Virtual engineering in lightweight design

1. driving industry by virtuality
Virtual engineering in lightweight design
Bart Teerlinck
Virtual Engineering
het collectief centrum van de Belgische technologische industrie

2. Content
• Virtual engineering
• Design
• Topology optimization
• Shape optimization
• Manufacturing
• Sirris Virtual Engineering
© sirris 2007 | www.sirris.be | info@sirris.be | 04/10/2011 2

3. What is virtual engineering
Virtual engineering will become a key technology in the industry.
No other technology has more potential to improve your
product design or optimize the efficiency of your proces
(study from Vlaamse raad voor Wetenschapsbeleid)
• Detailed insight
• Relatively low cost
• Short lead time
• Window of opportunities
© sirris 2007 | www.sirris.be | info@sirris.be | 04/10/2011 3

4. The power of virtual engineering
© sirris 2007 | www.sirris.be | info@sirris.be | 04/10/2011 4

5. The power of virtual engineering (ctd.)
© sirris 2007 | www.sirris.be | info@sirris.be | 04/10/2011 5

6. Classical design rules and finite elements
• For complex geometries the implementation of classical design rules
is fairly impossible.
• Classical design rules lead to oversizing
• The weight is not in the right place => Software support
• Finite element tools can offer the solution
• Knowledge of stresses facilitates the improvement of a geometry
• Design errors are revealed and excess material can be removed
• Design changes are easily evaluated
• Physical prototypes are not needed.
© sirris 2007 | www.sirris.be | info@sirris.be | 04/10/2011 6

7. Importance of good design
Costs of repairing a design error
increase exponentialy with time
before it is discovered
© sirris 2007 | www.sirris.be | info@sirris.be | 04/10/2011 7

8. Types of structural optimization
© sirris 2007 | www.sirris.be | info@sirris.be | 04/10/2011 8

9. Manual parametric optimization of a tower
crane.
• with a small increase in material realize a 33% increase in capacity
• thickness of plates are parameter for optimization
© sirris 2007 | www.sirris.be | info@sirris.be | 04/10/2011 9

10. The theory of non- parametric topology
optimization
• Goal: given a predefined domain space (2D or 3D) with boundary
conditions and load definitions, distribute a given mass (as % of
initial mass) such that a global measure takes a minimum (max.)
© sirris 2007 | www.sirris.be | info@sirris.be | 04/10/2011 10

11. Types of objective responses
• Displacements (stiffness) movie
• Volume of material
• Strain energy
• Moments of inertia
• Eigenfrequencies
• Reaction forces/moments
• Acoustics
• …
© sirris 2007 | www.sirris.be | info@sirris.be | 04/10/2011 11

12. Case: manual topology optimization of
support
© sirris 2007 | www.sirris.be | info@sirris.be | 04/10/2011 12

13. Automatic topology optimization of support
© sirris 2007 | www.sirris.be | info@sirris.be | 04/10/2011 13

14. Comparaison of optimization results
© sirris 2007 | www.sirris.be | info@sirris.be | 04/10/2011 14

15. Topology optim. of windturbine main frame
© sirris 2007 | www.sirris.be | info@sirris.be | 04/10/2011 15

16. Automated design of structural parts:
topology versus shape optimization
Topology optimization Shape optimization
© sirris 2007 | www.sirris.be | info@sirris.be | 04/10/2011 16

17. Topology versus shape optimization
SHAPE
OPTIMIZATION
TOPOLOGY
OPTIMIZATION
Courtesy of
© sirris 2007 | www.sirris.be | info@sirris.be | 04/10/2011 17

18. Shape optimization of a notch in a shaft
© sirris 2007 | www.sirris.be | info@sirris.be | 04/10/2011 18

19. Manufacturing and design
• Automated design tools generate in general doubly curved
shapes
• Freedom of shape in manufacturing is necessary
• Generated shapes by automated tools need to be instructed to
take manufacturing constraints into account
(Bron: JEC Composites)
© sirris 2007 | www.sirris.be | info@sirris.be | 04/10/2011 19

20. Typical manufacturing constraints
© sirris 2007 | www.sirris.be | info@sirris.be | 04/10/2011 20

21. From weld to near net shape manufacturing
Original welded support Design space Topology optimisation
Final casted part: 29% saving Casting simulation
© sirris 2007 | www.sirris.be | info@sirris.be | 04/10/2011 21

22. The cost of virtual engineering
Hardware: 3000 ~ 7000 € /year
Software: 10000€ ~ 25000€ /year
Engineer: ... € / jaar (min. 50% time on
engineering simulations) + CAD-engineers
=> Invest or outsource ?
© sirris 2007 | www.sirris.be | info@sirris.be | 04/10/2011

23. Conclusions
• Optimization tools have a large potential for lightweight design
• Maximal strength/fatigue resistance at a minimal weight
• Will make the difference in the near future for the structural functionality of
products
• Residual stresses due to the production should be taken into account.
• A boundary condition is the assumption of an error free production
• Eg. no shrinkage in a casting - no air inclusions in composites
• Consider tolerances of proces and material
• Are relatively expensive for SME’s( ca. 100 kEur/jr )
© sirris 2007 | www.sirris.be | info@sirris.be | 04/10/2011 23

24. Sirris Virtual Engineering
• Offering “Engineering Solutions”
• Strongly integrated within other SIRRIS expertises (SMALL lab, SLC lab)
• Close collaboration with universities and third parties
• www.sirris.be/virtual_engineering
© sirris 2007 | www.sirris.be | info@sirris.be | 04/10/2011 24

25. SIRRIS Virtual Engineering Private Sessions
• Expensive prototypes
or test environment?
• Long time to market?
• Trial and error?
• Quantative output?
© sirris 2007 | www.sirris.be | info@sirris.be | 04/10/2011 25

26. Closure
"Nobody trusts a computer simulation except the guy
who did it, and everybody trusts experimental data,
except the guy who did it.“
Thank you for your attention
© sirris 2007 | www.sirris.be | info@sirris.be | 04/10/2011 26