1、1 2016 ANSYS,Inc.October 27,2022ANSYS Topology Optimization ACT ExtensionANSYS Inc.17.0 Release 2 2016 ANSYS,Inc.October 27,2022ANSYS Topology Optimization-Overview ACT Application name:ANSYS Topology Optimization ACT Application version:R17.0 Target application:WB Mechanical ANSYS compatible versio
2、n:R17.0 Description:Exposes Topology Optimization capabilities in Workbench Mechanical.The optimized model can then be exported and edited in SpaceClaim to perform subsequent validation analysis,optionally import into a CAD system,and/or be sent to a 3D printer for manufacture.3 2016 ANSYS,Inc.Octob
3、er 27,2022Information Please pay attention to paragraph 9 of the CLICKWRAP SOFTWARE LICENSE AGREEMENT FOR ACS EXTENSIONS regarding TECHNICAL ENHANCEMENTS AND CUSTOMER SUPPORT(TECS):“TECS is not included with the Program(s)”Report any issue or provide feedback related to this app please contact:Steve
4、.P4 2016 ANSYS,Inc.October 27,2022Binary App Installation(1)Installing from the ACT Start Page:1.From the project page,select the“ACT Start Page”option2.Click on“Extension Manager”3.Press“+”symbol in the top right corner4.It will open a file dialog to select theappropriate“*.wbex”binary file5.The ex
5、tension is installedLoading the extension:1.From the Extension Manager,click on your extension and chooseLoad Extension2.The extension is loadedNotes:The extension to be installed will be stored in the following location:%AppData%Ansysv170ACTextensions The installation will create a folder in this l
6、ocation,in addition to the.wbex file5 2016 ANSYS,Inc.October 27,2022Binary App Installation(2)Once the binary extension is installed at default location,one can move the*.wbex and the folder to any other location Default path:%AppData%Ansysv170ACTextensions New path:Any location on your machine,shar
7、ed drive etc.All users interested in using the extension need to include that path in their Workbench Options1.In the“Tools”menu,select the“Options”2.Select“Extensions”in the pop up panel3.Add the path under“Additional Extensions Folder”Define additional folders in which ACT will search for extensio
8、ns in order to expose them in the Extension Manager123Notes:During the scan of the available extensions,the folders will be analyzed according to the following order:1.The application data folder(e.g.%AppData%Ansysv170ACTextensions)2.The additional folders defined in the“Additional Extension Folders
9、”property3.The installation folder4.The“extensions”folder part of the current Workbench project(if the project was previously saved with the extension)If an extension is available in more than one of these locations,the 1st one according to the scan order is used6 2016 ANSYS,Inc.October 27,2022User
10、Documentation Contents Overview User Guide Design Optimization Validation Analysis7 2016 ANSYS,Inc.October 27,2022ANSYS Topology Optimization ACT Extension Summary of capabilities:This ACT App installs a Topology Optimization System in the Workbench Project Schematic The ACT App exposes Topology Opt
11、imization capabilities in Workbench Mechanical Various optimization objective and constraint response types are available for optimizing Static Structural designs The shape of the optimized design can be viewed and saved in the form of an STL file SpaceClaim can be used to clean up,modify and conver
12、t the STL file into a solid model The design can be verified by importing the solid model into a downstream Static Structural System and performing validation analysis The STL file of the optimized model can be sent to a 3D printer for manufacture8 2016 ANSYS,Inc.October 27,2022Capabilities Overview
13、:Topology OptimizationObjective Functions Single and Multi Compliance Local Degree of Freedom Local Displacement Reaction Force Volume,MassConstraint Functions Local Degree of Freedom Reaction Force Volume,Mass Local Stress Global StressManufacturing Constraints Maximum Member Size Minimum Member Si
14、ze Symmetry ExtrusionMechanical Physics Linear Stress Steady State Linear Bonded Contact Solid Bodies(2D and 3D)9 2016 ANSYS,Inc.October 27,2022Capabilities Overview:Exposure and Workflow(1)Static Structural Problem Setup Set up in Static Structural System Optionally Solve to obtain reference soluti
15、onOptimize Design Link to downstream Topology Optimization System(ACT Extension)Define Design Objectives,Design and Manufacturing Constraints Solve to obtain optimized model Visualize,inspect and“extract”shape of optimized model Export/Save STL file of optimized model10 2016 ANSYS,Inc.October 27,202
16、2Capabilities Overview:Exposure and Workflow(2)Validate Design Edit STL model in SpaceClaim and convert to solid geometry Create downstream Static Structural System to validate optimized design Import model into downstream Static Structural System,remesh and reapply problem setup Perform validation
17、analysis11 2016 ANSYS,Inc.October 27,2022User Guide:Static Structural Problem Setup12 2016 ANSYS,Inc.October 27,2022STATIC STRUCTURAL PROBLEM SETUP FOR OPTIMIZATIONCreate“Design Space”Create geometry from scratch,or Import part or assembly to be optimizedApply loads,supports,material props,etc.Guide
