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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Abaqus, Isight, Tosca, fe-safe, Simpack
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• Durability Simulation
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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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Go to www.3ds.com/slc
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Legal Notices
The software described in this documentation is available only under license from Dassault
Systèmes or its subsidiaries and may be used or reproduced only in accordance with the terms of
such license.
This documentation and the software described in this documentation are subject to change
without prior notice.
Dassault Systèmes and its subsidiaries shall not be responsible for the consequences of any
errors or omissions that may appear in this documentation.
No part of this documentation may be reproduced or distributed in any form without prior written
permission of Dassault Systèmes or its subsidiaries.
© Dassault Systèmes, 2016
Printed in the United States of America.
Abaqus, the 3DS logo, and SIMULIA are trademarks or registered trademarks of Dassault
Systèmes or its subsidiaries in the US and/or other countries.
Other company, product, and service names may be trademarks or service marks of their
respective owners. For additional information concerning trademarks, copyrights, and licenses,
see the Legal Notices in the SIMULIA User Assistance.
Revision Status
Lesson 1 12/16 Updated for Tosca Structure 2017
Lesson 2 12/16 Updated for Tosca Structure 2017
Lesson 3 12/16 Updated for Tosca Structure 2017
Lesson 4 12/16 Updated for Tosca Structure 2017
Lesson 5 12/16 Updated for Tosca Structure 2017
Lesson 6 12/16 Updated for Tosca Structure 2017
Lesson 7 12/16 Updated for Tosca Structure 2017
Lesson 8 12/16 Updated for Tosca Structure 2017
Lesson 9 12/16 Updated for Tosca Structure 2017
Lesson 10 12/16 Updated for Tosca Structure 2017
Lesson 11 12/16 Updated for Tosca Structure 2017
Lesson 12 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
Workshop 2a 12/16 Updated for Tosca Structure 2017
Workshop 2b 12/16 Updated for Tosca Structure 2017
Workshop 3a 12/16 Updated for Tosca Structure 2017
Workshop 3b 12/16 Updated for Tosca Structure 2017
Workshop 4a 12/16 Updated for Tosca Structure 2017
Workshop 4b 12/16 Updated for Tosca Structure 2017
Workshop 5a 12/16 Updated for Tosca Structure 2017
Workshop 5b 12/16 Updated for Tosca Structure 2017
Workshop 6a 12/16 Updated for Tosca Structure 2017
Workshop 6b 12/16 Updated for Tosca Structure 2017
Workshop 7a 12/16 Updated for Tosca Structure 2017
Workshop 7b 12/16 Updated for Tosca Structure 2017
Workshop 8a 12/16 Updated for Tosca Structure 2017
Workshop 8b 12/16 Updated for Tosca Structure 2017
Workshop 9a 12/16 Updated for Tosca Structure 2017
Workshop 9b 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:
Preprocessing Shape Optimization
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
Preprocessing Shape 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
Executing Optimization
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
Executing Optimization
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