Tosca Structure 810

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www .3ds. com/ tosca V e rs ion 8 .1. 0 Rev . 1 - 05. 201 4

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V e rs ion 8 .1 .0 Rev . 1 - 05. 201 4 www .3ds. com/ tosca V e rs ion 8 .1. 0 Rev . 1 - 05. 201 4

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This work is protected by copyright. All rights are reserved. This especially applies to the translation, reproduction, presentation, use of illustrations and tables, electronic broadcast, transfer to microfilm or any other kind of duplica-tion or stored in an informaduplica-tion retrieval system, even as excerpts. Reproduc-tion of this work in part or whole for personal use is also only allowed as specified in the legal context of the current copyright laws of the Federal Republic of Germany from September 9, 1965. Reproduction is always sub-ject to compensation. The guidelines set by the Council of the European com-munity from May 14, 1991 regarding the protection of computer programs are applicable. Violations will be prosecuted under the conditions of the copyright law.

Copyright

©

Tosca Structure is a registered trademark of FE-DESIGN GmbH. All other products and product names are the property of their respective owners.

Karlsruhe, May 2014 FE-DESIGN GmbH Albert-Nestler-Straße 17 76131 Karlsruhe +49 (0) 721-96467-250 [email protected] www.fe-design.com

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Tosca Structure makes use of several software components of Ceetron AS. to provide certain features.

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.3ds. com/ tosca V e rs ion 8 .1. 0 Rev . 1 - 05. 201 4

SIMULIA Tosca Structure Documentation 8.1

General Remarks

0-i

Volume I

Start Manual

Preface

1-3

1 Getting Started with Tosca ANSA environment

1-5

1.1 User Interface . . . 1-6

1.1.1 General Buttons toolbar 1-8

1.1.1.1 FOCUS panel 1-9

1.1.1.2 VISIBILITY panel 1-10

1.1.2 Database and selection windows 1-11

1.1.3 Task Manager window 1-13

1.1.4 Input of an existing parameter file 1-14

1.1.5 Saving task and saving database 1-15

1.1.6 Highlighting 1-15

1.1.7 Input and output using Task Manager 1-18

1.1.8 Input and output using the main menu 1-19

1.1.9 Modules Buttons window 1-20

1.1.10 Selecting and deselecting the geometric objects 1-20

1.1.10.1 Selecting single objects 1-21

1.1.10.2 Box selection 1-21

1.1.10.3 Polygon area selection 1-22

1.1.11 View control 1-23

1.1.11.1 Rotating 1-23

1.1.11.2 Translating 1-24

1.1.11.3 Zooming 1-24

1.1.11.4 Faster view selection 1-24

1.1.11.5 Function keys related to view control 1-25

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V e rs ion 8 .1 .0 Rev . 1 - 05. 201 4 www .3ds. com/ tosca V e rs ion 8 .1. 0 Rev . 1 - 05. 201 4 1.1.13 Managing Groups 1-26

1.1.13.1 SET HELP window 1-26

1.1.13.2 Selection of objects in group selection mode 1-27 1.1.13.3 List of Tosca Structure commands with groups 1-30 1.1.14 Configuration of Tosca ANSA environment 1-31

1.2 Topology Optimization with Tosca ANSA environment . . . 1-33

1.2.1 What is Topology Optimization? 1-33

1.2.2 The Model 1-34

1.2.3 Optimization Task 1-37

1.2.4 Step by Step Manual: Summary 1-37

1.2.5 Preprocessing 1-38

1.2.5.1 Choice of the optimization type 1-38

1.2.5.2 Loading the input model file 1-39

1.2.5.3 Choice of the design area 1-40

1.2.5.4 Choice of the design constraints 1-43 1.2.5.5 Choice of the objective function 1-45

1.2.5.6 Choice of the constraints 1-46

1.2.5.7 Saving Tosca Structure parameter file 1-47

1.2.6 Start Optimization 1-48

1.2.6.1 Start Tosca Structure 1-48

1.2.6.2 Logging and monitoring 1-48

1.2.7 Postprocessing 1-48

1.2.8 Report Generation 1-50

1.2.9 Result Transfer and Validation Run (Smooth) 1-55

1.2.9.1 Generating smooth surface 1-55

1.2.9.2 Modifying the surface using RECONSTRUCT 1-57

1.2.9.3 Remeshing the model 1-58

1.2.9.4 Saving the resulting model in solver format 1-59 1.2.9.5 Running the solver with the new model 1-60 1.2.9.6 Saving the resulting model in solver format (alternative) 1-60 1.2.9.7 Running the solver with the new model (alternative) 1-61

1.2.10 Result Discussion 1-61

1.3 Shape Optimization with Tosca ANSA environment . . . 1-67

1.3.1 What is Shape Optimization? 1-67

1.3.2 The Model 1-68

1.3.5.3 Selection of mesh smoothing elements 1-74

1.3.5.4 Choice of design area 1-78

1.3.5.5 Choice of design variable constraint 1-82 1.3.5.6 Choice of the objective function 1-84

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1.3.6 Node Displacement Check (Check Inputs) 1-87

1.3.7.3 Viewing the results in the optimized model 1-91

1.3.10 Result transfer (Smooth) 1-100

1.3.12 Extensions 1-104

1.3.12.1 Design variable constraints 1-104

1.3.12.2 Define a volume constraint 1-107

1.3.12.3 Redefine the global stop condition 1-108 1.3.12.4 Selecting mesh smooth elements automatically 1-108

1.3.13 Troubleshooting 1-110

1.3.13.1 Suggestions in case of mesh problems 1-110

1.4 Bead Optimization with Tosca ANSA environment . . . 1-113

1.4.1 What is Bead Optimization? 1-113

1.4.1.1 Tosca Structure.bead 1-115

1.4.2 The Model 1-115

1.4.5.4 Choice of the objective function 1-123

1.4.5.5 Choice of the constraint 1-124

1.4.5.6 Optimization settings 1-126

1.4.5.7 Saving Tosca Structure parameter file 1-126 1.4.6 Node Displacement Check (Check Inputs) 1-127

1.4.7.3 Viewing the results in the optimized model 1-131

1.4.10 Result Transfer (Smooth) 1-140

1.5 Sizing with Tosca ANSA environment . . . 1-145

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V e rs ion 8 .1 .0 Rev . 1 - 05. 201 4 www .3ds. com/ tosca V e rs ion 8 .1. 0 Rev . 1 - 05. 201 4 1.5.2 Model 1-146 1.5.3 Optimization Task 1-148

