJ_FUNC
DVCON
= dvcon_sizing
CONSTRAINT
= volume_constraint
Link sizing Constraint
DVCON
= dvcon_sizing
Plane Symmetry
DVCON
= dvcon_plane
Rotation Symmetry
DVCON
= dvcon_rotation
Cyclic Symmetry
DVCON
= dvcon_cyclic
END_
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OPTIMIZE
SIMULIA
Tosca Structure
Sizing
5.3.4
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Fig. 144 Example of rotational symmetry (left) and cyclic translational

symmetry (right)
SIMULIA
Tosca Structure
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SIMULIA
Tosca Structure
Shape Optimization in Combination with
Shape Optimization in
Combination with Durability
Analysis
Often stress reduction already leads to a significant increase in durability.
Nevertheless for realistic models, stress peaks as identified by static analysis
may differ largely from areas of maximum damage. In these cases stress
based shape optimization may even worsen the design performance.
If the location of maximum damage and maximum stress are not matching,
fatigue life simulation should always be included in the optimization loop. In
this section, a typical setup including fatigue analysis is described.
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Fig. 145 Optimization based on stress and damage results
SIMULIA
Tosca Structure
Holeplate_dam: Femfat
6.1
Holeplate_dam: Femfat
Task
minimize maximum damage
Keywords
damage (fatigue) design response, Femfat
Commands
DRESP, TYPE = DAMAGE
In this simple model (realized as quarter model) two load cases are defined
as illustrated in the figure. The loads of load case two are twice as large as
the loads of the first load case.
loadcase 2
Fig. 146 Boundary conditions, cyclic loading and von Mises stress distribution for the 2 loadcases of the initial model.
The maximum von Mises stress in the initial model is located at the lower side
of the notch. Nevertheless, the maximum damage due to cyclic loading is
located at the upper side of the notch (see Fig. 149).
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loadcase 1
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Tosca Structure

Some additional settings have to set before an optimization based upon damage data can be started.
1. Durability preprocessing
The preprocessing for the damage calculation has to done using the
FEMFAT preprocessing system. All necessary data has to be provided for
the analysis.
In FEMFAT the results have to be requested in Tosca Structure ONF 600
format. The result file has to be named <jobname>_600.onf.
2. Definition of the Design Response
The type DAMAGE has to be selected in the design response.
DRESP
ID_NAME
DEF_TYPE
TYPE
UPDATE
ND_GROUP
GROUP_OPER
=
=
=
=
=
=
DRESP_MAX_DAMAGE
SYSTEM
DAMAGE
EVER
design_nodes
MAX
END_
3. Starting the optimization procedure

The damage calculation solver has to be stated on the command line
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TOSCA810 HOLEPLATE_DAM -SOLVER <SOLVERNAME> -LIFE FEMFAT
Fig. 147 Optimization result model holeplate_dam
SIMULIA
Tosca Structure
Holeplate_dam: fe-safe
6.2
Task
minimize maximum damage
Keywords
damage (fatigue) design response, fe-safe
Commands
DRESP, TYPE = DAMAGE
In this simple model (realized as quarter model) two load cases are defined
as illustrated in the figure. The loads of load case two are twice as large as
the loads of the first load case.
loadcase 2
Fig. 148 Boundary conditions, cyclic loading and von Mises stress distribution for the 2 loadcases of the initial model.
The maximum von Mises stress in the initial model is located at the lower side
of the notch. Nevertheless, the maximum damage due to cyclic loading is
located at the upper side of the notch (see Fig. 151).
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loadcase 1
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Tosca Structure

Some additional settings have to set before an optimization based upon damage data can be started.
1. Durability preprocessing
The standard preprocessing for the damage calculation has to done. All
necessary data has to be provided for the analysis. The .stlx and .ldf files
are exported from the fe-safe preprocessing system.
2. Definition of the Design Response
The type DAMAGE has to be selected in the design response.
DRESP
ID_NAME
DEF_TYPE
TYPE
UPDATE
ND_GROUP
GROUP_OPER
=
=
=
=
=
=
DRESP_MAX_DAMAGE
SYSTEM
DAMAGE
EVER
design_nodes
MAX
END_
3. Starting the optimization procedure

