Tutorial: Topology optimization of a cantilever beam

Umer Khan, Professor W. L. Cleghorn

Department of Mechanical and Industrial Engineering, University of Toronto

2000 N 2000 N

1000 mm

2000 mm 100 mm
OBJECTIVE Minimize Volume

DESIGN VARIABLE Element density

CONTRAINT Resultant Displacement is 0.01 mm at nodes where force is applied

Construct this model in any CAD system and save as IGES format. 1
 Terminology

Collectors - Collectors store data for collected entities. A collected entity must
belong to only one collector.

Card image- Card images allow for creation, editing, and deletion of a solver card
within a HyperMesh model.

Property - Property entities are used to define and store 1D, 2D, and 3D property
definitions for a model.

Component - All elements within a component are assigned the component

property and the component material.
2
 Process of Analysis

1. Import Geometry
12. Constraints 13. Objective

10. Design
11. Responses
Variable

This chart illustrates

9. Structural the steps taken
3. Property Optimization towards setting up a
2. Material Collector problem in Optistruct.
Collector
4. Component 7. Apply Loads Constraints
Collector
5. Mesh Geometry
8. Loadsteps

6. Load Collector
3
 Opening HyperWorks
We will now open HyperWorks and enter into the Optistruct Profile. This will allow us to perform
finite element analysis and structural optimization.

3. Click to import IGES file

1. Click to OptiStruct

2. Click OK

4
 Import IGES File
Choose the file beam.igs to import into HyperWorks.

1. Click on file

2. Click Open

5
 Import IGES
The geometry has been transferred into HyperWorks as a set of lines defining the perimeter of the
object.

1. Click Import

6
 Rename Component
The default name assigned to any component which is imported into HyperWorks is lvl0. We will
change this name to Beam.

1. Right click on the component lvl0

2. Click Rename, and enter the name Beam

7
 Create Material

Create the material collector early because it is

referred to by other collectors. It is also beneficial to
establish the right units in the beginning to ensure
consistency. The format of the material data will be
MAT1 which is used for linear isotropic materials. We
will first establish the following units:
Length – millimeters
Force – Newton
Mass - Kilograms
 Create Material
Creating a material requires defining the type and card image. We will choose isotropic properties
and a MAT1 card image. The MAT1 card image corresponds to an isotropic and linear elastic
material.

1. Right click on the colour bar and change the

colour to Red

4. Type “Steel” as the material name

5. Click on type and choose
“ISOTROPIC”
6. Click on card image and choose
MAT1
2. Click on the Material
Icon to create new 7. Click to create\edit
material to input material
properties
3. Click on create

9
 Material Properties
The material properties are:
E (Stiffness) = 2.1e5 N/mm2 , Nu (Poission’s Ratio) = 0.3, Rho (Density) = 7.9e-6 kg/mm3
These units correspond to the ones we have established.

1. Click on [E] (Stiffness) and input 2.1e+05

2. Click on [NU] (Poission’s Ratio) and input 0.3
3. Click on [RHO] (Density) and input 7.9e-06

4. Click Return on this screen and on

the next
10
 Create Property

A 2D surface mesh will require a property with the

card image of PSHELL whereas a 3D mesh would
require property with a card image of PSOLID. These
collectors differentiate the different parts of the finite
element model by storing specific data relating to each
element type. These property collectors in turn refer to
the material collectors defined previously.
 Create Property
A property will now be created for storing the data relating to a surface mesh (2D elements). An
element thickness of 1.0 mm is assigned.

3. Type Shell as the property name

1. Click on the Property Icon 4. Change the colour to green
to create new property 5. Click on type and choose 2D
6. Click on card image and choose PSHELL
7. Click on material and choose Steel

8. Click create/edit to create

and edit properties
2. Click on
create

In the next screen, click on [T] (Element Thickness) and input a value of 1.
12
Then click Return once to come back to this screen.
 Create Property
A property will now be created for storing the data relating to a solid mesh (3D elements).

1. Type Solid as the property name

2. Change the colour to yellow
3. Click on type and choose 3D
4. Click on card image and choose PSOLID
5. Click on material and choose Steel 7. Click
return
6. Click
create

13
 Create Components

Component collectors are used to store the data defining

different parts of the finite element model. Components are
created, edited, and deleted from the Model Browser and are
shown under the Component folder. Components also have a
component view within the Model Browser which lists only
components and has advanced options for component creation
and editing.
 Create Components
The shell component will store the data of the 2D mesh which will be created.

