Topological, shape and multidisciplinary combined optimization for fixed crossbeam in hydraulic press through the use of OptiStruct and HyperStudy Matteo Cova SACMI Imola, Italy Roberto Saponelli SACMI Imola, Italy Giulio Turinetti Altair Engineering Torino, Italy Roberto D Aria Altair Engineering Torino, Italy
SACMI HYDRAULIC PRESS Introduction The Series 2000 press has been designed according to the finite elements technique, used extensively in the aeronautical industry. The press table and the upper cross beam, for example, are made using casting processes that cannot be influenced by human error. The parts are assembled by tightening nuts on steel columns, thus preloading the structure: this procedure minimizes the structural fatigue and strain that are typical of the rapid cycles the machine is able to can carry out. It s as if the entire system were steadily gatheringits strength before unleashing its full power, thus compensating for and reducing the stresses caused by the enormous pressing forces. Topological, shape and multidisciplinary combined optimization for fixed crossbeam in hydraulic press 2
PRELIMINARY ANALISYS ON STANDARD FIXED CROSSBEAM CAD TO F.E. MODEL SIMPLIFICATION BY SYMMETRY DIAGRAM OF LOADS OIL PRESSURE BELT PRETENSION Topological, shape and multidisciplinary combined optimization for fixed crossbeam in hydraulic press 3
STRESS AND DISPLACEMENT RESULTS CONTOUR OF DISPLACEMENT MAGNITUDE CRITICAL AREA FOR STRESS CONCENTRATION AND DISPACEMENT IN X and Y DIRECTIONS VON MISES STRESS Topological, shape and multidisciplinary combined optimization for fixed crossbeam in hydraulic press 4
PURPOSE OF OPTIMIZATION TARGET OF THIS OPTIMIZATION IS DESIGN A LIGHTER FIXED CROSSBEAD OF HYDRAULIC PRESS, KEEPING MAXIMUM STRESS, IN CRITICAL AREA, UNDER SAFETY TRESHOLD AND LIMIT DISPLACEMENTS ON PRESCRIBED NODES OBJECTIVE : CONSTRAINTS : MANUFACTURING: CROSSBEAM MASS REDUCTION STRESS LIMIT IN UP THRUST ZONE OF OIL DISPLACEMENT LIMIT IN THE SAME AREA CROSSBEAM ARE MADE IN CAST IRON BY CASTING To reach the purpose objective 3 different Optimization phases has been set: Phase I: Topology Optimization Phase II: Topology + Shape Optimization Phase III: HyperStudy Analysis Topological, shape and multidisciplinary combined optimization for fixed crossbeam in hydraulic press 5
DESIGN AND NO DESIGN SPACE FOR TOPOLOGY OPTIMIZATION DESIGN SPACE NON DESIGN SPACE STRESS LIMIT CONSTRAINT DISPLACEMENT LIMITS ARE IMPOSED TO AVOID OUT OF ROUD OF THIS AREA Topological, shape and multidisciplinary combined optimization for fixed crossbeam in hydraulic press 6
SETUP OF OPTIMIZATION RESPONSES VOLUME FRACTION (VOLFRAC) COMPLIANCE OF DESIGN SPACE 3 3 2 4 4 1 DISP. X POINT 2 DISP. Z POINT 1 STRESS P1 (MAJOR) ZONE 4 only on STRESS P1 (MAJOR) ZONE 3 NDS OBJECTIVE MINIMIZE COMPLIANCE CONSTRAINTS DISP X < DT1 (TREHOLD 1) DISP Y > DT2 (TRESHOLD 2) P1 STRESS ZONE 4 < ST1 (TREHOLD 1) P1 STRESS ZONE 3 < ST2 (TREHOLD 2) VOL FRAC Topological, shape and multidisciplinary combined optimization for fixed crossbeam in hydraulic press 7
