Optimization of an additive manufactured combustion unit using Tosca and Abaqus

The combustion unit consists of several parts, such as the cylinder head, valves, liner and crankcase. These parts are subjected to complex mechanical and thermal loadings due to the combustion process of a reciprocating engine. Particularly the cylinder head is a very complex geometry consisting of a water jacket, intake and exhaust ports. With Additive Manufacturing casting restrictions can be overcome and new cooling concepts can be designed. In this context, Tosca was used for topology and shape optimization. This presentation gives an overview about the methodologies used for optimizing and analyzing the additive manufactured combustion unit with Finite Element Method using Tosca and Abaqus. It will be shown and discussed which boundary conditions were considered for topology optimization of the cylinder head as well as the approach for shape optimization of parts in terms of fatigue life.

Presenter: Johannes GRIMMINGER, Rolls-Royce Solutions GmbH

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Non-parametric optimization with multiphysics objectives

The electromagnetic forces are the root cause for propulsion and vibrations of an electrical machine and thus, contribute to the overhaul noise and vibration of e.g. an electrical vehicle. Non-parametric optimization can help to reduce the noise and vibration level by means of shape optimization during the design of the rotor. Changing the shape of the rotor not only influences the electromagnetic field but also the structural performance. Thus, structural constraints are needed in the optimization process to ensure integrity of the electrical machine during the entire lifecycle including overload conditions. A shape optimization example is shown with objectives and constraints coming from electromagnetics and structural simulation combining Tosca, CST Studio Suite and Abaqus.

Presenter: Martin SCHULZ, Dassault Systèmes

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Preform Design Optimization

PET (Polyethylene terephthalate) bottle manufacturers typically demand preform designs for a family of bottles of different bottle volumes whilst the neck diameter being the same. In such instances the preform designers face the challenge of coming up with optimum shape and thickness distribution to make best use of PET stretchability characteristics as well as obtain end bottles that are acceptable both In terms of mechanical performance and aesthetics. One of the typical preform design problems is the ring-like formation (material accumulation) in PET bottles. In this work, a historically problematic preform design was considered and GRSM (global response search method) based multi-objective optimization was performed to systematically vary the preform design parameters and obtain an optimized design of the preform that would eliminate the ring-like formation and at the same time reach certain top load criterion.

Presenter: Narendran ANUMULA, ALPLA Werke Alwin Lehner GmbH & Co KG

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Using SIMULIA Isight to speed up valvetrain spring design in motorcycle engine

Searching for optimal valve spring design in combustion engine valvetrain systems is an iterative process. Such a spring must deliver various performance parameters like strength, stiffness, fatigue durability, cost effective design, producibility and all this within limited packaging space. With the help of specialized software tools such process can be fully virtualized. Normally it consists of two stages. Building up the virtual representation of the system and running several loops with modified parameters to find acceptable solution. These simulations run as kinematic models first followed later by dynamic study. All in time domain. After each successfully finished iteration resulting data is postprocessed and system output parameters are compared to satisfactory criteria. For example, performance across whole engine speed spectrum, fatigue life and supplier specific conditions are often significantly limiting the count of optimal spring designs. Finding acceptable solution may thus become a job for experienced engineer only. Simulia Isight can significantly support this iterative process in two ways. First it can cut down iteration postprocessing duration. Secondly it improves the quality how design variables are handled inside design space from one iteration to another also in multi-objective tasks definition. Based on our experience time saving achieved in iteration process is reasonable in comparison with manual progress of experienced engineer but grows with less engineering experience level. This presentation shows important development factors of motorcycle valvetrain mechanism, highlights the role of SIMULIA Isight in the iteration process and summarizes the value added in technical, time and cost domain.

Presenter: Pavel GONDA, Ricardo GmbH

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