This workflow example shows the synergy potential between 2 different MODSIM roles: 

- Structural Generative Engineer (OPZ) 

- Concept Structure Engineer (BSD)

Initial design

It starts with a body-in-white design which is not respecting the performance targets for a torsion loadcase. (4.72 mm displacement of rear damper instead of 4.5 mm target). 

1/ Topology optimization

If the body-in-white engineer has no idea how to solve this issue, leveraging a topology optimization on the available volume can show him where an additional structural part could be added to stiffen the design and meet the target.

Model setup preparation

As a first step, the engineer needs to create an allocated volume for the topology optimization. This geometry is dynamically linked to the BIW concept geometry and packaging data. When these data are updated, the volume is automatically following.

Then this volume is meshed as tetra elements which are connected to the BIW concept FEMRep through Tie connections.

Topology optimization objectives and results

The objective of the optimization is to reduce the displacement (translation) with a relative low mass. The optimization process converges after 30 cycles.

2/ Concept interpretation and validation

This organic shape would be expensive and long to manufacture and is anyway overexceeding the target and too heavyweight.
But it gives a good idea about the optimal positioning of reinforcements inside the available volume to solve the torsion issue.

Now the engineer just needs to create a corresponding sheet metal concept design, taking into account the manufacturing constraints and rerun the simulation to validate the performance of the new design.

The design of the new reinforcement could be further refined through a parametric DOE to fit the target even more.

Values and KPIs

Thanks to the unified environment of the 3DEXPERIENCE, such a workflow - combining different solutions - can be executed in less than 3 hours, whereas it would take days with traditional tools.

Thanks @Huy Hoang NGUYEN and team for providing the IP-free body-in-white concept model. Thanks @Pauline HURTELOUP @Sébastien CÊTRE @Jean-Hugues DESPEISSES @Jens HARDER for your support.