1. Click on the Components Icon to create new

components

3. Type Shell as the comp name

4. Change the colour to green
5. Click on property and choose Shell

6. Click
create
2. Click on
create

15
 Create Components
The solid component will store the data of the 3D mesh which will be created.

1. Type Solid as the comp name

2. Change the colour to yellow 5. Click
3. Click on property and choose return
Solid

4. Click
create

16
 2D/3D Mesh

Mesh will first be created on the surface with 2D quad

elements. In order to create hexahedral elements,
these 2D elements will be offset, or extruded. There
are many different types of finite elements available,
and the use of each depends on application. There are
also many different methods of applying mesh in
HyperWorks. The method used for this tutorial is
element offset. Note that there are many factors
which play a role in the accuracy of the finite element
solution. Mesh densities and type of elements are a
two of these factors.
 Creating 2D Mesh
Making a component current will tell the program that we want to make changes to only this
component. The shell component corresponds to the 2D elements which we will create.

1. Right click on Shell, under components

2. Click on Make Current

18
 Creating 2D Mesh
We will now change the view to iso-view in order to get a better view of the surfaces of the model.

3. Click on iso view to change view

2. Click on automesh 1. Click on 2D

19
 Creating 2D Mesh
We will now choose the surface which will be meshed with 2D elements. When meshing, we will
select elems to current comp option. This will tell the program that we want the mesh to be
assigned to the current component, Shell. This will differentiate the 2D mesh from the 3D mesh.

1. Choose this surface for the mesh

2. Set element size = to 300

3. Click on mesh type and choose quads

4. Click and change to elems to current comp

5. Click mesh

Click return twice to return to the main menu 20

 Creating 3D Mesh
We are now going to create the 3D mesh by entering the elem offset (element offset) option.

1. Right click on Solid, under components, and

click Make Current

3. Click on element offset 2. Click on 3D

21
 Creating 3D mesh
We will now offset the 2D elements created earlier. The total thickness is set to 2000 mm and the
number of layer is set to 6. After the mesh has been created, it is represented by yellow signifying
that it corresponds to the Solid component.

4. Click on the two

surfaces highlighted in
white

2. Click on elems and choose all

5. Number of layer = to 6
1. Click on solid 6. Change initial offset = to 0
layers 7. Total thickness = to 2000

9. Click offset+

10. Click
3. Click on surfs return
8. Change to elements to current comp 22
 Load Collector

Load collectors define the different loads which will be

applied to the model. Multiple load cases can be
applied in order to simulate different conditions.
 Load Collector
Boundary conditions (BC) and forces are created with a different colour.

1. Click on the Load Collectors icon

2. Change loadcol name to Forces

3. Change colour to cyan

4. Click on create

5. Repeat this step again but in step 2, change the name to BC. 24
The click on return to proceed to the main menu.
 Boundary Conditions
The beam has a fixed boundary condition on the side surface replicating that of a cantilever beam.

2. Click on constraints 1. Click on Analysis

25
 Boundary Conditions
First we will select the nodes which will be constrained and then specify the types of constraints. The
following is the convention used in HyperWorks: dof1 = x displacement, dof2 =y displacement, dof3=z
displacement, dof3=rotation about x-axis, dof3=rotation about y-axis, dof3=rotation about z-axis. These
constraints are given with respect to the axis defined by HyperWorks shown at the bottom left hand
corner.

3. Choose the
following 8 nodes

4. Ensure that all dof are selected

5. Ensure that loadtypes = is set to SPC

2. Click on nodes 6. Click create

7. Click
1. Click on create return

26
 Forces
We will now create loads on the model. First we have to initiate the forces load collector by making
it current. This will tell the program that we want to create forces.

1. Right click on Forces, under

LoadCollector, and click Make Current

2. Click on
forces

27
 Forces
We will now create forces on two nodes as defined by the problem statement, 2000 N each. Note
that a negative sign has been placed before the force in order to stay consistent with the
HyperWorks coordinate system which is shown at the bottom left of the screen.

3. Choose these two nodes

2. Click on nodes
6. Click create

1. Click on create

4. Set magnitude = -2000

28
5. Choose y-axis 7. Click return
 Loadsteps
Loadsteps create a set of load collectors. You can use this to create different loading conditions by
grouping loads together.

1. Click on loadsteps

29
 Loadsteps
We will now gather our forces and constraints, into one loadstep. The analysis type is set to linear
elastic.

2. Click on = beside SPC and choose BC

3. Click on = beside LOAD and choose Forces

4. Choose linear static for

1. Set name = to analysis
LOAD1
5. Click
create

6. Click
return 30
 Optimization

We are now entering the optimization phase where we

will define the optimization parameters. For all parts, it
is recommended that a Radioss solution be run to view
the finite element results. After the results have been
verified, then the optimization process should begin.