1.5.5.4 Choice of thickness bounds (design variable constraint)1-155

1.5.5.5 Optional: Cluster groups 1-157

1.5.5.7 Choice of the constraint 1-159

2 Getting Started with Tosca Structure.gui

1-171

2.1 User interface. . . 1-171

2.1.1 Requirements, Settings and Program Start 1-171

2.1.2 Tosca Structure.pre 1-172

2.1.2.1 Overview 1-173

2.1.2.2 Creating, modifying and saving parameter files 1-174

2.1.2.3 Defining optimization tasks 1-177

2.1.2.4 Simplifications for the user 1-180

2.1.3 Starting the Optimization 1-183

2.1.4 Tosca Structure.smooth 1-185

2.1.5 Visualization with Tosca Structure.view 1-186 2.1.6 Postprocessing (Tosca Structure.report) 1-186

2.2 Topology Optimization with Tosca Structure.gui . . . 1-189

2.2.1 What is Topology Optimization? 1-189

2.2.2 The Model 1-190

2.2.5.1 Starting Tosca Structure Preprocessor 1-194

2.2.5.3 Group creation (Nastran users only) 1-196

2.2.5.4 Define the design area 1-198

2.2.5.5 Choice of the design variable constraints 1-198

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2.2.5.9 Definition of the optimization task 1-204 2.2.5.10 Saving Tosca Structure parameter file 1-206

2.2.9 Result Transfer and Validation Run 1-215

2.2.9.1 Surface generation using Tosca Structure.smooth. 1-216 2.2.9.2 Processing the optimized structure 1-217

2.3 Shape Optimization with Tosca Structure.gui . . . 1-223

2.3.1 What is Shape Optimization? 1-223

2.3.2 The Model 1-224

2.3.5.4 Select design area 1-234

2.3.5.5 Definition of design responses 1-234

2.3.5.6 Choice of the design variable constraint 1-236 2.3.5.7 Choice of the objective function 1-237

2.3.5.8 Select mesh smoothing elements 1-238

2.3.5.9 Definition of the optimization task 1-238

2.3.5.10 Define a stop condition 1-240

2.3.6 Check Inputs 1-241

2.3.6.1 TEST_SHAPE 1-241

2.3.6.2 Starting the test optimization 1-242

2.3.6.3 Viewing the test results 1-242

2.3.7 Start Optimization 1-246 2.3.8 Postprocessing 1-247 2.3.9 Report Generation 1-249 2.3.10 Result Transfer 1-257 2.3.11 Result Discussion 1-260 2.3.12 Extensions 1-260

2.3.12.1 Design variable constraints 1-260

2.3.12.2 Define a volume constraint 1-264

2.3.12.3 Updating the optimization task 1-266 2.3.12.4 Redefine the global stop condition 1-267 2.3.12.5 Selecting mesh smooth elements automatically 1-268

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2.3.13.1 How to workaround mesh problems? 1-269

2.4 Bead Optimization with Tosca Structure.gui . . . 1-271

2.4.1 What is Bead Optimization? 1-271

2.4.1.1 Tosca Structure.bead 1-273

2.4.2 Model 1-273

2.4.5.4 Select design area 1-281

2.4.5.7 Create bead height constraint 1-284

2.4.5.9 Optimization settings 1-286

2.4.6 Check Inputs 1-287

2.4.6.1 TEST_BEAD 1-288

2.4.6.2 Starting the test optimization 1-288

2.4.6.3 Viewing test results 1-290

2.4.8.1 Result Transfer 1-296

2.5 Sizing Optimization with Tosca Structure.gui. . . 1-305

2.5.1 What is Sizing Optimization? 1-305

2.5.2 Model 1-306

2.5.5.3 Define the design area 1-311

2.5.5.4 Choice of thickness bounds (design variable constraint)1-313

2.5.5.5 Optional: Cluster groups 1-314

2.5.5.9 Definition of the optimization task 1-320 2.5.5.10 Saving Tosca Structure parameter file 1-322

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.3ds. com/ tosca V e rs ion 8 .1. 0 Rev . 1 - 05. 201 4 2.5.7 Postprocessing 1-324 2.5.8 Report Generation 1-326 2.5.9 Result Discussion 1-332

3 Getting Started with Tosca Extension for ANSYS/WB

1-335

3.1 User Interface . . . 1-335

3.1.1 Buttons 1-337

3.1.2 Handling Tips 1-339

3.2 Topology Optimization with Tosca Extension for ANSYS/WB. . . 1-347

3.2.1 The model 1-347

3.2.2 Loading the Extension 1-347

3.2.3 Example files 1-348

3.2.4 Preparing the model 1-349

3.2.5 Optimization preprocessing 1-357

3.2.6.1 Optimization result view options 1-363

3.2.6.2 Iteration Animation 1-364

3.2.7 Validation Run 1-365

3.3 Shape Optimization with Tosca Extension for ANSYS/WB . . . 1-371

3.3.1 The model 1-371

3.3.2 Loading the extension 1-374

3.3.3 Example files 1-374

3.3.4 Preparing the model 1-375

3.3.5 Optimization preprocessing 1-384

3.3.6.1 Optimization result view options 1-391

3.3.6.2 Iteration Animation 1-391

Volume II

User Manual

Preface

2-3

1 Overview of Tosca Structure

2-5

1.1 The Tosca Structure Modules . . . 2-5

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1.1.2 Tosca ANSA environment 2-6

1.1.3 Tosca Structure.gui 2-6

1.1.4 Tosca Extension for ANSYS/WB 2-6

1.1.5 Tosca Structure optimization modules 2-7

1.1.6 Tosca Structure.report 2-7

1.1.7 Tosca Structure.view 2-7

1.1.8 Tosca Structure.smooth 2-7

1.2 Overview of the Optimization Process . . . 2-8

1.2.1 Planning 2-8

1.2.2 Preprocessing: Model generation 2-8

1.2.3 Check Run 2-9

1.2.4 Optimization Loop 2-9

1.2.5 Postprocessing: Evaluation of Optimization results 2-10

1.3 Workflow for Optimization . . . 2-11

2 Working with Tosca Structure

2-13

2.1 Working with Tosca ANSA environment . . . 2-13

2.1.2 Check Run 2-15

2.2 Working with the Graphical User Interface Tosca Structure.gui . . 2-17

2.3 Working with Tosca Extension for ANSYS/Workbench . . . 2-22

2.4 Working with Tosca Structure in the Command Shell . . . 2-26

2.4.1 Logging in command shell 2-27

2.4.4 Start optimization 2-28

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.3ds. com/ tosca V e rs ion 8 .1. 0 Rev . 1 - 05. 201 4 2.4.6 Result Transfer 2-29

3 The Model

2-31

3.1 Models for Optimization. . . 2-31

3.1.1 Models for topology optimization 2-31

3.1.2 Models for shape optimization 2-32

3.1.3 Models for bead optimization 2-32

3.1.4 Models for sizing 2-33

3.2 Optimizable Element Types. . . 2-33

3.3 Preprocessing FE Models for Optimization . . . 2-34

3.3.1 Abaqus/CAE 2-35

3.3.2 Preprocessing with ANSYS/Prep7 2-35

3.3.2.1 Generation of the finite element input file 2-35

3.3.2.2 Load cases 2-36

3.3.2.3 Check of the batch input file 2-36

3.3.2.4 Generation of groups 2-37

3.3.3 Preprocessing with ANSYS Workbench 2-37

3.3.3.1 Export of finite element input model 2-37

3.3.3.2 Generation of groups 2-38

3.3.3.3 Suitable meshes for topology optimization 2-40

3.4 Loading FE Data . . . 2-41

3.4.1 Analysis Files for Optimization (FEM_INPUT) 2-42

3.4.2 LIFE_FILE 2-44

3.4.3 TEMPERATURE_FILE 2-44

3.4.4 ADD_FILE 2-44

3.4.5 COPY_FILE 2-45

3.4.6 Special FEM_INPUT-commands 2-45

3.4.7 Options for loading FE Data (OPTIONS) 2-46 3.4.7.1 Loading displacement restrictions 2-46 3.4.7.2 Identifying surface nodes for shape optimization 2-47

