A SIMULIA e-Learning Resource
Created using Abaqus 6.14-2 including Tosca Structure 8.0.1
still valid for current version 2016

Do you know how to ...

... efficiently change mechanical parts to avoid material failure and increase durability? Shape optimization with Tosca Structure allows you to apply specific detail modifications to improve your designs.

Using Abaqus/CAE you can easily setup, submit and postprocess a shape optimization. In this simple example a standard shape optimization process is shown for the example of a wind turbine hub. Starting with an existing design with appropriate load scenarios design changes will be applied to reduce stress peaks and thus avoid material failure. The files required for this example are provided with each Tosca Structure installation.

Watch the videos below to learn how to perform this standard shape optimization task. The process is still applicable to current versions of Abaqus/CAE.

Narrated video:

The following video shows the processing of a shape optimization task:

Setup and Submission:

- Introduction and Model (0:00 - 0:45)

- Optimization Task(0:45 - 4:25)

- Design area (1:01 - 1:17)
- Smoothing area (1:18 - 1:55)
- Design Responses (1:56 - 2:44)
- Objective Function (2:45 - 3:14))
- Geometric Restrictions (3:18 - 4:25)

- Optimization Process and Submission(4:40 - 5:15)

Postprocessing:

- Monitoring Optimization Process (5:16 - 5:49)

- Combining Results (5:50 - 6:20)

- Visualization (6:21 - 7:00)

Now You try it!

Setup:

1.  Copy the hub files to your local directory  from the Abaqus installation directory< abaqus_install_dir > \\code\\bin\\SMAExternal\\TOSCA\\abaqus\\examples\\shape\\hub or directly from the Tosca Structure installation< Tosca_structure_install_dir > \\abaqus\\examples\\shape\\hub.
2. Import your model (hub.inp  (not hub_analysis! as in the video))
3. Create a shape optimization task
   • Choose DESIGN_NODES as design area
   • Freeze boundary condition regions
4. Create Mesh smoothing
   • Specify smoothing region (element group SMOOTH)
   • Fix no adjoining node layers
   • Set quality criteria to medium
5. Create necessary design responses
   • Maximum von Mises stress for DESIGN_NODES
6. Create your objective function
   • set target to minimize
   • assign max-mises-stress
7. Create geometric restrictions
   • Rotational symmetry with axis in direction (1,0,0),
     apply to DESIGN_NODES,
     120 degree repeating pattern
   • Node fixations in all 3 static directions for node group FIX
8. Create Optimization process
   • assign optimization task
   • define settings
   • submit

Postprocessing:

1. Monitor your results
   • Check objective function values, plot
2. Combine your results
   • Choose relevant results for visualization
3. Switch to visualization
   • Navigate through optimization cycles
   • View optimization displacement (DISP_OPT)
   • Check stress distribution

References

Getting started with shape optimization
(e-Learning session - general overview on shape optimization with Tosca Structure)

Getting started with topology optimization
(e-Learning session - general overview on topology optimization with Tosca Structure)

Efficient Design Optimization in Your CAE Environment
(eSeminar recording - basic overview on Tosca Structure)