GRM TruProducts

Integrated Optimisation Tools for Abaqus

Software Introduction

Martin Gambling

GRM
 Overview
Background & Motivation

TruProducts Overview

Examples

Summary

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 Background & Motivation
Non-Linear Optimisation Research (LS-DYNA & Abaqus)
German LS-DYNA Conference 2008
Efficient Topology, Topometry and Sizing Optimisation for
LS-DYNA Analysis Problems Coupling
LS-DYNA to VR&D Genesis.

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 Background & Motivation
Non-Linear Optimisation Research (LS-DYNA & Abaqus)
Simulia Abaqus Customer Conference 2009
Efficient Shape Optimisation of an Aircraft Landing
Gear Door Locking Mechanism by Coupling Abaqus
to GENESIS.
Objective (Mass Change)

Abaqus Simulation

Shape Change History

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 Background & Motivation
Conclusions of 2008/2009 Research

2009 GRM join Simulia Abaqus Alliance Partner Programme to

develop TruProducts

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TruProducts Integrated Optimisation Tools
for Abaqus/CAE

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 The TruProducts Range
TruForm
Topology
TruPly
Composite Laminate;
Sizing and Topometry
Launched in 2010

TruProducts Design
TruShape Released 2013
Shape and
Topography
TruSize
Shell Gauge;
Sizing and Topometry

A suite of optimisation tools integrated within the Abaqus/CAE environment providing

specific solutions for design

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 TruForm
Topology Optimisation for
Abaqus/CAE

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 TruForm Overview
Provides Abaqus Topology Optimisation

Simple, Single Menu Set-up Interface

Linear & Non-Linear Analysis

Methods Include:
Maximise Stiffness with Target Mass
Minimise Mass for Target Stress
Minimise Mass for Target Plastic Strain

Supports Multiple Load Steps

Fast Solving, Approximately 5 Abaqus Solves

to Converge

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 TruForm Overview
(Support of Multiple Manufacturing Constraints)

Free Pressed Form

Additionally, following can be applied: Extrusion

Mirror & Cyclic Symmetry
Single and two part pressed form
Free and fixed casting split lines

Casting

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Fixed Mass, Maximise
Stiffness
Standard solver mode from v1.0
Updated to support nlgeom and
non-linear materials
Minimise Mass, Constrained
Maximum Stress Limit
New mode in v2.0
Process minimises mass
incrementally, monitoring peak
stresses in part
Primary optimisation objective is
to minimise strain energy
Solver Modes
Minimise Mass, Constrained
Maximum Plastic Strain Limit
New mode in v2.0
Process minimises mass
incrementally, monitoring peak
plastic strains in part
Primary optimisation objective is
to minimise strain energy
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 Case Study Lotus F1 Team Rocker Arm

Formula 1 teams using TruForm to remove mass

from existing or newly developed parts

TruForm Studies submitted with no modification

of existing Abaqus models

Example demonstrates the application on a

complex assembly considering 9 individual Load
Steps

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 Case Study Abaqus Control Arm Example

Abaqus example control arm model used

to demonstrate available TruForm
optimisation modes
Studies Performed:
Maximise Stiffness, Mass Fraction = 57%
Minimise Mass, Linear Stress < 370MPa
Minimise Mass, Non-linear Stress < 370MPa*
Minimise Mass, Plastic Strain < 1%*
Minimise Mass, Plastic Strain < 1%**

* - Yield Stress = 355MPa

** - Yield Stress = 180MPa

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 Case Study Abaqus Control Arm Example

Maximise Stiffness Study

Study performed to benchmark TruForm
with ATOM
TruForm converged after 5 Abaqus
iterations
ATOM Solution after
Result compares very closely to ATOM 17 Abaqus Solves

solution
Over 3 x speed up over ATOM for linear
optimisation example
TruForm Solution
Converged after 5
Abaqus Solves