3.5 Include Files . . . 2-47

3.6 Group Definition (

GROUP_DEF

,

GROUP_AUTO_DEF

) . . . 2-47

3.6.1 Default predefined groups 2-48

3.6.2 Group definition in Tosca ANSA environment 2-48 3.6.3 Group definition in Tosca Extension for ANSYS/WB 2-49 3.6.4 Manual group definition in Tosca Structure.gui 2-49 3.6.5 Automatic node group definition (GROUP_AUTO_DEF) 2-50

3.7 Selection of Objects in Tosca Structure.gui. . . 2-53

3.8 Coordinate Systems (

CS_DEF

) . . . 2-59

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3.8.2 Definition by coordinates of three points 2-63 3.8.3 Definition by origin and rotation angles 2-66 3.8.4 General remarks about coordinate systems 2-67

3.9 Solids (Geometric Primitives). . . 2-68

3.9.1 Definition in Tosca ANSA environment 2-68

3.9.2 Definition in Tosca Structure.gui 2-69

4 Terms for Optimization

2-71

4.1 Overview . . . 2-71

4.1.1 Mathematical formulation 2-72

4.2 Objective Function . . . 2-72

4.2.1 Overview 2-73

4.2.2 Minimization or maximization of an objective function 2-75 4.2.3 Multidisciplinary objectives (minmax formulation) 2-76

4.3 Constraints . . . 2-79

4.4 Design Responses . . . 2-83

4.4.1 Compliance (Stiffness Optimization) 2-87

4.4.1.1 Compliance example 2-88

4.4.2 Energy stiffness measure 2-92

4.4.2.1 Example for energy stiffness measure 2-95

4.4.3 Displacement and rotation 2-97

4.4.3.1 Example of a displacement design response 2-98

4.4.4 Reaction force 2-102

4.4.4.1 Example of reaction force design response 2-103

4.4.5 Internal force 2-105

4.4.5.1 Example internal force 2-107

4.4.6 Eigenfrequency 2-109

4.4.6.1 Eigenvalue example 2-111

4.4.6.2 Mode tracking 2-114

4.4.7 Equivalent stress 2-114

4.4.8 Stress in topology optimization 2-118

4.4.8.1 Example: Stresses in objective function 2-123 4.4.8.2 Example: Stresses in constraint definition 2-125

4.4.9 Center of gravity 2-127

4.4.10 Moment of inertia 2-131

4.4.11 Volume 2-135

4.4.11.1 Volume design response example 2-135

4.4.12 Weight 2-137

4.4.12.1 Example of a weight design response 2-137

4.4.13 DENSITY_MEASURE 2-139

4.4.14 Bead height 2-142

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4.5.1 Group operations for design responses 2-144

4.5.1.1 Group Operations for Stresses 2-145

4.5.1.2 Group Operations for Stiffness 2-145

4.5.1.3 Group Operations for Displacements 2-146 4.5.1.4 Group operations for reaction forces/moments 2-152 4.5.1.5 Group Operations for Internal Forces 2-156

4.5.2 Load case combination and selection 2-160

4.5.2.1 Load case specification (LC_SET) 2-160 4.5.2.2 Selection criteria for load cases (LC_SEL) 2-164

4.5.3 Design response combination 2-165

4.5.3.1 Combined responses in sensitivity based optimization 2-167 4.5.3.2 Combining design responses (Tosca ANSA environment)2-171 4.5.3.3 Combining displacements and rotations 2-174 4.5.3.4 Combining reaction forces and internal forces 2-175 4.5.3.5 Combining absolute values of responses 2-176 4.5.3.6 Controller based combined terms 2-176 4.5.3.7 Other operators for controller based shape optimization2-178

4.6 Logging and Monitoring . . . 2-178

5 Topology Optimization

2-179

5.1 General Information. . . 2-179

5.2 The Optimization Task. . . 2-180

5.2.1 Controller versus sensitivity based topology optimization 2-181

5.2.2 How to create the optimization model 2-183

5.3 Design Area. . . 2-186

5.3.1 Design variables 2-186

5.3.1.1 Results from previous runs as initial material distribution2-188 5.3.2 Manufacturing conditions and geometrical restrictions 2-189

5.3.2.1 Frozen areas 2-190

5.3.2.2 Prevention of undercuts in the model 2-192 5.3.2.3 Tightness constraint for the resulting structure 2-199

5.3.2.4 Stamping restriction 2-203

5.3.2.5 Minimum truss thickness (minimum member size) 2-203 5.3.2.6 Maximum truss thickness (maximum member size) 2-207

5.3.2.7 Symmetry conditions 2-210

5.3.2.8 Combination of manufacturing restrictions 2-215 5.3.2.9 Tips on defining restrictions with Tosca Structure.gui 2-216

5.4 Objective Function. . . 2-217

5.4.1 Overview 2-217

5.4.2 Minimization or maximization of an objective 2-217 5.4.3 Multidisciplinary objective (minmax formulation) 2-219

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5.6 Typical Tasks for Static Analysis . . . 2-226

5.6.1 Minimizing compliance under volume constraint 2-226 5.6.2 Minimizing displacement/rotation under volume constraint 2-228 5.6.3 Constraint for difference between two displacements 2-235 5.6.4 Minimization of a reaction or internal force 2-240 5.6.5 Minimization of the volume under displacement constraint 2-250 5.6.6 Minimize the maximum stress with volume constraint 2-254 5.6.7 Minimize the material volume with stress constraint 2-256

5.7 Typical Optimization Tasks for Modal Analysis . . . 2-257

5.7.1 Maximization of the first eigenfrequencies 2-258 5.7.2 Maximizing the eigenfrequency of a certain eigenmode 2-262

5.7.3 Maximization of the band gap 2-267

5.7.4 Constraining an eigenfrequency 2-270

5.8 Settings . . . 2-273

5.8.1 Parameters for standard linear static topology optimization 2-273 5.8.1.1 Increments of volume modification (SPEED) 2-273 5.8.1.2 Volume reduction in first iteration (START_DELETE) 2-274

5.8.1.3 Tips on speed control 2-274

5.8.1.4 Relation between relative density and stiffness 2-274 5.8.2 Settings for the general sensitivity based optimization 2-276