The damage calculation solver has to be stated on the command line
Fig. 149 Optimization result model holeplate_dam
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TOSCA810 HOLEPLATE_DAM -SOLVER <SOLVERNAME> -LIFE FE-SAFE
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SIMULIA
Tosca Structure
SIMULIA
Tosca Structure
Morphing
Morphing
Tosca Structure.morph allows the easy setup and analysis of model variants.
Thereby morphing areas are simply defined through groups of surface nodes.
7.1
Crane hook
Task
morphing (creation of model variants)
Keywords
morphing displacement, morphing area
Commands
MORPH_AREA
MORPH
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In this crane hook example, the maximum stresses for both load cases (see
Fig. 151) are in an area (see Fig. 151) which cannot be modified, for example, by a shape optimization. On the other hand, the outer side of the crane
hook can be modified to reduce the stresses on the inner side..
Fig. 150 Loadcase definition for load case 1 and 2
SIMULIA
Tosca Structure
Crane hook
Fig. 151 Stress distribution for load case 1 and 2
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Tosca Structure.morph is used to examine model variants where areas on the

outer side of the crane hook are modified. These morphing areas
Morphing_1, ... Morphing_7 as well as the critical area (= with high
stresses) are defined as groups as shown in Fig. 152 in your preprocessor.
SIMULIA
Tosca Structure
Morphing
Fig. 152 critical area(left) and morphing areas (right)
The morphing areas will then be modified, based on the user defined design
of experiment. In this experiment plan a constant displacement (positive, negative or zero) for each morphing area is defined. The modified model will be
analyzed by your FE solver.
7.1.1
Model: cranehook_morph.ext from the examples directory for your optimization task
Design area: DESIGN_NODES (combination of all MORPH_AREAs)
Mesh smooth: three layers based on DESIGN_NODES
Objective: minimize the stresses in the critical area
Morphing: morph the morphing area with the experiment plan
cranehook_morph.csv
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Procedure: Summary
7.1.2

First, a shape optimization task has to be defined. For this task, use the group
DESIGN_NODES for the design area. The objective will be to minimize the
SIMULIA
Tosca Structure
Crane hook
maximum stress in the critical area. These definitions are required to get
results for evaluation of the quality of the model model variants.
Define your design area as area which contains all regions which are allowed
to be morphed. The objective is used only for post-processing and does not
influence the morphing results.
.
Fig. 154 Completely defined shape optimization task
Fig. 156 New morphing task
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Add a new MORPHING folder to your optimization task within the Task Manager with right clicking on Tosca Structure Task -> New -> MORPHING
SIMULIA
Tosca Structure
Morphing
The MORPHING folder appears in Tosca Structure Task
Fig. 158 New morphing folder
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For each morphing area add a MORPH_AREA block via right-click on MORPHING folder
Fig. 160 Defining new morphing areas

For each MORPH_AREA different properties can be defined. Define a name
for your MORPH_AREA, here MORPH_AREA_1, then select GROUP_DEF,
SIMULIA
Tosca Structure
Crane hook
under ND_GROUP. In GROUP_DEF, enter a ? and select or define a

node_group describing the area to morph. Under TYPE, select the direction
of the morphing displacements vectors. So far only NORMAL is supported
Under TRANSITION_ZONE the number of nodes as transition zone can be
entered.
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Create the set of necessary MORPH_AREA definitions. The definitions can

be highlighted interactively on the FE model.
SIMULIA
Tosca Structure
Morphing
Add a new MORPH command via right-click on MORPHING folder and adding New -> MORPH.
Fig. 166 New morph command

Define a name in the pop-up window.
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Fig. 168 Morph command

To link your MORPHING with a valid shape optimization task, click in OPTIMIZE and select via typing ? your previously defined shape optimization,
here OPTIMIZE_1_SHAPE_OPTIMIZATION_CONTROLLER.
Please note: all manufacturing and design variable constraints defined in this
optimization task are considered during the morphing.
Fig. 170 Morph command: Linking to shape optimization task
SIMULIA
Tosca Structure
Crane hook
Define an experiment plan. Save your morphing scheme in a *.csv -file, e.g.
cranehook_morph.csv (see, e.g. vol.2 Morphing parameter file), where the
first line refers to the morphing areas and each following line corresponds to
one model variant:
0,
1,
2,
3,
4,
5,
6,
7,
8,
9,
Morph1, Morph2, Morph3, Morph4, Moph5, Morph6, Morph7

