Post on 12-Feb-2017
L’OTTIMIZZAZIONE TOPOLOGICA, ELEMENTO ESSENZIALE
NELLA PROGETTAZIONE DI COMPONENTI REALIZZATI IN ALM
Giulio Turinetti, Apr 20 2016
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Copyright © 2015 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
The ALM Process – 3 Main elements
Metallic Powders
• Final material strenght• External roughness• Chemical properties
ALM Process
3D printing Machines
• Production time• Process controls• Hybrid capabilities
Topology Optimization
• Load path based design• Minimun material• Designed by performances
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AMTopology
Optimization
Geometric Freedom
Design Individuality
Accelerated Product Development
+
Injects Innovation
Complementary Technologies
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Why Topology Optimization?
ALM offers a broad range of possibilities in shape design
How can a designer come up with the best possible shape?
Helping to choose thecnology, Traditional Vs. ALM
In ALM reducing the volume parts means saving time
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Topology Optimization
IDENTIFING THE LOAD PATHS
CHOOSE THE BEST MASS DISTRIBUTION
Topology optimization is a mathematical approach that optimizes material
layout within a given design space under given operating conditions.
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Altair Topology Optimization is OptiStruct
Altair is the premier provider of design optimization software, driving design processes of leading manufacturers for over 20 years
Not just an exercise
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Optistruct Classical Manufacturing Constraints
Draw direction
Free / no Holes
Extrusion
Draw + Member
Max member dimension
Min member
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Technology symbiosis
Performance
Performance
Performance
Performance
Unconstrai
ned
Topology optimization provides the most efficient structure for a given
load situation, but for traditional manufacturing designers always have to
trade performance for manufacturabilitytrade performance for manufacturabilitytrade performance for manufacturabilitytrade performance for manufacturability!
Draw
Direction Member SizeCyclic
Repetition
Symmetry
Manufacturing Manufacturing Manufacturing Manufacturing
ConstraintsConstraintsConstraintsConstraints
…
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Technology symbiosis
Topology optimization provides the most efficient structure for a given
load situation, with added manufacturing designers no more no more no more no more have to trade trade trade trade
performance for manufacturabilityperformance for manufacturabilityperformance for manufacturabilityperformance for manufacturability
Performance
Performance
Performance
Performance
Unconstrai
ned
Draw
Direction Member SizeCyclic
Repetition
Symmetry
Manufacturing Manufacturing Manufacturing Manufacturing
ConstraintsConstraintsConstraintsConstraints
Suitable for ALM
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Optimization - Advanced features
Non- Linear Optimization Multi-model OptimizationDifferent Physics in a
single analysis
Static
Modal
FRF
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Copyright © 2015 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
How can a designer come up with the
best possible shape?
The Additive Manufacturing Design Challenge
picture by courtesy of Laser Zentrum Nord
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Inspiration by Nature
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For Design Engineers
helps design products:
Faster
Smarter
Lighter
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Concept Design Validation Production
Never too soon to optimize
ConceptDesign + CAE
Validation Production
Concept
Inspire
Design
CAEValidation Production
� Weight saving� Time saving� Cost saving
Δ
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Start with original CAD design
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Create Package Space and Load Cases
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Inspire Concept Shape
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Explore Different Designs / Shapes
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Validate Inspire Concept Shape / Proposal
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Inspire Results back into CAD
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Original Design vs. Inspire Design
New Design: 25% Lighter
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How can the engineer draw it in a CAD system?
Conventional CAD systems rely on boolean operations of simple geometric entities
Too Complex Organic shape
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So “drafting” something like this
can take weeks with a conventional system:
How can the engineer draw it in a CAD system?
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Nurbify – Evolve technology
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Design Space Preparation
- CAD assembly
- CAD to FEM export
- Indicate Loads on part
Topology Optimization
- Mesh Optimization
- Linear stresses
- Design requirements
Design for AM
- STL Cleanup
Based on Digital CAD (STL)
- Lattice design
- Export to FEA/CAD
AM production
- CAM software for 3D printing
Supports
- Positioning
- Platform validation
- Scan profiles
3-maticSTLMagics RP
[not in APA]
Optistruct
Inspire
Topology Optimization Workflow from Altair to Materialise
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How to consider the NEW Manufacturing Constraints?
Types of supportTypes of support
Downward facing surfacesDownward facing surfaces
Angled surfaces and holesAngled surfaces and holes
Is ALM technology Limitless?
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Minimise Support Structure by Overhang Angle Control
Product Industrialisation - Manufacturing
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How to reduce support structures
We are working on it!
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Copyright © 2015 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Copyright © 2015 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Copyright © 2015 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
3D Printed Antenna Bracket forSentinel-1 Satellite:
• 43% weight reduction (from 1.626 kg to 0.936 kg)
• Increased Eigen frequency (70Hz � 90 Hz)
• Improved static behaviour, strength, stiffness, stability
From the Printer into Space
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Copyright © 2015 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Optimization Aided Design - Process
Orginal CAD model Orginal bracket
Analysis TopologyOptimization Setup
Design Interpretation
New CAD Design
Design/Analysis loopNew Final CAD
Courtesy of Thales Alenia Space
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Topology optimized structures
are pretty good,
but lattice structures could be even better
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Lattice structure Design Characteristics
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Control Arm – Concept Design (Phase 1)
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Control Arm – Concept Design to Lattice Design
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Demouldable Design vs. Lattice Structure
3% Stiffer
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Summary
Topology Optimization is the technology behind the scene
Inspire is the easy to use software to take shape inspiration
Nurbify can easy draw organic shapes
Lattice can even improve the design
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Altair Vision - Not a traditional Optimization tool
Version-0
Version-1
Version-2
Version-3
Not just to improving design
Optimization Driven Design
Help to make decisionSuggest the best shape
from the beginning
Help to think different