Topology Optimisation2015

Want to know more about design for 3D printing, including Topology

Optimisation?

Contact us at: info@fransisco.nl

Education:1999 – 2003: Bachelor Automotive Engineering2003 – 2007: Master Mechanical Engineering

Work experience:2007 – 2008: Inalfa Roofsystems Venray2009 – 2011: Stork Foodsystems2011 – 2014: SKF2009 – now: Fransiscó

in/GilbertPetersGilbert Peters

GilbertPetersNL @Fisco_GP

FransiscóSince 2009 | Design support for clients | 3D printed Adventure Motorcycle

Why 3D printing?Local production | Complex parts | Customer specific

Industrial revolutionSince 1800 | Begin mechanisation | Mass manufacturing | Limited design variables

Expensive toolingLarge investments required | Large production numbers | No customisation

Production linesLimited flexibility | Large investments required | Large production numbers

3D printing = goodbye big factories

But how to design for 3D printing?

Topology optimisation

“is a mathematical approach that optimises material layout within a given design space, for a given set of loads and boundary conditions

such that the resulting layout meets a prescribed set of performance

targets.”

SizeOptimisation

Topology Optimisation

ShapeOptimisation

e.g. Thickness of a beam or X-section

e.g. Position of a hole

Complete shape, including holes

F F F

Relevance for 3D printingOrganic complex shapes | Based upon bone growth | Lightweight & Stiff

Topology Optimisation design flow

Traditional design flowDesign

(CAD)CAE

Virtual test Build Test

RedesignRedesign

DesignOptimisation

Design(CAD)

CAEVirtual test Build Test

OptimisationResource savings

Working principleDefine contribution of elements | Test against optimisation criteria

F

Design goalsMinimum weight | Certain Eigen-frequency | Maximize stiffness @ weight %

Swingarm redesignOptimised for 3D printing in titanium

Design SpaceNon Design Space

Design spaceWhat can be optimised & what not

• Brake• Accelerate• Cornering• Obstacles

Load cases & functionalityWhat’s the use case of the component | This is the hard part

ResultsOptimised for maximum stiffness | Raw output | Resembles a bone | Large voids

2015 Additive World Award Winner

DetailingOrganic shapes | Integrated functionality

Benchmark

1part

16parts

Motorcycle swingarm redesignLess parts | Customised | Less machining | Brake system integration

GE Engine BracketDesign Challenge | +/- 700 entries | Simple load case & dimensions

Large variations700 different solutions to a ‘simple’ well defined problem

Person behind the buttons has huge influence

Market players

AltairEstablished name | Powerful engine | 3D printing mindset

Concept Engineer Simulation Engineer

For inspirational optimisation

studies

Industry standardIncreased

functionality, requires a specialist

AutodeskFocused on 3D printing | Generative Design | Lattice structures

CAD integrated Lattice structures

Lattice StructuresSupport for hollow structures | Dedicated analysis required

Dassault SystemsFE-Design | Abaqus – NASTRAN - ANSYS plugin

CAESSRequires PTC Creo | Plugin | Powerful cleanup tool | Lattice structures

Frustum CloudmeshRemote computing power | Lower upfront investment | Beta test Q4 2015

nTopology ElementLattice structures | Beta testing now running

Future DevelopmentsIncorporate 3D print rules, process & material | Integrate 3D CAD | Auto smoothing

• Use it for inspiration• Shorten

development time• Engineer still needed

Takeaways:

info@fransisco.nl