3.0, 0.0, 0.0, 0.0, 0.0, 0.0, 0.0
0.0, 3.0, 0.0, 0.0, 0.0, 0.0, 0.0
0.0, 0.0, 3.0, 0.0, 0.0, 0.0, 0.0
0.0, 0.0, 0.0, 3.0, 0.0, 0.0, 0.0
0.0, 0.0, 0.0, 0.0, 3.0, 0.0, 0.0
0.0, 0.0, 0.0, 0.0, 0.0, 3.0, 0.0
0.0, 0.0, 0.0, 0.0, 0.0, 0.0, 3.0
3.0, 3.0, 3.0, 3.0, 3.0, 3.0, 3.0
0.0,-2.0, 0.0, 3.0, 3.0, 0.0,-2.0
In this example, each morphing area will first be morphed with a displacement of 3 mm. Then we will morph all the design areas simultaneously to see
the effect of a large-scale geometric change. In the last experiment, a new
geometry of the crane hook will be created. For this experiment, some
MORPH_AREA will shrink, and others will grow. This is controlled by a negative/positive sign in the *.csv-File.
Remark
1. Displacement must be given as real values. So do not forget the dot. For
example, write 1.0 instead of 1.
Fig. 172 Morph command: MORPH_PARAM_FILE and selection of morph

areas
PARALLEL_JOBS and SMOOTHING can be defined optionally. With
PARALLEL_JOBS the number of parallel solver runs being started by Tosca
Structure can be defined. E.g. 2 means that Tosca Structure runs always 2 FE
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Select your MORPH_PARAM_FILE csv file describing your morphing task

and the combinations of morphing displacements to be executed. Then select
the morphing areas.
SIMULIA
Tosca Structure
Morphing
solver runs in parallel (as long as enough morphing variants are available for
calculation)
SMOOTHING switches surface smoothing of nodes in modified morphing
areas on/off.
Fig. 174 Morph command: PARALLEL_JOBS and SMOOTHING
Fig. 176 Run your defined morph task

Create your visualization sequence using Tosca Structure.report in the same
way like for shape optimization results: select your results using MORPHING
| MORPH POST-PROCESSING | GENERATE_MORPH_POST_FILE | CONTOURPLOT and visualize with MORPHING | MORPH POST-PROCESSING
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After these settings you can run the morph task. Add a RUN_MORPH command via right-click on MORPHING folder.
SIMULIA
Tosca Structure
Crane hook
| GENERATE_MORPH_ POST_FILE | MORPH_VTF_VISUALIZATION |

VIEW..
Fig. 177 Postprocessing morphing results
7.1.3

First, a shape optimization task has to be defined. For this task, use the group
DESIGN_NODES for the design area. The ofjective will be to minimize the
maximum stress in the critical area. These definitions are required to get
results for evaluation of the quality of the model model variants.
Then define your morphing areas Morph1,... Morph7 using the corresponding groups in your input deck with the MORPH_AREA command:
MORPH_AREA
ID_NAME
=
ND_GROUP
=
TYPE
=
TRANSITION_ZONE
Morph1
MORPHING_1
NORMAL
= 1
Each morphing area has to be defined separately.

Define an experiment plan. Save your morphing scheme in a *.csv -file, (see,
e.g. vol.2 Morphing parameter file) where the first line refers to the morphing
areas and each following line corresponds to one model variant:
0,
1,
2,
3,
4,
5,
6,
7,
8,
9,
Morph1, Morph2, Morph3, Morph4, Moph5, Morph6, Morph7