5.8.2.1 Mode tracking 2-276

5.8.2.2 Initial values of density 2-278

5.8.2.3 Removing soft elements for increasing performance 2-279 5.8.2.4 Limits for design variables and changes 2-285 5.8.2.5 Update strategy of the method of moving asymptotes 2-286

5.8.2.6 Settings of the mesh filter 2-287

5.8.2.7 FILTER_TYPE 2-288

5.8.2.8 Material interpolation 2-289

5.9 Stop Condition . . . 2-292

5.9.1 Convergence Criteria 2-292

5.9.1.1 Stop criterion: change in objective function 2-293 5.9.1.2 Stop criterion: change in element densities 2-293 5.9.1.3 Start iteration for convergence check 2-294 5.9.2 Global Stop Criterion (Number of iterations) 2-294

5.10 References. . . 2-295

6 Shape Optimization

2-297

6.1 General Information . . . 2-297

6.1.1 Theoretical background 2-298

6.2 The Optimization Task . . . 2-298

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6.3.1 Design variables (DV_SHAPE) 2-302

6.3.2 Mesh smoothing (MESH_SMOOTH) 2-305

6.3.2.1 Element group for mesh smoothing 2-306 6.3.2.2 Fixation of free surface nodes (FREE_SF) 2-309 6.3.2.3 Fixation of the MESH_SMOOTH area boundary 2-311 6.3.2.4 Automatic MESH_SMOOTH area (MS_LAYER) 2-311 6.3.2.5 Convergence of the smoothed mesh (LEVEL_CONV) 2-312 6.3.2.6 Enforcing restrictions (LEVEL_DVCON) 2-313 6.3.2.7 Quality control and improvement (LEVEL_QUAL) 2-313 6.3.2.8 Quality criteria of the solver (SOLVER_CHECK) 2-316 6.3.2.9 Correction of distorted elements (CORRECT_ELEMENTS)

2-317

6.3.2.10 Mesh smooth strategy (STRATEGY) 2-318 6.3.2.11 Definition in Tosca ANSA environment 2-319

6.3.3 Restrictions (DVCON_SHAPE) 2-320

6.3.3.1 Node group for design variable constraints 2-322 6.3.3.2 Restricting the amount of displacement 2-323 6.3.3.3 Minimum or maximum member size 2-324 6.3.3.4 Displacement check against solids (CHECK_SOLID) 2-326 6.3.3.5 Penetration check (CHECK_ELGR, PENETRATION_CHECK)

2-328

6.3.3.6 Restricting displacement directions (CHECK_BC, CHECK_DOF) 2-329 6.3.3.7 Restricting displacement to a slide surface 2-330 6.3.3.8 Assigning link/coupling conditions (CHECK_LINK) 2-333 6.3.3.9 Definition in Tosca ANSA environment 2-334 6.3.3.10 Definition in Tosca Structure.gui 2-334

6.3.3.11 Command syntax 2-334

6.3.4 Link and coupling conditions (LINK_SHAPE) 2-336 6.3.4.1 Determining the master node (MASTER) 2-338 6.3.4.2 Displacement of the client nodes (CLIENT) 2-340

6.3.4.3 Plane symmetry (PLANE_SYM) 2-342

6.3.4.4 Plane symmetry for non-symmetric meshes

(SURF_PLANE_SYM) 2-343

6.3.4.5 Cyclic symmetry for non-symmetric meshes

(SURF_CYCLIC_SYM) 2-344

6.3.4.6 Cyclic-plane symmetry combination

(SURF_CYCLIC_PLANE_SYM) 2-345

6.3.4.7 Point symmetry (POINT_SYM) 2-347

6.3.4.8 Rotational symmetry (ROTATION_SYM) 2-348 6.3.4.9 Coupling displacement coordinates (VECTOR) 2-349 6.3.4.10 Coupling displacement direction (DIRECTION) 2-350 6.3.4.11 Coupling amount of displacement (LENGTH) 2-351 6.3.4.12 Coupling coordinates in the FE displacement coordinate system

(DISP_CS) 2-352 6.3.4.13 Stampable surface (SURF_STAMP) 2-352

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6.3.4.14 Turnable surface (SURF_TURN) 2-353

6.3.4.15 Drillable surface (SURF_DRILL) 2-354 6.3.4.16 Demoldable surface (SURF_DEMOLD) 2-354

6.3.4.17 Command examples 2-357

6.4 Objective Function . . . 2-358

6.4.2 Reference stress 2-359

6.4.3 Objective function terms 2-360

6.5 Constraints . . . 2-362

6.5.1 Volume constraint 2-362

6.5.2 Weight constraint 2-364

6.6 Typical Optimization Tasks for Static Analysis . . . 2-364

6.6.1 Minimization of maximum equivalent stress 2-364 6.6.2 Notch optimization with fixed reference value 2-367 6.6.3 Notch relief with variable reference value 2-369

6.7 Advanced Tosca Structure.shape Optimizations . . . 2-371

6.7.1 Highly nonlinear shape optimization 2-371

6.7.2 Minimization of contact pressure 2-373

6.8 Settings . . . 2-376

6.8.1 Scale of displacement (SCALE) 2-377

6.8.2 Treatment of the midside nodes (MID_NODES) 2-378 6.8.3 Curvature based modification of optimization displacements 2-379 6.8.4 Filter function for the optimization displacements (FILTER) 2-380 6.8.5 Updating the optimization displacement vectors (VECTOR) 2-382 6.8.6 Control of the amount of optimization displacement (DISP) 2-383

6.9 Check run (TEST_SHAPE) . . . 2-383

6.9.1 General 2-383

6.9.2 Test run (CHECK_INPUTS) in Tosca ANSA environment 2-384

6.9.3 Test run in Tosca Structure.gui 2-385

6.9.4 Command syntax 2-385

6.10 Morphing . . . 2-387

6.10.1 General 2-388 6.10.1.1 Morphing areas 2-389 6.10.1.2 Morphing displacement 2-392 6.10.1.3 Morphing task 2-393

6.10.2 Morphing in Tosca ANSA environment 2-395

6.10.3 Morphing in Tosca Structure.gui 2-396

6.10.4 Command Syntax 2-396

6.10.6 Evaluation 2-399

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6.11.1 Global Stop Condition 2-400

6.11.2 Local Stop Condition 2-400

6.11.3 Stop Condition in Tosca ANSA environment 2-401 6.11.4 Stop Condition in Tosca Structure.gui 2-402

6.11.5 Examples 2-403

6.12 References . . . 2-404

7 Bead Optimization

2-405

7.1 General Information. . . 2-405

7.2 The Optimization Task. . . 2-406

7.2.1 Controller based bead optimization 2-407

7.2.2 Sensitivity based bead optimization 2-408

7.2.3 Differences between bead optimization algorithms 2-408

7.3 Design Area. . . 2-416

7.3.1 Design variables (DV_BEAD) 2-416

7.3.2 Restrictions (DVCON_BEAD) 2-418

7.3.2.1 General 2-418

7.3.2.2 Restricting the absolute displacement 2-420 7.3.2.3 Displacement check against solids (CHECK_SOLID) 2-422 7.3.2.4 Displacement check against elements (CHECK_ELGR)2-423 7.3.2.5 Restricting the direction of displacement 2-424 7.3.2.6 Symmetry conditions (CHECK_LINK) 2-425

