sirris materials day 2011 invest in design - loose weight pre-prototype design - bart teerlinck

het collectief centrum van de Belgische technologische industrie

Virtual engineering in lightweight designBart Teerlinck

Virtual Engineering

driving industry by virtuality

Content

• Virtual engineering • Design• Topology optimization• Shape optimization• Manufacturing• Sirris Virtual Engineering

04/10/2011© sirris 2007 | www.sirris.be | [email protected] | 2

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 | [email protected] | 304/10/2011

The power of virtual engineering


The power of virtual engineering (ctd.)


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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.

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Importance of good design


Costs of repairing a design errorincrease exponentialy with time before it is discovered

Types of structural optimization



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

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The theory of non- parametric topologyoptimization

• 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.)


Types of objective responses

• Displacements (stiffness)• Volume of material• Strain energy• Moments of inertia• Eigenfrequencies• Reaction forces/moments• Acoustics• …


movie

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Case: manual topology optimization of support

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Automatic topology optimization of support

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Comparaison of optimization results

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Topology optim. of windturbine main frame


Automated design of structural parts: topology versus shape optimization


Topology optimization Shape optimization

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Topology versus shape optimization


TOPOLOGY OPTIMIZATION

SHAPE OPTIMIZATION

Courtesy of

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Shape optimization of a notch in a shaft


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)

Typical manufacturing constraints



From weld to near net shape manufacturing

Design space

Final casted part: 29% saving

Original welded support Topology optimisation

Casting simulation

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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 ?

04/10/2011© sirris 2007 | www.sirris.be | [email protected] |


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 )

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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


http://www.sirris.be/virtual_engineering.aspx�

SIRRIS Virtual Engineering Private Sessions


• Expensive prototypes

or test environment?

• Long time to market?

• Trial and error?

• Quantative output?

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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 materials day 2011 invest in design - loose weight pre-prototype design - bart teerlinck

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