3.0, 0.0, 0.0, 0.0, 0.0, 0.0, 0.0
0.0, 3.0, 0.0, 0.0, 0.0, 0.0, 0.0
0.0, 0.0, 3.0, 0.0, 0.0, 0.0, 0.0
0.0, 0.0, 0.0, 3.0, 0.0, 0.0, 0.0
0.0, 0.0, 0.0, 0.0, 3.0, 0.0, 0.0
0.0, 0.0, 0.0, 0.0, 0.0, 3.0, 0.0
0.0, 0.0, 0.0, 0.0, 0.0, 0.0, 3.0
3.0, 3.0, 3.0, 3.0, 3.0, 3.0, 3.0
0.0,-2.0, 0.0, 3.0, 3.0, 0.0,-2.0
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END_
SIMULIA
Tosca Structure
Morphing
In this example, each morphing area will first be morphed with a displacement of 3 mm. Then we will morph all the design areas simultaneously to see
the effect of a large-scale geometric change. In the last experiment, a new
geometry of the crane hook will be created. For this experiment, some
MORPH_AREA will shrink, and others will grow. This is controlled by a negative/positive sign in the *.csv-File.
Remark
1. Displacement must be given as real values. So do not forget the dot. For
example, write 1.0 instead of 1.
Assign this experiment plan to your task using the MORPH command:
MORPH
ID_NAME
OPTIMIZE
MORPH_AREA
MORPH_AREA
MORPH_AREA
MORPH_AREA
MORPH_AREA
MORPH_AREA
MORPH_AREA
MORPH_PARAM_FILE
=
=
=
=
=
=
=
=
=
=
tosca_morph
<my_opt_task>
Morph1
Morph2
Morph3
Morph4
Morph5
Morph6
Morph7
cranehook_morph.csv
END_
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Now save your definitions to a parameter file (e.g. my_morph_job) and start
your morphing task on the screen Start TOSCA Structure.
Fig. 178 Start of a morphing run for shape optimization in Tosca Structure.gui
Create your visualization sequence using Tosca Structure.report in the same
way like for shape optimization results: The only difference is that the report is
generated
from
the
files
TOSCA_MORPH_xxx.onf
instead
of
SHAPE_xxx.onf.
SIMULIA
Tosca Structure
Crane hook
7.1.4
In the *.vtfx-File, you can see the controller input (f.e. stresses) and the nodal
displacements for all experiments. Each frame corresponds to an experiment.
In this example, the experiment 8 with the large-scale modification of the
geometry gives the best results for the stresses. The experiment 9 which is a
combination of grow and shrink gives good results too, and the modified
geometry is significantly lighter than the geometry in the experiment 8. So the
experiment 9 can be a good compromise for further processing (e.g. a subsequent local shape optimization...).
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Fig. 179 Stress distribution and morphing displacements for the last
experiment
SIMULIA
Tosca Structure
INDEX
A
Abaqus
Optimization using an all-in-one file
ments 2-423
Displacement check against solids 22-
623
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ADD_FILE 2-424
Advanced Modus 2-378
Analysis File 2-42
Analysis model 2-9
ANSYS
Groups 2-37
Input deck 2-35
Loadcases 2-36
Preprocessing 2-35
B
Band gap 2-267, 2-439
Bead height 2-142
Bead Optimization
Surface Calculation 2-519
Bead optimization 2-405
CHECK_ELGR 2-423
CHECK_GROW 2-420
CHECK_LINK 2-425
CHECK_SOLID 2-422
Controller based 2-407
Differential Stress Tensor (DST) 2-407
Displacement check against elements 2423
Displacement check against solids 2-422

Model 2-32
Optimization algorithm 2-445
Restricting the absolute displacement 2420
Restricting the direction of displacement

2-424
Restrictions
Design variable constraints 2-418
Displacement amount 2-420
Displacement check against ele-
422
Displacement direction 2-424

SCALE 2-417, 2-445
Sensitivity based 2-408
Symmetry conditions 2-425
Boundary conditions
Import of 2-649
C
Center of gravity 2-127
CHECK_BC 2-329
CHECK_DOF 2-329
CHECK_ELGR 2-328, 2-423
CHECK_GROUP 2-355
CHECK_GROW 2-323, 2-420
CHECK_LINK 2-333, 2-425
CHECK_MAX_MEM 2-324
CHECK_MIN_MEM 2-324
CHECK_SHRINK 2-323
CHECK_SLIDE 2-330
CHECK_SOLID 2-326, 2-422
Child group 2-50
Client nodes 2-340
CLIENT_DIR 2-348, 2-352
Combination of restrictions 2-215
Combined Terms 2-143
Commands
CONFIG 3-3
CONSTRAINT 3-24
CS_DEF 3-29
DRESP 3-31
DV_BEAD 3-67
DVCON_AUTO_SHAPE 3-52
DVCON_BEAD 3-53
DVCON_SHAPE 3-55
DVCON_TOPO 3-61
DV_SHAPE 3-68
4 - 201
SIMULIA
Tosca Structure
4 - 202
Volume 2-226, 2-228, 2-362, 2-483