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 Case Study Abaqus Control Arm Example

Minimise Mass for Plastic Strain Target

Plastic Strain Limit of 1% defined for non-
linear material model
Nlgeom activated and plasticity defined
with yield at 355MPa
Optimisation converged in 17 Abaqus
iterations
Converged Mass Fraction of 0.34

Optimised Plastic
Strain History
Optimisation

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 Case Study Abaqus Control Arm Example

Minimise Mass for Plastic Strain Target

Plastic Strain Limit of 1% defined for non-
linear material model
Nlgeom activated and plasticity defined
with yield at 180MPa
Optimisation converged in 10 Abaqus
iterations
Converged Mass Fraction of 0.53

Optimised Plastic
Strain History
Optimisation

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 Case Study Abaqus Control Arm Example
OPTIMISATION SUMMARY

Constrained Linear Constrained Non- Constrained Plastic Constrained Plastic

Maximise Stiffness
Stress Linear Stress Strain (355 Yield) Strain (180 Yield)
Mass Fraction = 0.57
Mass Fraction = 0.64 Mass Fraction = 0.45 Mass Fraction = 0.34 Mass Fraction = 0.54

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TruProducts Design Overview
TruProducts Design is an integrated
environment providing parametric
design optimisation to Abaqus/CAE
users
3 key modules are available:
TruSize Shell Gauge (Sizing & Topometry)
TruPly Composite Laminate (Sizing & Topometry)
TruShape Topography & FreeShape
Design modules provides complete
suite of optimisation capabilities,
which can be combined in a single
optimisation study

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 TruPly Overview & Benefits
Composite Laminate optimisation tool for:
Determining optimum Ply Boundaries
Optimising Number of Plies and Orientation of existing
Laminates
Optimise and automatically update Composite Layup
Definitions
Optimise for multiple loading requirements simultaneously

Develop Optimal Composite Laminates

Eliminate time-consuming iterative
laminate design process
Maximise potential of composite material

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Simple Cantilever Example
TruPly Methods

TruPly Set-up
Minimise Mass
Maximum Displacement Constraint

Optimised Number of Plies

0 45 0 45 0 45
Sizing Result Topometry Result Coarse Topometry Result
(Constant Thickness) (Variable Thickness) (Variable Thickness)

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 TruSize Overview & Benefits
Simple Plate
Efficiently optimise the thickness/gauge of Example
shell panels
Optimise thickness distribution of
castings/mouldings/machined parts
Optimise for stiffness, strength, modal & TruSize Set-up
linear buckling requirements simultaneously Minimise Mass
Maximum Displacement Constraint

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TruSize Case Study - Automotive BIW Optimisation
Panels optimised to minimise mass whilst Linearized
Crashworthiness Loads
maintaining structural performance Optimisation
Design Variables automatically generated Load Cases
using TruSize, following user defined rules

Global and Local Stiffness

Panels Optimised using

TruSize

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TruSize Case Study - Automotive BIW Optimisation

Body mass reduced by 16kg

Baseline Panel with no degradation in Optimised Panel
Thickness Thickness
structural performance

Change in Panel
Thickness

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 TruShape Overview & Benefits
Optimise reinforcement patterns in
shell panels and outer form of solid
parts to:
Maximise stiffness
Minimise peak stress
Maximise frequency

Topography Shell
Part Optimisation

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 TruShape Case Study Automotive Suspension
Minimise:
Turret
Maximum Stress
Stress Stress
Maximum Displacement

Displacement Displacement

202% increase in stiffness and

Optimised Performance
65% reduction in stress with no
Baseline Performance mass increase

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 Summary
TruProducts provides a complete structural optimisation toolset for
Abaqus

TruForm focussed on ease of use, minimum solve time and practical

application of Topology optimisation

TruProducts is a developing product, delivering

efficient optimisation to the Abaqus community

Solutions integrated with existing

Genesis optimisation toolset

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