As mentioned in the problem statement:

OBJECTIVE FUNCTION Minimize volume

RESONSE Volume and Deflection

DESIGN CONTRAINT Max. Deflection of 0.02 mm where forces are applied

 Optimization
We will now enter the optimization parameters by entering the optimization options.

1. Click on
optimization

32
 Topology
The topology option will allow us to define our design variable as stated in the problem statement.
This will also tell the program that we want to perform topology optimization.

1. Click on topology

33
 Design Variable
The design variable we have set is the element density of the solid 3D mesh. This is one method of
differentiating between the design space and the non-design space because under the props
(properties) option, only Solid is selected. Therefore, different components can be created to
differentiate between the design/nondesign space. We will call the design variable Disp.

4. Click on props and set to Solid

5. Click
2. Set desvar = Disp create

1. Click on
create

6. Click return
3. Choose PSOILD 34
 Responses
We will now define the responses of the system.

1. Click on responses

35
 Responses
The first response will be the magnitude of deflection at the two nodes where forces are applied.

1. Set responses = to deflection

2. Click and set to

static 3. Choose these two nodes
displacement

5. Click
create

4. Set to total disp 36

 Responses
The second response will be the total volume of the part.

2. Set responses = to volume

3. Click
create
1. Click and set
to volume

4. Click
return
37
 Optimization Constraints
It is now time to set the constraints on the response.

1. Click on dconstraints

38
 Optimization Constraints
A constraint will now be imposed on one of the response, the deflection. Here we are specifying
that the maximum deflection permitted is 0.02 mm at the nodes where the forces are applied, as
defined in the problem statement.

2. Set constraint = to magdisp

3. Click response = and select deflection

4. Click on loadsteps and choose Loads

5. Click
1. Check upper create
bound = and set it
to 0.02

6. Click 39
return
 Objective
We will now define the objective of the optimization.

1. Click on objective

40
 Optimization Objective
The objective of the optimization, as defined in the problem statement, is to minimize the volume.
We use the response of volume and set the objective function to minimize it.

1. Click and set to min

2. Click response = and select volume

3. Click create

4. Click return
5. Click return on the next screen to reach the main menu 41
 Optimization Controls
We will now activate the SCREEN control. This allows us to view the result of each iteration
performed during the optimization process.

1. Click on control cards

2. Click next two times on the following screen 42

Optimization Setup

2. Click return
two times

1. Click on screen

43
Optistruct

1. Click on OptiStruct

44
 Optistruct
It is very important that a new folder is created because several data files are saved at the same
location. After the optimization is complete, the results can be viewed using HyperView.

1. Choose a location where to save the files

2. Click on OptiStruct

3. Click on HyperView after the optimization is completed 45

 HyperView
There were a total of seven iterations performed. We want to view the results from the seventh
iteration. Note that the part is represented by two colours which correspond to the two
components created, shell (green) and solid (pale green).

3. Click OK
1. Click on Design

2. Click on Iteration 7

46
 Iso Density Plot
There are several ways of viewing the results in HyperView. An iso element density plot give us the
ability to only view elements which have densities over, under, or at a certain value. This can be
used to set an element density which gives us a feasible solution. Note that as you vary the
densities, the dark green component (2D elements) does not change because it is a “non-design”
area.

5. Move the bar left and right to get an idea

of the element densities in the design space

1. Click here to view iso

plots

4. Set this to Above

3. Click apply
47
2. Choose Element Densities
 Contour Plot
A contour plot is another way of viewing results. Colours correspond to different density values
with red being close to 1.0 and blue being close to 0.

1. Click here to view contour plots

2. Choose Element Densities

3. Click apply

48
 Masking Element
Another way of viewing results is to mask elements. For this tutorial, we will mask elements with
densities under 0.45 because in the iso density plot this seemed like a good solution.

1. Click here to mask elements

2. Choose Elements

49
 Masking Elements
By performing this step, the program will highlight all elements with element densities under 0.45.

1. Choose Elements

2. Choose to Add elements

4. Click Add

3. Enter <=0.45
50
 Masking Elements
The final solution we have obtained is a simple truss like structure.

1. Choose Mask

2. Click Mask Selected

51
 Final Solution
Starting with a cantilever beam with a point load, by applying topology optimization, we have
obtained a truss structure. This simple yet powerful example clearly shows the potential of
topology optimization.

Topology
Optimization
52