Contact pressure 2-373
Convergence criteria 2-292, 2-499
Coordinate systems
Definition 2-59
Definition tips 2-67
Predefined 2-68
Rotation angles 2-66
Three nodes 2-60
Three points 2-63
CRITICAL 2-696
CS_DEF 2-59, 3-29
Cyclic symmetry 2-211
D
Definition of a minimum truss thickness
203, 2-471
DEMOLD_DIR 2-355
Design area 2-186, 2-301, 2-416, 2-463
Design nodes
Determination of the normal vectors
2-
2-
303
Design response 2-83, 2-167, 3-31

Design variable constraints
Bead optimization 2-418, 3-53
Shape optimization 2-320, 3-55
Topology optimization 2-189, 2-465, 3-61
Design variables
Bead optimization 2-416, 3-67
Topology optimization 2-186, 2-463, 3-70
Differential Stress Tensor (DST) 2-407
DIRECTION 2-350
Directories
After optimization 2-721
SAVE.ext 2-722
TOSCA_DB 2-721
TOSCA_POST 2-722
DISP_CS 2-352
Displacement 2-97, 2-228, 2-250, 2-483
Difference 2-235
Displacement restrictions
Amount of displacement 2-323, 2-420
Direction of displacement 2-329, 2-424
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DV_TOPO 3-70
FEM_INPUT 3-72
GROUP_AUTO_DEF 3-75
GROUP_DEF 3-78
GROUP_IMPORT 3-81
INCLUDE 3-82
LINK_BEAD 3-83
LINK_SHAPE 3-84
LINK_TOPO 3-97
LIST 3-100
LIST, info 3-106
LOGICAL 3-107
MESH_REFINE 3-109
MESH_SMOOTH 3-109
OBJ_FUNC 3-118
OPTIMIZE 3-120
OPTIONS 3-123
OPT_PARAM 3-129
SELECT 3-146
SF_IDENT 3-153
SMOOTH 3-154
SOFT_DELETE 3-135, 3-136
SOLID 3-162
STOP 3-163
TEST_BEAD 3-166
TEST_SHAPE 3-168
USER_FILE 3-170
VARIABLE 3-178
Compliance 2-87, 2-226, 2-432, 2-483
CONFIG 3-3
Configuration
Check actual settings 2-712
Configuration 2-712
Configuration files 2-712
CONSTRAINT 3-24
Constraints 2-79
Displacement 2-250
Displacement difference 2-235
Eigenfrequency 2-270
Multiple materials 2-223
Shape optimization 2-362
Topology optimization 2-220, 2-481
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SIMULIA
Tosca Structure
Penetration check 2-328, 2-423

Reading 2-46
Slide surface 2-330
Solid check 2-326, 2-422
DRESP 1-180, 2-83, 2-167, 3-31
Bead height 2-142
Center of gravity 2-127
Combined Terms 2-143
Displacement 2-97
Modetracking 2-114
Equivalent stress 2-114
Group operations 2-167
GROUP_OPER 2-167
Internal force 2-105
Loadcases 2-160
Moment of inertia 2-131
Rotation 2-97
Strain energy 2-87
VAR_OPER 2-167
Volume 2-135
Weight 2-137, 2-139
DV_BEAD 3-67
DVCON_AUTO_SHAPE 3-52
DVCON_BEAD 2-418, 3-53
DVCON_SHAPE 3-55
Command description 2-334
DVCON_TOPO 3-61
DV_SHAPE 3-68
DV_TOPO 3-70
E
Eigenfrequency 2-109, 2-267, 2-270, 2-433
Modetracking 2-114
Element types 2-33
Equivalent stress 2-114, 2-364
Damage 2-114
Von Mises 2-114
F
FEM_INPUT 3-72
File link 2-41
Files
After optimization 2-721
TOSCA.OUT 2-722
Forging 2-354
FREE_SF 2-309
G
Geometric Primitives 2-68
GROUP_AUTO_DEF 2-50, 3-75
GROUP_DEF 3-78
GROUP_IMPORT 3-81
Groups 2-47
Automatic node group definition 2-50
Default groups 2-48
Definition 2-47
Isosurfaces 2-536
TOSCA.smooth 2-536
Types of 2-48
I
Identifying surface nodes 2-47
INCLUDE 2-47, 3-82
Include Files 2-47
Interface
Internal 2-43
Internal force 2-105, 2-240, 2-486
Isosurfaces
Group Processing 2-536
Isovalue 2-521
Smoothing Parameters 2-520
Isovalue 2-521
L
LENGTH 2-351
LEVEL_CONV 2-313
Link conditions 2-336
Coupling displacement coordinates 2-349
Deformable surface 2-354
Displacement CS 2-352
Drilling surface 2-354
Forging surface 2-354
Link direction 2-350
Link length 2-351
Plane symmetrie 2-342
Point symmetry 2-347
Rotational symmetrie 2-348
Stamping surface 2-352
4 - 203
SIMULIA
Tosca Structure
4 - 204
Options for loading 2-46