7.3.2.7 Example LINK_BEAD 2-426

7.4 Objective Function. . . 2-428

7.5 Typical Optimization Tasks for Linear Static Analysis . . . 2-430

7.5.1 Maximize stiffness with controller based algorithm 2-430 7.5.1.1 Combining static load cases (controller based algorithm)2-431 7.5.2 Linear static sensitivity based optimization 2-432

7.5.2.1 Minimize compliance 2-432

7.6 Typical Optimization Tasks for Modal Analysis . . . 2-433

7.6.1 Maximization of the lowest natural frequency (controller) 2-433 7.6.2 Sensitivity based eigenvalue optimization 2-434 7.6.2.1 Maximize the first natural mode (first eigenvalue) 2-434

7.6.2.2 Maximize a range of modes 2-435

7.6.2.3 Maximize a certain mode 2-437

7.6.2.4 Adjust eigenvalue 2-438

7.6.2.5 Maximize band gaps 2-439

7.7 Constraints . . . 2-440

7.8 Settings . . . 2-441

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7.8.1 Parameters for controller based bead optimization 2-444 7.8.1.1 Scaling of displacements (SCALE) 2-445 7.8.1.2 Update of optimization displacement vectors (VECTOR)2-445

7.8.1.3 Bead width (BEAD_WIDTH) 2-445

7.8.1.4 Number of iterations (BEAD_ITER) 2-446 7.8.1.5 Penalty conditions (BEAD_MIN_STRESS and

BEAD_MAX_MEMBRANE) 2-446

7.8.1.6 Mesh enhancing parameters

(CURV_SMOOTH and BEAD_NODE_SMOOTH) 2-448 7.8.2 Optimization parameters (sensitivity based bead optimization) 2-449

7.8.2.1 Filtering (FILTER_RADIUS) 2-449

7.8.2.2 MMA parameters 2-449

7.8.2.3 Optimization parameters for mode tracking 2-450 7.8.2.4 Optimization parameters for frequency response 2-450

7.9 Check run (TEST_BEAD) . . . 2-451

7.10 Stop Condition . . . 2-455

7.11 Special Remarks Using Sensitivity Based Algorithm . . . 2-456

7.12 References. . . 2-458

8 Sizing Optimization

2-459

8.1 General Information . . . 2-459

8.2 The Optimization Task . . . 2-460

8.3 Design Area . . . 2-463

8.3.1 Design variables 2-463

8.3.2 Manufacturing conditions and geometrical restrictions 2-465

8.3.2.1 Frozen areas 2-466

8.3.2.2 Shell thickness bounds 2-467

8.3.2.3 Cluster groups 2-469

8.3.2.4 Width control (minimum cluster width) 2-471 8.3.2.5 Definition of symmetry conditions 2-473

8.3.2.6 Tips on defining restrictions 2-476

8.4 Objective Function . . . 2-477

8.4.2 Minimization or maximization of an objective 2-477 8.4.3 Multidisciplinary objective (minmax formulation) 2-479

8.5 Constraints . . . 2-481

8.6 Typical Tasks for Static Analysis . . . 2-483

8.6.1 Minimizing mass with stiffness restrictionst 2-483

8.7 Typical Optimization Tasks for Modal Analysis . . . 2-486

8.7.1 Maximization of the first eigenfrequencies 2-487 8.7.2 Maximizing the torsional modal eigenfrequency 2-491

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8.8 Settings . . . 2-495

8.8.1 Mode tracking 2-495

8.8.2 Update strategy of the method of moving asymptotes 2-497

8.8.3 Settings of the mesh filter 2-498

8.8.4 FILTER_TYPE 2-499

8.9 Stop Condition . . . 2-499

8.9.1 Convergence Criteria 2-499

8.9.1.1 Stop criterion: change in objective function 2-500 8.9.1.2 Stop criterion: change in element thickness 2-500 8.9.1.3 Start iteration for convergence check 2-501 8.9.2 Global Stop Criterion (Number of iterations) 2-501

9 Result Transfer and Validation Run

2-505

9.1 Tosca Structure.smooth . . . 2-505

9.1.1 Starting Tosca Structure.smooth (Tosca ANSA environment) 2-506 9.1.2 Starting Tosca Structure.smooth (Tosca Structure.gui) 2-507 9.1.3 Starting Tosca Structure.smooth (Tosca Extension for ANSYS/

Workbench)2-508

9.1.4 Defining the parameters for Tosca Structure.smooth 2-510 9.1.5 Processing results of topology optimization 2-516 9.1.6 Processing results from shape or bead optimization 2-519

9.1.7 Isosurface and smoothing parameters 2-520

9.1.8 Reduction parameters 2-525

9.1.9 Output parameters 2-529

9.1.10 Slices through 3D models and border of 2D models 2-533

9.1.11 Processing of groups 2-536

9.1.12 Volume control 2-538

9.1.13 Correction of defects in topology optimization results 2-540

9.2 Validation Run in Tosca ANSA environment . . . 2-544

9.2.1 BATCH_RECONSTRUCT and MANUAL_RECONSTRUCT 2-545

9.2.2 SOLID_MESH 2-549

9.2.3 Generating the model for validation run 2-549

9.2.4 Starting the validation run 2-552

9.3 Validation Run in Tosca Extension for ANSYS/Workbench . . . . 2-553

9.4 Workarounds Using Other Environments . . . 2-561

9.5 Result Transfer . . . 2-562

9.5.1 Result transfer to CATIA RSO module 2-562

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10 Postprocessing of Optimization Results

2-565

10.1 Generation of Postprocessing Data . . . 2-565

10.1.1 Tosca Structure.report in Tosca ANSA environment 2-566 10.1.2 Tosca Structure.report in Tosca Structure.gui 2-568 10.1.3 Tosca Structure.report in Tosca Extension for ANSYS/Workbench

2-571

10.1.4 Starting Tosca Structure.report in Commandline 2-573

10.1.5 Standard Reports 2-574

10.1.5.1 Tosca Structure.topology results 2-574

10.1.5.2 Tosca Structure.shape results 2-575

10.1.5.3 Tosca Structure.bead results 2-577

10.1.5.4 Tosca Structure.sizing results 2-577

10.1.5.5 Morphing results 2-578

10.1.5.6 Sensitivity plots 2-579

10.2 Tosca Structure.view . . . 2-580

10.2.1 Starting and using Tosca Structure.view 2-580

10.2.2 User Interface Tosca Structure.view 2-582

10.2.3 Model and group visualization 2-588

10.2.4 Visualization of topology optimization results 2-591 10.2.5 Visualization of shape optimization results 2-592 10.2.6 Visualization of bead optimization results 2-594

