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Mizzou MAE 4980 - Structural Optimization

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Pro/Mechanica – Structural Optimization» Tutorial: Copy beam.prt into a folder on the hard drive← set as working directory» Open beam.prt in Pro/Engineer (part file, not assembly file)1. Pro/E Toolbar: Applications → Mechanica2. Perform pre-processing of finite element model (constraints, loads, materials, etc.)» Apply a -45,000 N force load on the top surface of the beam in the y-direction» Create a displacement constraint on one end of the beam: no translation in any direction» Assign Al6061 as beam material3. Create new Static Analysis a. Analysis → Mechanica Analysis/Studiesb. In “Analysis and Design Studies” dialog box: File → New Static Analysis… (See “Pro/Mechanica Procedure” handout)» Create new static analysis called “Beam_Loading” with the following parameters: Method: Multi-Pass AdaptivePolynomial Order Maximum: 9Convergence Percentage: 5» In “Configure Run Settings” , set Memory Allocation to 1024 MB4. Create new Optimization Design Studya. Analysis → Mechanica Analysis/Studiesb. In “Analysis and Design Studies” dialog box: File → New Optimization Design Studyc.Input name and description (optional) of optimization studyd. Select Optimization under Type» Create new optimization design study called “mass_minimization”5. Define Objective Functiona. Click Measures → “Measures” dialog box:b. Select the desired “Predefined Measure” to be optimized (total_mass, max_stress_vm, etc.) → OKc.Select Minimize or Maximize under Goal» Set “mass” as the objective function to be minimized6. Define Design Constraintsa. Click New Design Limit → “Measures” dialog box:b. Select the desired “Predefined Measure” to set as a constraint → OKc.Define constraint as equality (=) or inequality (<, >)d. Define constraint Valuee. Click New Design Limit to add additional constraintsf. Click Delete Design Limit to delete a constraint» Constrain the maximum von Mises stress to be less than 255 N/mm27. Define Design Variablesa. Click Select Dimension from Model b. Click part or assembly feature in workspace or model tree to view its dimensionsc.Click the dimension to assign as a design variabled. Set Minimum and Maximum limits of design variablee. Rename design variable (optional)f. Click Select Dimension from Model to define additional design variablesg. Click Delete Variable to delete a design variableh. Click OK» Select the following three dimensions as design variables and specify minimum and maximum limits as shown in the figure above:d2: d3:d4:8. Set Design Study Optionsa. Specify Optimization Algorithm (Click Options)i. Sequential Quadratic Programming (SQP) [default]- Faster, guarantees global optimum design if initial design is feasible, but does not guarantee feasible intermediate designsii. Gradient Projection (GDP)- Slower, guarantees feasible intermediate designs if initial design is feasible, but does not guarantee global optimum designb. Specify Optimization Convergence and Maximum Iterations (usually can leave at default)c.Select Repeat P-Loop Convergence if significant changes will occur in model’s shape (slower)d. Select Remesh after each shape update to update mesh after each iteration (slower)» Keep default options9. Run Analysisa. Click Start Run to begin processing and Display Study Status to view progress10. View Optimize Historya. In “Analysis and Design Studies” dialog box: Info → Optimize Historyb. Click Accept Value repeatedly to view each iteration of optimization and to “leave model at the optimized shape”11. View Optimization Pass Plotsa. Click Review Results of a Design Study or Finite Element Analysis (or in Mechanica toolbar: Analysis → Results)b. In “Result Window Definition” Dialog Box:i. Select Graph under Display Typeii. Select Measure in Quantity tabiii. Click to define variable to plot vs. optimization pass (max_stress_vm, total_mass, etc.) → OK → OK and Show12. View stress fringe plots and additional output as described in “Pro/Mechanica Procedure”


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