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Topology Optimization Janne Juhola, Dtream Oy Soukanlahdenkatu 17 A, 33100 Tampere www.dtream.fi Examples from Timo Turkkila, Dtream Oy Mikko Ukonaho, Tampere University of Applied Science
Topology OptimizationJanne Juhola, Dtream Oy
Soukanlahdenkatu 17 A, 33100 Tampere
www.dtream.fi
Examples fromTimo Turkkila, Dtream Oy
Mikko Ukonaho, Tampere University of Applied Science
High-Tech Engineering
Mika Nikander CEO/Sales
Pasi Laine 3D Design/Sales
Timo Turkkila (PhD)CTO
Optimization/Analysis
Janne JuholaCFO
Production Technology 6+Mechanical Design 7+Project Management 25+ Software Management 5+
Structural optimization 25+Structural analysis 12+Statistics (SixSigma) 10+Design automation 12+Teaching in University 12+
Mechanical Design 25+Manufacturing Technology 25+Project management 5+NC-Programming 2+Design for Manufacturing 2+
Project and Project Portfolio Management 25+Consumer Analysis 10+Multimedia Technology 25+DSP Design 5+
FEM structural analysis 20+Material expert 20+Optimization 1+Thermal Analysis 1+
Jyrki Riihentaus Optimization /
Analysis
Mikko Kettunen Marketing
Project Management 14+Visual Quality 5+Product Engineering 5+Mechanical Design 4+
Founded 2016 by previous Nokia/Microsoft employee
High-Tech Engineering Dtream Supports Your Develoment
REVERSE ENGINEERING
PROBLEM SOLVING
SIMULATION AND ANALYSIS
TOPOLOGY / FEATURE OPTIMIZATION
CONCEPT DESIGNPROTOTYPING /
TESTINGMANUFACTURING
3D PRINTING TECHNOLOGIES
High-Tech Engineering
TOPOLOGY OPTIMIZATIONFEM
DROP TEST SIMULATIONTHERMAL
CFDSTATISTICAL MODELING
VIBRATIONLIFE TIME PREDICT CORRELATIONS
MOLDFLOW
CASTING MACHINED PARTS
SHEET METALINJECTION MOLDING
3D FOR METAL3D FOR PLASTIC3D FOR CERAMIC
3D FOR SAND3D FOR COMPOSITE
Tools & Technologies
Let’s optimize first and make competitive, reliable design!
Altair Optisctruct ™
Solid Edge ™
Radioss ™
Inspire ™
Acusolve ™
High-Tech Engineering
What is Topology Optimization
• Wikipedia defines topology optimization as:• “Topology optimization (TO) is a mathematical method that optimizes
material layout within a given design space, for a given set of loads, boundary conditions and constraints with the goal of maximising the performance of the system”
High-Tech Engineering
Topology optimization examples
DTREAM OY 6
Buildings/StructuresTruss structure
Solid parts/3D printingConsumer electronics:Support soldering ball layout in memory component
High-Tech Engineering
Topology Optimization Procedure
1. Specify design space (space reservation), loads cases and optimization problem
2. Create element mesh for the design space (FE-model)
3. Solve topology optimization problem. Modify parameters and study sensitivity of optimization result
4. Create new FE-model for the most promising topologies and optimize them• Shape optimization can be applied but it needs also hard work
High-Tech Engineering
Possibilities of topology optimization
• Topology optimization is a systematic way to create new design ideas which uses all potential and add competitive advance
• There are many combinations which can be used in topology optimization• For example with new thinking it is possible to reduce mass and increase
stiffness simultaneously
• Many are thinking that 3D printing is needed to manufacture topology optimized parts but it can be applied to other manufacturing methods as well – especially in casting
High-Tech Engineering
Work Flow for Topology Optimization
Optistruct
VerificationTopology optimizationDesign input:• Supports• Loadings• Design Space
Finalized model
Inspire/Solid Edge Optistruct/Radioss
Original design:Material steel S355
Volvo
V70
Weight -74%
Optimized weight: 1.2 kgWeight before: 4.6 kg
High-Tech Engineering
Controlling Optimization
Optistruct
VerificationTopology optimization
Design input:• Supports• Loadings• Design Space
Finalized model
Inspire/Solid Edge Optistruct/Radioss
High-Tech Engineering
Bracket Example
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• Bracket from a table saw• Three load cases• Material plastic (ABS)
Supports Design space
z
x
y
From NAFEMS presentationSee full material
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Optimization solutions -1
Case 1 (Max stiffness) Case 2 (Max stiffness + symmetry in xy plane)
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Mass target 35%Fx = 400 N, Fy = -400 N, Fz = 100 NMinimum thickness 2 mm
High-Tech Engineering
Optimization solutions -2
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Case 4 (Min mass + displacement)Case 3 (Minimize mass)
Stress constraintFx = 400 N, Fy = -400 N, Fz = 100 NMinimum element size 0.65 mm
Case 3 + displacement constraint 0.5 mm
High-Tech Engineering
Bedplate example – for casting
• Our own example but similar case has been done for our customer
• Material cast iron ASTM Class 30• E = 100 GPa
• ν = 0.29
• ρ = 7150 kg/m3
• Re- =752 MPa (Compression)
• Re+ =214 MPa (Tension)
• n=3
Four screw holes for M12 bolts
Constant pressure = 0.5 MPa
From RM50 presentationSee full material
High-Tech Engineering
Space reservation and boundaries
Contact between wall and this plane
High-Tech Engineering
Optimization problem• Maximize stiffness and minimize mass
• Subject to• Mold opening direction specified
• Stress not above limits in large area
• Mass target is more important than compliance
Mold opening direction
High-Tech Engineering
Topology optimization - visualization
• Please see animation how Altair Optistcruct moves material during the optimization process
• http://www.dtream.fi/topologian-optim…in-visualisointi/
High-Tech Engineering
Optimal designs
After topology optimization Final design
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Comparisons
Original Structure after topology optimization*
Final structure
Mass 12.1 kg 8.5 kg 8.6 kg
Max displacement 1.14 mm 0.2 mm 0.79 mm
*Not manufacturable with casting
Maximum displacement is located in these corners
Optimized structure is30 % lighter40 % stifferWithout any extra manufacturing cost
High-Tech Engineering
Conclusions
• Topology optimization• Analyze first • Get the design ideas and guidelines• Optimize the wanted parameters and design for the selected manufacturing
method• Saving opportunities in
• Materials, manufacturing• Installation, maintenance• Energy consumption, • Lifetime cost
“Kun insinöörin järki loppuu, pitää ottaa ohjelmistot käyttöön”
Thank you
Links in this presentation
NAFEMS presentation:http://www.dtream.fi/dtream-events/timon-esitys-nafems-seminaarissa/
Rakenteiden mekaniikan RM50-seminaari presentation:https://rakenteidenmekaniikka.journal.fi/article/view/64936
Visualization of Topology optimization:http://www.dtream.fi/topologian-optimoinnin-visualisointi/