10.2.7 Visualization of sizing results 2-595

10.2.8 Visualization of morphing results 2-596

10.2.9 VTFX PlugIn for Office applications and Webbrowser 2-596 10.2.9.1 Prerequisites and installation 2-596 10.2.9.2 Embedding the PlugIn into PowerPoint 2-597 10.2.10Integrating VTFX files in internet pages 2-599

10.2.11Limitations of the PlugIn 2-600

10.3 Postprocessing with Tosca Extension for ANSYS/Workbench . . 2-600

10.3.1 Optimization result view options 2-600

10.3.2 Iteration Animation 2-602

10.3.3 Result files 2-603

10.4 Tosca Structure Report Builder. . . 2-603

10.4.1 Capturing Data for the Report 2-604

10.4.2 Report generation 2-606

10.4.3 Add-Ins for Tosca Structure Report Builder 2-607

10.4.3.1 Add-in for MS Word 2-608

10.4.3.2 Add-in for MS Powerpoint 2-609

10.4.3.3 Templates 2-610

10.5 Toolbox for Postprocessing . . . 2-611

10.5.1 Numerical variables (VARIABLE) 2-611

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10.5.3 Stop conditions (STOP) 2-613

10.5.4 User defined output files (USER_FILE) 2-615

10.5.4.1 Tabular output 2-616

10.5.4.2 Modification file for CATIA RSO module 2-616

10.5.4.3 Modification file for NX 2-617

10.5.4.4 ONF output 2-618

11 Solver Specific Features

2-619

11.1 Abaqus . . . 2-622

11.1.1 Files and formats 2-622

11.1.2 Supported element types 2-624

11.1.3 Node and Element Groups 2-630

11.1.4 Coordinate Systems 2-632

11.1.5 Materials and Properties 2-632

11.1.6 Analysis Types 2-635

11.1.7 Loads and Boundary Conditions 2-637

11.1.8 Remarks for sensitivity based optimizations 2-638 11.1.9 Nonsupported Features (Cards/Keywords...) 2-639

11.2 ANSYS . . . 2-639

11.2.1 Files and Formats 2-640

11.2.2 Supported Element Types 2-642

11.2.8 Remarks for sensitivity based optimizations 2-649

11.3 Marc. . . 2-652

11.3.8 Frequency spectrum 2-659

11.4 MSC Nastran . . . 2-659

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11.4.8 Frequency spectrum 2-668

11.5 PERMAS . . . 2-668

11.5.8 Remarks for sensitivity based optimizations 2-676 11.5.9 PERMAS Configuration for use with Tosca Structure 2-676 11.5.10Nonsupported Features (Cards/Keywords...) 2-676

11.5.11Frequency spectrum 2-677

11.6 Shape Optimization Based on a Durability Analysis . . . 2-677

11.6.1 Supported durability solvers 2-677

11.6.2 Workflow 2-678

11.6.2.1 Preprocessing 2-678

11.6.2.2 Optimization loop 2-679

11.6.2.4 Start of the optimization 2-680

11.6.2.5 Postprocessing 2-682 11.6.3 FEMFAT 2-682 11.6.3.1 General 2-682 11.6.4 fe-safe 2-685 11.6.5 ONF 2-687 11.6.5.1 General 2-687

12 Tosca Structure Control

2-689

12.1 Program Sequence and Data Flow of Tosca Structure . . . 2-689

12.2 Starting Tosca Structure . . . 2-691

12.2.1 List of command line options 2-691

12.2.1.1 Deprecated command line options 2-694

12.2.2 General 2-695

12.2.3 Logging 2-695

12.2.3.1 TOSCA.OUT 2-696

12.2.3.2 Special logfiles 2-697

12.2.3.3 Viewing TOSCA.OUT using Tosca ANSA environment 2-698 12.2.3.4 Viewing TOSCA.OUT using Tosca Structure.gui 2-699

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12.2.3.5 Viewing TOSCA.OUT using Tosca Extension for ANSYS/WB2-700

12.2.3.6 Changing logging using the command shell 2-701 12.2.3.7 Tips and tricks viewing TOSCA.OUT 2-701

12.2.4 Solver interface 2-703

12.2.5 Durability interface 2-703

12.2.6 Tosca Structure.report run 2-703

12.2.6.1 Configuring default Tosca Structure.report run 2-704 12.2.7 Automatic Tosca Structure.smooth run 2-704 12.2.7.1 Configuring default Tosca Structure.smooth run 2-705

12.2.8 Testing the optimization process 2-705

12.2.8.1 Test level 1 2-705

12.2.8.2 Test level 2 2-706

12.2.8.3 Test level 3 2-707

12.2.8.4 Test level 4 2-708

12.2.9 Restart modes 2-709

12.2.9.1 Requirements for a restart 2-709

12.2.9.2 Restart process 2-709

12.2.10Online help 2-710

12.2.11Sequential temperature analysis 2-711

12.2.12Arbitrary analysis sequence 2-711

12.3 Configuration . . . 2-712

12.3.1 Configuration files 2-712

12.3.2 Environment variables 2-714

12.4 Script Entry Points . . . 2-715

12.4.1 Adding files to the working directory 2-719

12.5 Optimization Preprocessing (TOSCA_PREP) . . . 2-719

12.5.1 TOSCA_PREP 2-719

12.5.2 Files after preprocessing (TOSCA_PREP) 2-720

12.6 Solver Run. . . 2-720

12.7 Optimization Module (TOSCA_OPT). . . 2-720

12.7.1 RES2VTM 2-721

12.7.2 TOSCA_OPT 2-721

12.7.3 FEM_MODIF 2-721

12.8 Completion of the Optimization Process . . . 2-721

12.8.1 Directories and files after the completion of optimization 2-721

13 Troubleshooting

2-723

13.1 Errors During Optimization . . . 2-723

13.2 Determining the Point of Program Termination . . . 2-724

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13.3 Program Abort at the Start of the Optimization . . . 2-728