18、lines for meshing design space Set Physics Preference to Mechanical Use quadrilateral elements(Mid Side Nodes Kept)Preferred elements are Hexs followed by Wedges,followed by Tets Where possible use a constant element size13 2016 ANSYS,Inc.October 27,2022User Guide:Design Optimization14 2016 ANSYS,In
19、c.October 27,2022TOPOLOGY OPTIMIZATION APP INSTALLATIONInstalling from the ACT Start Page:1.From the project page,select the“ACT Start Page”option2.Click on“Extension Manager”3.Press“+”symbol in the top right corner4.It will open a file dialog to select thedownloaded“TopologyOptimization.wbex”binary
20、 file5.The extension is installedLoading the extension:1.From the Extension Manager,click on your extension and chooseLoad Extension2.The extension is loadedNotes:The extension to be installed will be stored in the following location:%AppData%Ansysv170ACTextensions The installation will create a fol
21、der in this location,in addition to the.wbex file15 2016 ANSYS,Inc.October 27,2022ACCESSING THE TOPOLOGY OPTIMIZATION SYSTEMLinking the Topology Optimization System to the Static Structural System introduces the“Ansys Topology Optimization”folder in the Workbench Mechanical Project Outline Topology
22、Optimization controls can be“Inserted”using this folder These controls are also available on the Workbench Mechanical ToolbarAnalysis Settings exposes various solver settings and controls Default settings are appropriate for most cases Note:Topology Optimization solution must converge before results
23、 can be viewed.Tip:A rough and quick solution can be obtained by relaxing the Convergence Tolerance to 1%16 2016 ANSYS,Inc.October 27,2022SPECIFY AREAS OF THE MODEL TO BE OPTIMIZED AND AREAS TO BE EXCLUDEDInsert the“Design Region”control and scope to areas to be optimized May be an entire assembly,a
24、 sub-assembly,or a multi-or single-body partInsert the“Exclusion”control to identify areas of the Design Region where material should not be removed May be any Geometry Selection or Named Selection Note:Exclusions may also be applied to selective areas of the mesh.Use the Worksheet Scoping Method of
25、 the Named Selections control to select the target mesh region.17 2016 ANSYS,Inc.October 27,2022SPECIFY DESIGN OPTIMIZATION OBJECTIVESInsert the“Objective”control and select desired Objective Response Type and corresponding Goal.Following Response Types are supported in R17.0 Single and Multiple Com
26、pliance Local Degree of Freedom Local Displacement Reaction Force Volume Mass Note:Only one Objective can be used per analysis Note:Multiple load cases may be used per analysis.Each load case should represent a single step in the Static Structural problem set up.E.g.,three load steps will require th
27、e Number of Steps under the Analysis Settings Control to be set to 318 2016 ANSYS,Inc.October 27,2022SPECIFY DESIGN OPTIMIZATION CONSTRAINTSInsert the“Constraint”control and select desired Constraint Response Type and corresponding settings.Following Response Types are supported in R17.0 Local Degre
28、e of Freedom Reaction Force Volume Mass Local Stress Global Stress Note:In R17.0 Local Degree of Freedom and Reaction Force Constraints can be scoped to a single mesh node only,and the Local Stress Constraint can be scoped to a single mesh element only.Important Note:The problem definition will be i
29、ncomplete if a single Constraint is used that has the same Response Type as that selected in the Objective-e.g.,a single Volume(or Mass)Constraint in combination with Volume(or Mass)Objective.If the goal is to obtain the stiffest possible structure at a given fraction of the Design Space Volume(or M
30、ass),use the Single or Multiple Compliance Objective in combination with a Volume(or Mass)Constraint.Important Note:Special care should be taken when applying Local Degree of Freedom,Reaction Force,Local Stress and Global Stress Constraints to ensure the design optimization problem statement is well
31、-defined.It is strongly recommended that the corresponding Structural Static problem be solved first on the Design Space(i.e.,un-optimized model)to develop a“feel”for appropriate lower and/or upper bounds for setting these constraints.E.g.,setting an Upper Bound value for the Global Stress Constrain
32、t that is significantly lower than the Maximum Stress encountered in solving the un-optimized model is not a realistic constraint and will likely lead to a Solver Error.19 2016 ANSYS,Inc.October 27,2022SPECIFY MANUFACTURING CONSTRAINTSFollowing manufacturing constraints are supported in R17.0 Minimu
33、m Member Size Maximum Member Size Extrusion Symmetry Note:To ensure proper numerical resolution,it is recommended that a Minimum Member Size Constraint always be applied and its value to be set to at least 2.5 times the typical mesh element size Note:The application of the Extrusion or Symmetry Cons
