Introduction to Tosca Structure - 4RealSim · Lesson 2 Workflow with Tosca Structure Lesson 3 Topology Optimization Basics Workshop 1 Stiffness Optimization of a Brake Booster Lesson

Introduction to Tosca Structure

2017

Course objectives

Upon completion of this course you will be able to create optimal design concepts or improve

existing designs of mechanical structures:

Solve fundamental topology, shape, sizing and bead optimization problems

Optimize parts regarding weight, stiffness and durability

Visualize, evaluate and transfer optimization results

Targeted audience

Simulation Analysts independent of FE-Solver and Pre-/Postprocessing environment in use

Prerequisites

None (basic knowledge of finite element analysis)

About this course

2 days

Day 1

Lesson 1 Introduction to Optimization

Lesson 2 Workflow with Tosca Structure

Lesson 3 Topology Optimization Basics

Workshop 1 Stiffness Optimization of a Brake Booster

Lesson 4 Geometric Restrictions for Topology Optimization

Workshop 2 Stiffness Optimization of a Control Arm

Lesson 5 Postprocessing and Validation of Optimization Results

Lesson 6 Sensitivity-based Topology Optimization

Workshop 3 Topology Optimization of a Crane Hook

Day 2

Lesson 7 Shape Optimization Basics

Workshop 4 Shape Optimization of a Plate with a Hole

Lesson 8 Geometric Restrictions for Shape Optimization

Workshop 5 Shape Optimization of a Connecting Rod

Lesson 9 Sensitivity-based Shape Optimization

Workshop 6 Sensitivity-based Optimization of a Crane Hook

Lesson 10 Sizing Optimization

Workshop 7 Sizing Optimization of a Holder

Lesson 11 Bead Optimization

Workshop 8 Bead Optimization of an Oil Pan

Workshop 9 Bead Optimization of a Hood (optional)

Lesson 12 Configuration and Solver Interfaces

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Safety Factors Creep-Fatigue Interaction

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• Durability Simulation

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• Weld, High Temperature, Non-metallics fe-safe

Material Calibration Workflow Automation

Design Exploration Isight

• Process Integration

• Design Optimization

• Parametric Optimization

• Six Sigma and Design of Experiments

Realistic Human Simulation High Speed Crash & Impact

Noise & Vibration Abaqus

• Routine and Advanced Simulation

• Linear and Nonlinear, Static and Dynamic

• Fluid, Thermal, Electrical, Acoustics

• Extended Physics through Co-simulation

• Model Preparation and Visualization

Tosca • Non-Parametric Optimization

• Structural and Fluid Flow Optimization

• Topology, Sizing, Shape, Bead Optimization

Conceptual/Detailed Design

Weight, Stiffness, Stress

Pressure Loss Reduction

Complete System Analyses (Quasi-)Static, Dynamics, NVH, Flex Bodies, Advanced Contact

• 3D Multibody Dynamics Simulation

• Mechanical or Mechatronic Systems

• Detailed Transient Simulation (Offline and Realtime) Simpack

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Legal Notices

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This documentation and the software described in this documentation are subject to change

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© Dassault Systèmes, 2016

Printed in the United States of America.

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Revision Status

Lesson 1 12/16 Updated for Tosca Structure 2017












Workshop 1a 12/16 Updated for Tosca Structure 2017

Workshop 1b 12/16 Updated for Tosca Structure 2017

















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Lesson content:

Motivation

Optimization definitions

Optimization strategies

Lesson 1: Introduction to Optimization

30 minutes

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Lesson content:

Tosca Structure Modules

Optimization Workflow

Optimization Module within Abaqus/CAE

Optimization Module within Tosca ANSA Environment

Tosca Extension for ANSYS Workbench

Tosca Structure.gui

Documentation

File Organization

Lesson 2: Workflow with Tosca Structure

45 minutes

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Lesson content:

Topology Optimization

Stiffness Optimization

Preprocessing Topology Optimization

Executing Optimization

Postprocessing

Workshop 1: Stiffness Optimization of a Brake Booster

Lesson 3: Topology Optimization Basics

45 minutes

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Lesson content:

Manufacturing Restrictions

Symmetry Conditions

Workshop 2: Stiffness Optimization of a Control Arm

Lesson 4: Geometric Restrictions for Topology Optimization

30 minutes

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Lesson content:

Directory and File Structure after Optimization

Visualization with Tosca Structure.view

Postprocessing in Abaqus/CAE

Visualization with Tosca Extension for ANSYS Workbench

Tosca Structure.smooth

Result Transfer: Generation of new CAD model

Validation Run

Validation in Abaqus/CAE

Workshop 2 (cont’d): Postprocessing control arm

Lesson 5: Postprocessing and Validation of Optimization Results

45 minutes

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Lesson content:

Preprocessing Topology Optimization

Terms for Optimization

Load Case Settings

Controller Algorithm for Stiffness Optimization

Sensitivity-Based Optimization

Controller vs. Sensitivity Based Optimization

Workshop 3: Topology Optimization of a Crane Hook

Lesson 6: Sensitivity-based Topology Optimization

1 hour

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Lesson content:

Shape Optimization

Preprocessing Shape Optimization

Execution

Postprocessing

Transfer of Optimization Results into the Construction Process

Workshop 4: Shape Optimization of a Plate with a Hole

Lesson 7: Shape Optimization Basics

1 hour

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Lesson content:


Mesh Smoothing

Manufacturing, Coupling and Symmetry Constraints

Displacement Restrictions

Symmetry Constraints

Coupling Restrictions

Checking Inputs

Morphing

Workshop 5: Shape Optimization of a Connecting Rod

Lesson 8: Geometric Restrictions for Shape Optimization

45 minutes

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Lesson content:

Motivation

Optimization Methods: Controller vs Sensitivity-based Optimization


Optimization Tasks

Model

Objective and Constraint

Displacement Restrictions

Link Conditions

Workshop 6: Sensitivity-based Optimization of a Crane Hook

45 minutes

Lesson 9: Sensitivity-based Shape Optimization

Currently sensitivity-

based shape optimization

is only supported by the

Tosca Structure.gui

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Lesson content:

Introduction to Sizing Optimization

Optimization Workflow

Preprocessing Sizing Optimization

Examples


Postprocessing

Workshop 7: Sizing Optimization of a Holder

Lesson 10: Sizing Optimization

1 hour

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Lesson content:

Introduction

Bead Optimization Strategies

Bead Optimization Workflow


Postprocessing

Result Transfer

Workshop 8: Bead Optimization of an Oil Pan

Workshop 9 (optional): Bead Optimization of a Hood

Lesson 11: Bead Optimization

45 minutes

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Lesson content:

Optimization Control

Solver Interfaces

Troubleshooting

Lesson 12: Configuration and Solver Interfaces

30 minutes

Introduction to Tosca Structure - 4RealSim · Lesson 2 Workflow with Tosca Structure Lesson 3 Topology Optimization Basics Workshop 1 Stiffness Optimization of a Brake Booster Lesson

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