13.3.1 Check of program installation and paths 2-728

13.3.2 Analysis files not found 2-730

13.4 Program Abort in TOSCA_PREP. . . 2-731

13.5 Program Abort During FE Analysis . . . 2-733

13.5.1 Error in the analysis model 2-733

13.5.2 Error with the solver license 2-735

13.5.3 Incorrect solver settings 2-735

13.6 Program Abort in the Optimization Module . . . 2-735

13.6.1 FE model of the next iteration is not calculated 2-735

13.6.2 Insufficient disk space 2-737

13.7 Tosca ANSA environment Specific Tips . . . 2-737

14 Appendix

2-741

14.1 Additional Tosca Structure optimization modules . . . 2-741

14.1.1 Tosca Structure.durability 2-741

14.1.2 Tosca Structure.nonlinear 2-741

14.1.3 Tosca Structure.morph 2-742

14.2 Limits of Tosca Structure . . . 2-743

14.3 Predefined Output Macros . . . 2-744

Volume III

Commands Manual

CONFIG

3-3

CONSTRAINT

3-24

CONTOURPLOT

3-26

CS_DEF

3-29

DRESP

3-31

DVCON_AUTO_SHAPE

3-52

DVCON_BEAD

3-53

DVCON_SHAPE

3-55

DVCON_SIZING

3-58

DVCON_TOPO

3-61

DV_BEAD

3-67

DV_SHAPE

3-68

DV_SIZING

3-69

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DV_TOPO

3-70

FEM_INPUT

3-72

GROUP_AUTO_DEF

3-75

GROUP_DEF

3-78

GROUP_IMPORT

3-81

INCLUDE

3-82

LINK_BEAD

3-83

LINK_SHAPE

3-84

LINK_SIZING

3-95

LINK_TOPO

3-97

LIST

3-100

LIST, info

3-106

LOGICAL

3-107

MESH_SMOOTH

3-109

MORPH

3-115

MORPH_AREA

3-117

OBJ_FUNC

3-118

OPTIMIZE

3-120

OPTIONS

3-123

OPT_PARAM

3-129

REPORT

3-143

SELECT

3-146

SF_IDENT

3-153

SMOOTH

3-154

SOLID

3-162

STOP

3-163

TEST_BEAD

3-166

TEST_SHAPE

3-168

USER_FILE

3-170

VARIABLE

3-178

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Volume IV

Examples Manual

Preface

4-3

1 Topology Optimization

4-5

1.1 Example overview . . . 4-5

1.2 Airbeam . . . 4-6

1.2.1 Model 4-6 1.2.2 Optimization Task 4-6 1.2.3 Procedure: Summary 4-7

1.2.4 Procedure in Detail: Tosca ANSA environment 4-7 1.2.5 Procedure in Detail: Tosca Structure.gui 4-7

1.2.6 Results 4-10

1.3 Picker_arm . . . 4-11

1.3.1 Model 4-11

1.3.3 Procedure: Summary 4-11

1.3.6 Optimization results 4-15

1.4 Crane Hook . . . 4-15

1.5 Beam with Symmetry Restrictions (airbeam_sym) . . . 4-21

1.6 Minimum und Maximum Member Size (plate_min_max) . . . 4-26

2 Sensitivity Based Topology Optimization

4-31

2.1 Example overview . . . 4-31

2.2 Crane hook . . . 4-32

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2.2.3 Procedure in detail: Tosca Structure.gui 4-37

2.3 Symmetric Plate (plate_sym_freq) . . . 4-44

2.3.2 Procedure in detail: Tosca ANSA environment 4-45 2.3.3 Procedure in detail: Tosca Structure.gui 4-46

2.4 Bonnet with Minmax Formulation . . . 4-50

2.5 Crankshaft . . . 4-56

2.5.1 The model 4-56

2.5.2 Optimization task 4-57

2.5.3 Optimization task definition in Tosca ANSA environment 4-57 2.5.4 Optimization task definition in Tosca Structure.gui 4-59

2.5.5 Result discussion and validation run 4-62

2.6 Mechanism . . . 4-64

2.7 Internal Forces. . . 4-68

2.7.2 Procedure in detail: Tosca ANSA environment 4-71 2.7.3 Procedure in detail: Tosca Structure.gui 4-72 2.7.4 Optimization results when considering force constraints 4-77

2.8 Temperature Loading . . . 4-78

2.9 Stress Constraint . . . 4-84

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3 Shape Optimization

4-89

3.1 Example overview . . . 4-89

3.2 Holeplate . . . 4-91

3.3 Two Hole (Relief Notch) . . . 4-94

3.4 Shaft . . . 4-98

3.5 Carrier . . . 4-103

3.6 Carrier_stamp . . . 4-108

3.6.4 Optimization result 4-112

3.7 Shaft_turn . . . 4-112

3.8 Shaft_drill . . . 4-117

3.9 Clip . . . 4-122

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3.10 Rim . . . 4-127

3.10.1 The model 4-128 3.10.2 Optimization task 4-128

3.10.5 Result discussion 4-134

3.11 Threehole . . . 4-135

3.12 Hub . . . 4-138

3.12.1 The model 4-139

4 Bead Optimization

4-147

4.1 Example overview . . . 4-147

4.2 Plate . . . 4-148

4.3 Hood . . . 4-152

4.4 Hood_eig and Hood_eig_sens . . . 4-157

4.4.1 Eigenfrequency optimization with Tosca Structure.bead 4-157 4.4.2 Eigenfrequency optimization using controller algorithm 4-158 4.4.3 Eigenfrequency optimization using sensitivity algorithm 4-160

4.4.4 Discussion of differences 4-162

4.5 Holder . . . 4-164

5 Sizing

4-169

5.1 Examples overview . . . 4-169

5.2 Beam2D. . . 4-170

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V e rs ion 8 .1 .0 Rev . 1 - 05. 201 4 www .3ds. com/ tosca V e rs ion 8 .1. 0 Rev . 1 - 05. 201 4 5.2.1 Model 4-170 5.2.2 Optimization Task 4-171 5.2.3 Procedure: Summary 4-171

5.2.6 Results 4-176

5.3 Beam with Symmetry Restrictions (beam_sym) . . . 4-177

6 Shape Optimization in

Combination with Durability Analysis

4-183

6.1 Holeplate_dam: Femfat . . . 4-184

6.2 Holeplate_dam: fe-safe . . . 4-186

7 Morphing

4-189

7.1 Crane hook . . . 4-189

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General Remarks

Documentation Manuals

Tosca Structure documentation is contained in the following manuals: • Getting Started with Tosca Structure (volume 1)

• User Manual (volume 2) • Commands Manual (volume 3) • Examples Manual (volume 4) • Installation Manual

Description of Manuals

A short description and comment of the content of each manual is given below:

Getting Started Manual (volume 1)

This manual gives a compact introduction to Tosca Structure and the work with the frontends Tosca ANSA environment, Tosca Structure.gui and Tosca Extension for ANSYS/Workbench. The set-up, running and evalution of typi-cal optimization tasks for each type of optimization are explained in detail. Thus in particular new users are able to find an access to Tosca Structure quickly and efficiently whereas experienced users can look up detailed descriptions of specific work steps.

User Manual (volume 2)

The main usage of the Tosca Structure functionalities are explained here along with entry of the control instructions required to generate an optimiza-tion model. A descripoptimiza-tion of the individual command syntax is not given, only how they work and interact with each other. The Commands Manual lists a full description of the command syntax.

The User Manual is divided into various parts: firstly, the user receives an overview of the program procedures and the program modules. Require-ments for optimizable finite element models are described.

Next a detailed explanation of the functionalities for topology, shape, bead and sizing optimization is given. Visualization and postprocessing possibilities are also shown. Finally, a description of additional tools and examples of con-trol records for topology, shape, bead and sizing optimization is presented.

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Commands Manual (volume 3)

The Commands Manual is the lexicon of Tosca Structure.topology, Tosca Structure.shape, Tosca Structure.bead and Tosca Structure.sizing. The lexi-con lexi-contains a complete description of all commands used.

Each command and its syntax is listed in alphabetical order with an explana-tion. Cross-references on how to use other commands are also listed here. Most commands are listed with an entry example.