Temperature calculation input 2-44
Model generation 2-8
Modetracking 2-114
Moment of inertia 2-131
Monitoring 2-178
MSC Nastran
Import of boundary conditions 2-666
Supported MSC Nastran cards
Boundary Conditions 2-666
Materials 2-663
Properties 2-663
MS_LAYER 2-311
Multidisciplinary optimization 2-76
N
Nodal restrictions 2-321, 2-334
Node groups
Automatic definition 2-50
Continuous search 2-50
Discrete search 2-51
Predefined 2-48
Normal vectors
Determination of the normal vectors
2-
303
O
Objective function 2-72
Maximization 2-75
Band gap 2-267, 2-439
Stiffness 2-430
Minimization 2-75
Compliance 2-226, 2-432, 2-483
Contact pressure 2-373
Displacement 2-228, 2-483
Internal force 2-240, 2-486
Maximum equivalent stress 2-364
Reaction force 2-240, 2-486
Relief notch 2-369
Rotation 2-228, 2-483
Volume 2-250
Minmax 2-76
Multidisciplinary optimization 2-76
OBJ_FUNC 3-118
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. Rev.
1 - 05.2014
1 - 05.2014
Turning surface 2-353

LINK_BEAD 3-83
LINK_SHAPE 2-336, 3-84
LINK_TOPO 2-213, 2-475, 3-97
LIST 3-100
LIST, info 3-106
Loading File 2-41
Identifying surface nodes 2-47
OPTIONS 2-46
Logging 2-178
LOGICAL 2-612, 3-107
M
Manufacturing restrictions 2-215
Marc 2-652
Master node 2-338
Automatic determination 2-339
Maximum member size 2-324
Memory management 2-720
Mesh
Quality 2-32
Mesh smoothing 2-305
MESH_REFINE 3-109
MESH_SMOOTH 2-305, 3-109
Automatic mesh_smooth elementgroup
definition 2-311
Convergence Level
LEVEL_CONV 2-312
Enforcing restrictions 2-313
Fixation of free surface nodes 2-309
Quality control
LEVEL_QUAL 2-313
Solver Quality Criteria
SOLVER_CHEK 2-316, 2-317
Strategy 2-318
Midside nodes
Minimum member size 2-203, 2-324, 2-471
Model 2-31
Load analysis file 2-42
Loading FE Data 2-41
Options 2-46
www.3ds.com/simulia
Version 8.1.0 Rev. 1 - 05.2014
SIMULIA
Tosca Structure
Optimization
Controller based
Combined terms 2-176
Element types 2-33
Sensitivity based
Design responses 2-167
Optimization boundary conditions
Import 2-666
Reading 2-46
Subcase ID 2-667
Optimization database 2-719
Optimization Model 2-9
Optimization parameters
Optimization Postprocessing
VRML 2-616
Optimization Preprocessing 2-719
ANSYS 2-35
OPTIMIZE 3-120
OPTIONS 2-43, 2-46, 3-123
OPT_PARAM 3-129
CURV_SMOOTH 2-379
DISP 2-383
FILTER 2-380
SCALE 2-377, 2-417, 2-445
VECTOR 2-382
P
Parent group 2-50
Parts & Assemblies 2-35, 2-622
PLANE_SYM 2-342
Point symmetry 2-211, 2-474, 4-181
POINT_SYM 2-347
Postprocessing with FE postprocessors 1-186
R
Reaction force 2-240, 2-486
DRESP
Reaction force 2-102
Read Options 2-43
READ_ADD 2-44
Reading FE-Data
Additional nodes and elements 2-44
Relief notch 2-369