34、traints requires that the mesh reflect the extruded or symmetry characteristics of the constraint.E.g.,when applying an Extrusion Constraint in the X-direction,the mesh should be generated in such a way that it also extrudes in the X-direction.Typically in such cases one will use the Sweep or MultiZ
35、one mesh methods.Note:The Symmetry and Extrusion Constraints cannot be combined in a given simulation Note:A suite of examples are available in the ACT extension package that demonstrate the setup of Optimization Objectives and Constraints for a range of problems20 2016 ANSYS,Inc.October 27,2022LAUN
36、CH TOPOLOGY OPTIMIZER,MONITOR SOLUTION CONVERGENCETo launch the optimizer,right-click on the Solution folder under the Ansys Topology Optimization folder and select“Solve”Note:Shared memory parallel(SMP)processing is supported and up to the maximum number of the physical CPUs can be usedThere are th
37、ree ways to monitor solution convergenceSolver output in Solution Information Worksheet viewIteration progress text window launches automaticallySolution Convergence Graphs Note:The progressing solution can be stopped,but not interrupted Note:Solution must converge before the results can be retrieve
38、d Tip:The Solution Convergence graph and table do not get automatically refreshed once activated from the Show dropdown command.To update the Solution Convergence graph and table manually,clear the data via the Hide dropdown command,and then reissue the Show command.21 2016 ANSYS,Inc.October 27,2022
39、RETRIEVING OPTIMIZER RESULTSThe Optimizer returns a 3D solution field of pseudo density elemental values that range from 0.0 to 1.0.A value close to 1 indicates material is experiencing load and must be retained,a value close to 0 indicates the material is redundant and may be removed.From the Solut
40、ion folder,Insert“Values”and/or“Averaged Node Values”to retrieve the solution“Values”represent the raw pseudo densities defined at element centroids“Averaged Nodal Values”represent the smoothed pseudo densities mapped to the element nodes Important Note:It is strongly recommended that the“Average No
41、de Values”result be used for visualizing the optimizer results,especially for visualizing the shape of the optimized model and extracting it for validation analysis in a downstream Workbench Mechanical System.See Next slide.22 2016 ANSYS,Inc.October 27,2022VISUALIZE AND EXPORT OPTIMIZED SHAPEBest wa
42、y to visualize the 3D shape of the optimized model is to use“Capped Isosurface”contouring command with the“Bottom Capped IsoSurface”optionThe slider bar may be used to visualize how the shape of the optimized model changes with different values of pseudo densityLower values of pseudo density lead to
43、“chunkier”shapes,higher values lead to“slender”shapes.Important Note:You should use intuition and engineering judgement to pick the pseudo density value that results in the“best”optimized shape.Tip:It is good practice to err on the side of caution and resist the urge to remove too much material!Typi
44、cal values of pseudo density range from 0.3 to 0.7.To export the optimized shape,right click on Average Node Values and select Export STL File Tip:To ensure portability of the project,save the STL file in the user_files subdirectory of the Workbench Projects*_files directory23 2016 ANSYS,Inc.October
45、 27,2022User Guide:Validation Analysis24 2016 ANSYS,Inc.October 27,2022EDIT STL FILE IN SPACECLAIM(1)The STL file exported from WB Mechanical is not suitable for performing validation analysis or for sending to a 3D printerImport the STL file into SpaceClaim to:Fix intersecting,overlapping facets Ma
46、ke STL surface mesh watertight Coarsen to reduce the number of facets Smooth organic surfaces generated by optimizer Optionally,add more material near bolt holes,areas of contact etc.Convert back to solid geometry and export to downstream Workbench Mechanical System to perform design validation anal
47、ysisImportant notes:The Facets capability in SpaceClaim is used to edit STL geometry A separate license is required to use the Facets capability Use SpaceClaim Options to activate Facets tab in the GUIFile SpaceClaim Options LicenseCheck STL Prep checkbox25 2016 ANSYS,Inc.October 27,2022EDIT STL FIL
48、E IN SPACECLAIM(2)Important notes:On import,explicitly set STL units to be same as units in the original Design Space Geometry file Use Measure command to confirm model has correct length units after importTip:It is recommended that the original Design Space also be imported into SpaceClaim.This pro
49、vides the option of reusing parts from the original geometry to modify the optimized geometry.Important notes:Use the“Check Mesh”command to check the imported raw STL model for errors It is strongly recommended that you use the“Auto Fix”mesh command first to automatically fix all or most of the erro
50、rs Other commands under Cleanup,Organize,and Modify can be used to fix any remaining errors and obtain a valid faceted geometry 26 2016 ANSYS,Inc.October 27,2022EDIT STL FILE IN SPACECLAIM(3)After obtaining a valid STL geometry you may proceed to smooth the model and reduce the number of facets in r