How to use the main functionalities is explained in the Users Manual. Examples Manual (volume 4)

The examples provided with the installation are described in more detail in this manual. Not only does this aid in creating a better understanding of the problems involved in finding a solution, but also gives an understanding of the obtained solutions to the problems.

Reference to Spelling Used in the Manuals

To differentiate between command names, parameters, fixed and open parameter values, several different styles of fonts are used as highlighted in the examples below:

• Command names and parameter labels are always written in capital let-ters.

• Fixed options used for switching parameters are written in capital letters and are also emphasized where necessary.

• Names selected by the user are written in small letters.

• Names which refer to a predefined ID are written in small, cursive letters. • Names which are addressed in detail in the text or which have a special

meaning in context are written in bold letters. • Chosen values are marked in square brackets.

• Tosca ANSA environment buttons and functions are denoted in Courier New.

• Tosca Structure commands and parameters are either linked to the corre-sponding commands manual entry or denoted in Courier New.

• If an action (normally right mouse click) or choice is required, brackets [] are used.

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Examples for Tosca Structure commands: GROUP_DEF

ID_NAME =design_elements--> user name TYPE =ELEM--> given option

FORMAT =SELECTED--> given option END_

DV_TOPO

ID_NAME = dv_design_elements--> user name

EL_GROUP = design_elements--> reference to a group END_

STOP

ID_NAME = stop_condition--> user name ITER_MAX = <value>--> chosen value END_

Examples for Tosca ANSA environment functions:

PRE-PROCESSING| SHAPE_OPTIMIZATION_CONTROLLER | DESIGN_AREA | [EDIT]

In the task manager choose (evtl. open / expand) Folder PRE-PROCESSING, subfolder SHAPE_OPTIMIZATION_CONTROLLER, subfolder DESIGN_AREA, right mouse click and choose EDIT.

Documentation and Introduction to Optimization

The entire content of the documentation is available as context sensitive online help directly accessible from Tosca Structure.gui or the windows start menu.

Further, a printable pdf document can be found under the filename: $tosca/docu/tosca_structure_v810.pdf

The online documentation supports hypertext functions, therefore the naviga-tion through the various manuals is easy and fast.

Acrobat Reader from Adobe or another pdf reader is needed to visualize the pdf document. The reader is available at the internet address http:// www.adobe.com.

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Start Manual

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Preface

This manual demonstrates how to work with the structural optimization pack-age Tosca Structure. In the chapters chapter 1 Getting Started with Tosca ANSA environment, chapter 2 Getting Started with Tosca Structure.gui and chapter 3 Getting Started with Tosca Extension for ANSYS/WB, it is explained how these three different front ends can be used in order to define, start and process the optimization task. The following tutorials demonstrate for all front ends how to set up, run and evaluate typical topology, shape, bead and siz-ing optimization tasks. The step by step explanation contained in the tutorials enables a user inexperienced with Tosca Structure to set up a simple zation task. No emphasis has been placed on details about the single optimi-zation settings. These details are covered in vol.2 User Manual and vol.3 Commands Manual.

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1 Getting Started with Tosca ANSA

environment

Tosca ANSA environment is used in order to define an optimization task for Tosca Structure based on an existing finite element input deck. The finite ele-ment model, including the loads and boundary conditions, is loaded into Tosca ANSA environment, so that the user is able to examine the model in detail. Then, the optimization task is defined by the user step by step. The geometric information represented in Tosca ANSA environment enables the interactive group selection as well as other actions that facilitate the definition of optimization task.

Then, the optimization in Tosca Structure is started from within Tosca ANSA environment using the original finite element model and the optimization task definition. The results of optimization are used in order to create a postpro-cessing model or a model for validation run; the processed optimization results can be saved in a format suitable for CAD transfer.

Please note:

The current version of Tosca ANSA environment does not yet support sizing optimization.

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1.1 User Interface

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The position of different toolbars is configurable. In order to show or hide a specific toolbar or window, use the corresponding command in the menu items Windows, Containers and Tools :

The most important toolbars and windows are the following: • Modules Buttons: provides

the access to optimization task related information defined using Task Manager; it is necessary to use this window for several commands (e.g., defini-tion of a new coordinate system) that are not supported in Task Manager.

• General Buttons: manages the representation of geometry, including the visibility of

elements and nodes; • Ansa Info: window for

logging, warnings and errors; • Settings: configuration dialog; • Database: represents the

contents of the finite element model in a structured form;

• Task Manager: represents Tosca Structure tasks;

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Certain windows and toolbars can also be shown or hidden using Windows toolbar:

1.1.1 General Buttons toolbar

The buttons on General Buttons toolbar define the visualization parame-ters and serve for the selection or deselection of geometric objects as well as some other geometric operations. Each button corresponds to a command with a certain name; this name is shown in the tool tip for the button.

Task manager Includes Properties Materials Sets Database Mesh Parameters Measure

Tosca Structure 810

©

Table of Contents

SIMULIA Tosca Structure Documentation 8.1

General Remarks

0-i

Volume I

Start Manual

Preface

1-3

1

Getting Started with Tosca ANSA environment

1-5

1.1

User Interface . . . 1-6

1.2

Topology Optimization with Tosca ANSA environment . . . 1-33

1.3

Shape Optimization with Tosca ANSA environment . . . 1-67

1.4

Bead Optimization with Tosca ANSA environment . . . 1-113

1.5

Sizing with Tosca ANSA environment . . . 1-145

2

Getting Started with Tosca Structure.gui

1-171

2.1

User interface. . . 1-171

2.2

Topology Optimization with Tosca Structure.gui . . . 1-189

2.3

Shape Optimization with Tosca Structure.gui . . . 1-223

2.4

Bead Optimization with Tosca Structure.gui . . . 1-271

2.5

Sizing Optimization with Tosca Structure.gui. . . 1-305

3

Getting Started with Tosca Extension for ANSYS/WB

1-335

3.1

User Interface . . . 1-335

3.2

Topology Optimization with Tosca Extension for ANSYS/WB. . . 1-347

3.3

Shape Optimization with Tosca Extension for ANSYS/WB . . . 1-371

Volume II

User Manual

Preface

2-3

1

Overview of Tosca Structure

2-5

1.1

The Tosca Structure Modules . . . 2-5

1.2

Overview of the Optimization Process . . . 2-8

1.3

Workflow for Optimization . . . 2-11

2

Working with Tosca Structure

2-13

2.1

Working with Tosca ANSA environment . . . 2-13

2.2

Working with the Graphical User Interface Tosca Structure.gui . . 2-17

2.3

Working with Tosca Extension for ANSYS/Workbench . . . 2-22

2.4

Working with Tosca Structure in the Command Shell . . . 2-26

3

The Model

2-31

3.1

Models for Optimization. . . 2-31

3.2

Optimizable Element Types. . . 2-33

3.3

Preprocessing FE Models for Optimization . . . 2-34

3.4

Loading FE Data . . . 2-41