Removing soft elements 2-279, 3-135, 3-136
Restart 2-709
Requirements 2-709
Restricted area
With elements 2-44
Restrictions
Results
ONF-format 2-618
Rotation 2-97, 2-228, 2-483
ROTATION_SYM 2-348
S
SCALE 2-417, 2-445
SELECT 2-53, 3-146
Selection
Criteria 2-55
Example 2-56
Lists 2-53
Types 2-54
Sensitivity based bead optimization 2-408
Band gap optimization 2-439
Eigenvalue optimization 2-434
Frequency response
Optimization parameters 2-450
Mode tracking 2-437
Valid design nodes 2-417
Settings
SF_IDENT 3-153
Characteristics of the analysis model 2-31
Coupling displacement coordinates 2-349
Create optimization model 2-183, 2-298, 2461
Deformable surface 2-354

Design variables 2-301, 2-302
Drilling surface 2-354
Forging surface 2-354
4 - 205
SIMULIA
Tosca Structure
326
Displacement check against elements 2-328

Link Conditions 2-333
Member Size 2-324
Restricting the displacement amount
2-323
Solids 2-326
Restrictions (design variable constraints)
2-320
Rotational symmetrie 2-348

Stamping surface 2-352
STOP conditions 2-399
Testdisplacements 2-383, 2-387
Turning surface 2-353
Volume constraint 2-362
Sizing 2-459
Sizing optimization 2-459
Slide surface 2-330
SMOOTH 3-154
SOFT_DELETE 2-279, 3-135, 3-136
SOLID 2-68, 2-422, 3-162
Solids 2-326
SPCADD 2-667
Stamping restriction 2-203
Stiffness 2-87, 2-430
STOP 2-613, 3-163
Stop condition
Definition 2-613
4 - 206
Maximum number of iterations
2-455, 2-
614

True 2-613
Strain energy 2-87, 2-430
Surface Calculation
Group Processing 2-536
Surface mesh
Calculation with TOSCA Structure.smooth 2-519
Surface nodes 2-47
Identification 2-47
Optimization displacements 2-32
SURF_DEMOLD 2-354
SURF_DRILL 2-354
SURF_STAMP 2-352
SURF_TURN 2-353
T
Temperature analysis 2-711
Test run 2-705
TEST_BEAD 3-166
Testlevel 1 2-705
Testlevel 2 2-706
Testlevel 3 2-707
Testlevel 4 2-708
TEST_SHAPE 2-383, 2-387, 3-168
Tightness constraint 2-199
Topology Optimization 2-179, 2-459
Design responses 2-167
General tips 2-179, 2-459
Isosurfaces 2-516
Manufacturing constraint
Combination of restrictions 2-215
Cyclic symmetry 2-211
deformation angle 2-194
LINK_TOPO 2-213, 2-475
Minimum membersize 2-203, 2-471
Point symmetry 2-211, 2-474, 4-181
pull direction 2-194
Stamping restriction 2-203
symmetry conditions 2-210, 2-473
Tightness constraint 2-199
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. Rev.
1 - 05.2014
1 - 05.2014
Link conditions 2-336

Link direction 2-350
Link length 2-351
Linking in displacement CS 2-352
Mesh smoothing 2-305
Model 2-32
Optimization displacement vectors 2-302
Plane symmetrie 2-342
Point symmetry 2-347
Restrictions
Direction of displacement 2-329
Displacement check agains solids 2-
SIMULIA
Tosca Structure
Manufacturing restriction 2-192, 2-471

Model 2-31
Prevention of undercuts in the model 2192, 2-471
Removing soft elements 2-279, 2-495
SOFT_DELETE 2-279, 2-495
Topology Optimization Results
TOSCA Structure.view 2-591
TOSCA Structure
Restart 2-709
Start 2-28
Starting optimization 1-183
Test run 2-705
TOSCA Structure.gui
Settings 1-172
TOSCA Structure.pre
Defining optimization tasks 1-177
Handling 1-174
Standard Design Responses 1-180
Wizard 1-182
TOSCA Structure.report
Preparing results for FE postprocessing
www.3ds.com/simulia
Version 8.1.0 Rev. 1 - 05.2014
1-186
Result transformation for TOSCA Structure.view 2-580

