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Carsten Gerdes-Götz, FE-Design GmbH
Dirk Pieper, pike-engineering & CAE-
Forum.de
the optimization company
Topologieoptimier-
ung als Ansatz für
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Materialeinsparung
und Ressourcen-
schonung
the optimization company
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Manifestationen des Kopfes, des Herzens und
der Seele, dass das Leben in seinem
Ausdruck erkennbar ist, dass die Form immer
der Funktion folgt.“
-Quelle: Wikipedia
Structural optimization
Design process
► Reduction of weight
Optimized
► Enforcing desirable design Initial design
stiffness and dynamic geometry space geometry
process
► Maximize the maximum
stresses of several
Shape
loadcases
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optimization Finite element model
► Minimize damage
and increase durability
► Include manufacturing
constraints
Validation run Optimization model
► Design for
displacements/forces/
eigenfrequences Smoothing and
generation of
validation file Topology optimization
03.12.2012
FE-DESIGN
Your partner for optimization
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ENGINEERING SERVICES
optimization processes due to a steady know-
how transfer through FE-DESIGN
► Customers leverage FE-DESIGN´s knowledge,
with long-term business relationships
TRAINING, SUPPORT AND CONSULTING
3.12.2012 г.
Product development values by using TOSCA
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accelerations, shorter cycle times
► Lower stresses increase durability
► Savings of material at ensured product quality
► Earlier product launches due to shorter
development times
03.12.2012
FE-DESIGN
Fields of application
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Wind power generation Marine technology Medical devices
03.12.2012
the optimization company
Main Frame
Development
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Courtesy of
Topology optimization of a main frame
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Design space for
Series production topology optimization
03.12.2012 Courtesy of
Main frame - comparison
1
0,9
0,8
Norm. mass/load 0,7
0,6
0,5
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0,4
0,3
0,2
0,1
0
S.64 Conventional S.52 Optimized S.82 Optimized
03.12.2012 Courtesy of
the optimization company
Hub
optimization
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Topology optimization of a hub
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Verification of new
conceptual design Design space model
Verification of new
conceptual design Topology optimization
03.12.2012
the optimization company
Topology
Optimization
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Example
Transverse Link at
AUDI With the friendly permission of
Initial situation
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With the friendly permission of
03.12.2012
Topology optimization of a transverse link at AUDI
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Design
Cutting splines space model
Topology optimization
03.12.2012
Courtesy of
Comparison
Existing design – new design
Result
100
► Speed-up of the development process
80 ► 45% stress reduction, 10% weight reduction
► The 1st prototype passed all mechanical tests !
Admissible
Stress
60
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40
20
0
Weight Max. stress Max. displacement
03.12.2012
the optimization company
Structural
Optimization of
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Washing Mashine
Components
Parts in FEA model
H2
H1
H3
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H4
H5
H6
H7
Traverse
(braces)
H9
03.12.2012
the optimization company
Topology
Optimization of a
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Washing Mashine
Spider Arm
Definition of the optimization task
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displacement nodegroup is restricted to 4.5 mm
03.12.2012
Optimization I results (without cast constraint)
450000 6
400000
5
350000
300000 4
250000
3
200000
150000 2
100000
DRESP_VOL_TOPO 1
50000
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DRESP_MAX_DISPLACEME
0 0
0 5 10 15 20 25 30 35
410000 7
400000 6
390000
5
380000
4
DRESP_VOL_TOPO
370000
DRESP_MAX_DISPLACEME 3
360000
2
350000
340000 1
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330000 0
0 10 20 30 40 50 60
Optimization of
a bike stem
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Topology optimization of a bike stem
Conventional design
New design
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Load cases
Smoothed results
Design space
Customers of FE-DESIGN
Excerpt
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3.12.2012 г.
the optimization company
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