MODELLING AND SIMULATION


Optimising engineering


ROBERT ROE TAKES A LOOK AT THE DIFFERENT SIMULATION TECHNIQUES AVAILABLE TO OPTIMISE ENGINEERING DESIGNS


The use of optimisation methods in engineering simulation such as topological optimisation or design optimisation opens up new possibilities to deliver products with the increased performance or shorter time to market. Optimisation algorithms are being used in many disciplines to produce a feedback loop based on key design parameters. Making use of simulation techniques


to optimise designs can help to reduce validation testing and also enable new products. Techniques such as topology optimisation can reduce component weight and provide better performance characteristics, especially when paired with additive manufacturing. Another growing area is the use of multidisciplinary design optimisation (MDO), which considers multiple different systems in the same simulation workflow providing optimisation of various desired parameters to deliver improvements in multiple areas while maintaining the interaction between subsystems. An example of this could be strengthening engine parts of a vehicle while also considering drivetrain, acoustic performance, or thermal loads.


Topology techniques While topology optimisation was first demonstrated by combining topology and shape optimisation by Martin Bendsoe and Noburo Kikuchi in 1988, the development of the technique as a commercial software package was not introduced until the late 1990s. The concept of mathematical optimisation allows a user to provide a guided objective and constraints, then let the computer run the study in the loop to find the ideal answer. Topology


20 Scientific Computing World February/March 2020


optimisation algorithms follow a similar process by applying these techniques to the shape and topology of a structure. The resultant outputs produce parts that meet size and functional requirements within the allotted design space, using the minimum amount of material. The development of topology optimisation has been used in many engineering disciplines, such as aerospace and automotive, for the last several years. However, the combination of topology optimisation and additive manufacturing opens up new possibilities to easily create structures that match


”Part replacement could be a major opportunity with topology optimised structures for things that are ageing”


the optimal design. As metal printing and composites have become available through additive manufacturing, the field is opening up for engineers and designers to use this technique in new areas. In a recent blog post, Jeff Brennan, chief


marketing officer at Altair, commented on the additive manufacturing revolution and its importance to the future of design: ‘There is still so much out there. The ability to tie a digital twin directly to 3D printing and be able to adjust shapes quickly, evaluate them quickly. ‘Part replacement could be a major


opportunity, with topology optimised structures for things that are ageing. You might not ever have to have a CAD file for a part that needs to be replaced from 1960, you’d just need to know its position,


its volume, its load cases, and you could quickly generate the ideal shape, have it printed and you’ll have a replacement overnight from someplace like Amazon,’ Brennan continued. James Scapa, Altair CEO, added:


‘We’re adding a tremendous amount of nonlinear simulation to OptiStruct. We have displaced a lot of the traditional linear analysis solutions with OptiStruct over the years and we’re now starting to do the same with the nonlinear analysis solutions. A lot of the reason for that is because of how integrated optimisation is within all our solutions.’


Better braking The use of optimisation is not just limited to the shape and structure of components. Today optimisation techniques are applied to a number of different areas to help engineers solve problems that would be very difficult and costly to iterate with traditional methods.


@scwmagazine | www.scientific-computing.com


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