TOSCA Structure.smooth
Groups 2-536
Isosurface Calculation 2-520
Smoothing 2-520
Start 1-185, 2-29
Troubleshooting 2-540
TOSCA Structure.view 2-580
Start 2-580
Topology Optimization Results 2-591
TOSCA.OUT 2-722
TOSCA_POST 2-722
TOSCA_PREP 2-719
Troubleshooting
directories
DB_ERROR 2-723
protocol files 2-723
TOSCA Structure.smooth 2-540
U
UNDERCUT_TOL 2-354, 2-355
USER_FILE 3-170
V
VARIABLE 2-611, 3-178
Variable
Condition of logical variables 2-611
Logical 2-612
Combining logical variables 2-612
Comparing numerical variables 2-612
Status 2-612
Numerical
Database access 2-611
definition 2-611
Mathematical operators 2-611
VECTOR 2-349
Volume 2-135, 2-226, 2-250, 2-362, 2-483
VRML
Create data 2-616
W
Weight 2-137, 2-139
Wizard 1-182
4 - 207
www.3ds.com/tosca
Version
Version
8.1.0 8.1.0
Rev. Rev.
1 - 05.2014
1 - 05.2014
SIMULIA
Tosca Structure
4 - 208

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www.3ds.

Version 8.1.0 Rev. 1 - 05.2014

SIMULIA Tosca Structure

Version 8.1.0 Rev. 1 - 05.2014

Karlsruhe, May 2014

Tosca Structure makes use of several software components of Ceetron AS. to

Getting Started with Tosca ANSA environment

Version 8.1.0 Rev. 1 - 05.2014

1.1 User Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

1.1.13 Managing Groups

What is Topology Optimization?

1.3 Shape Optimization with Tosca ANSA environment . . . . . . . . . . . 1-67

What is Shape Optimization?

1.2 Topology Optimization with Tosca ANSA environment . . . . . . . . . 1-33

1.3.6 Node Displacement Check (Check Inputs)

Version 8.1.0 Rev. 1 - 05.2014

1.4 Bead Optimization with Tosca ANSA environment . . . . . . . . . . . 1-113

1.5 Sizing with Tosca ANSA environment . . . . . . . . . . . . . . . . . . . . . 1-145

Getting Started with Tosca Structure.gui

2.1.1 Requirements, Settings and Program Start

2.2 Topology Optimization with Tosca Structure.gui . . . . . . . . . . . . . 1-189

What is Topology Optimization?

2.1 User interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-171

2.2.5.8 Choice of the constraints

2.3 Shape Optimization with Tosca Structure.gui . . . . . . . . . . . . . . . 1-223

Version 8.1.0 Rev. 1 - 05.2014

What is Shape Optimization?

2.3.13.1 How to workaround mesh problems?

2.4 Bead Optimization with Tosca Structure.gui . . . . . . . . . . . . . . . . 1-271

What is Sizing Optimization?

2.5 Sizing Optimization with Tosca Structure.gui. . . . . . . . . . . . . . . . 1-305

Getting Started with Tosca Extension for ANSYS/WB

3.1 User Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-335

3.2 Topology Optimization with Tosca Extension for ANSYS/WB. . . 1-347

3.3 Shape Optimization with Tosca Extension for ANSYS/WB . . . . . 1-371

Version 8.1.0 Rev. 1 - 05.2014

Overview of Tosca Structure

1.1 The Tosca Structure Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Tosca ANSA environment

1.2 Overview of the Optimization Process . . . . . . . . . . . . . . . . . . . . . . . 2-8

1.3 Workflow for Optimization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Working with Tosca Structure

2.1 Working with Tosca ANSA environment . . . . . . . . . . . . . . . . . . . . 2-13

2.3 Working with Tosca Extension for ANSYS/Workbench . . . . . . . . . 2-22

2.4 Working with Tosca Structure in the Command Shell . . . . . . . . . . 2-26

Logging in command shell

2.4.6 Result Transfer

3.1 Models for Optimization. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31

Models for topology optimization

3.2 Optimizable Element Types. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33

3.4 Loading FE Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41

Version 8.1.0 Rev. 1 - 05.2014

Analysis Files for Optimization (FEM_INPUT)

3.5 Include Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47

Default predefined groups

3.7 Selection of Objects in Tosca Structure.gui. . . . . . . . . . . . . . . . . . 2-53

3.8.2 Definition by coordinates of three points

3.9 Solids (Geometric Primitives). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-68

Terms for Optimization

4.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-71

4.2 Objective Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-72

4.4.1 Compliance (Stiffness Optimization)

4.5 Combined Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-143

4.3 Constraints. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-79