Phase I: OPTIMIZATION 1 OBJECTIVE MIN COMPLIANCE CONSTRAINTS VOL FRAC = 0.20 OBJECTIVE REACHED WITHOUT CONSTRAINT VIOLATION Topological, shape and multidisciplinary combined optimization for fixed crossbeam in hydraulic press 8
Phase I: OPTIMIZATION 2 OBJECTIVE MINIMIZE COMPLIANCE CONSTRAINTS DISP X < DT1 (TREHOLD 1) DISP Y > DT2 (TRESHOLD 2) P1 STRESS ZONE 4 < ST1 (TREHOLD 1) P1 STRESS ZONE 3 < ST2 (TREHOLD 2) VOL FRAC = 0.30 THE RESULTS OF DENSITY DISTRIBUTION IS TOO SPARSE FOR CASTING PROCESS Topological, shape and multidisciplinary combined optimization for fixed crossbeam in hydraulic press 9
Phase I: OPTIMIZATION 3 OBJECTIVE MINIMIZE COMPLIANCE CONSTRAINTS DISP X < DT1 (TREHOLD 1) DISP Y > DT2 (TRESHOLD 2) P1 STRESS ZONE 4 < ST1 (TREHOLD 1) P1 STRESS ZONE 3 < ST2 (TREHOLD 2) MINDIM: 120 VOL FRAC = 0.20 USING MINDIM OPTION THE DENSITY DISTRIBUTION MAKE NEW CROSS BEAM MORE FEASIBLE Topological, shape and multidisciplinary combined optimization for fixed crossbeam in hydraulic press 10
Phase I: OPTIMIZATION 4 OBJECTIVE MINIMIZE COMPLIANCE CONSTRAINTS DISP X < DT1 (TREHOLD 1) DISP Y > DT2 (TRESHOLD 2) P1 STRESS ZONE 4 < ST1 (TREHOLD 1) P1 STRESS ZONE 3 < ST2 (TREHOLD 2) MINDIM: 120 VOL FRAC = 0.20 MANUFACTURING CONSTRAINT DRAW DIRECTION Topological, shape and multidisciplinary combined optimization for fixed crossbeam in hydraulic press 11
NEW GEOMETRY CONSTRAINTS P1 STRESS ZONE 5 < ST3 (TREHOLD 3) INTRODUCTION OF FILLET ZONE. THIS NEW GEOMETRY IS CONSIDERD NO DESIGN SPACE AND A NEW STRESS CONSTRAINT IN THIS AREA WAS ADDED TO ANALISYS Topological, shape and multidisciplinary combined optimization for fixed crossbeam in hydraulic press 12
SHAPE CHANGE FOR SHAPE OPTIMIZATION sh2 IN ORDER TO PERFORM THE PURPOSES OF OPTIMIZATION, 4 SHAPE CHANGE ARE INCLUDED IN THE ANALISYS UPPER AND LOWER PLAN CAN TRANSLATE VERTICALLY sh4 sh3 sh1 SHAPE 1 LOWER PLANE SHAPE 2 FILLET SHAPE (POSITION AND RADIUS) SHAPE 3 MULTIPLIER ZONE SHAPE 4 UPPER PLANE Topological, shape and multidisciplinary combined optimization for fixed crossbeam in hydraulic press 13
Phase II: TOPOLOGY AND SHAPE OPTIMIZATION 5 OBJECTIVE MINIMIZE COMPLIANCE CONSTRAINTS DISP X < DT1 (TREHOLD 1) MINDIM: 240 VOL FRAC = 0.25 4 SHAPE CHANGE DISP Y > DT2 (TRESHOLD 2) P1 STRESS ZONE 4 < ST1 (TREHOLD 1) P1 STRESS ZONE 3 < ST2 (TREHOLD 2) P1 STRESS ZONE 5 < ST3 (TREHOLD 3) Topological, shape and multidisciplinary combined optimization for fixed crossbeam in hydraulic press 14
Phase II: TOPOLOGY AND SHAPE OPTIMIZATION 6 OBJECTIVE MINIMIZE COMPLIANCE CONSTRAINTS DISP X < DT1 (TREHOLD 1) MINDIM: 240 VOL FRAC = 0.20 4 SHAPE CHANGE DISP Y > DT2 (TRESHOLD 2) P1 STRESS ZONE 4 < ST1 (TREHOLD 1) P1 STRESS ZONE 3 < ST2 (TREHOLD 2) P1 STRESS ZONE 5 < ST3 (TREHOLD 3) MANUFACTURING CONSTRAINT DRAW DIRECTION Topological, shape and multidisciplinary combined optimization for fixed crossbeam in hydraulic press 15
Phase II: TOPOLOGY AND SHAPE OPTIMIZATION 7 OBJECTIVE MINIMIZE COMPLIANCE CONSTRAINTS DISP X < DT1 (TREHOLD 1) MINDIM: 240 VOL FRAC = 0.20 4 SHAPE CHANGE DISP Y > DT2 (TRESHOLD 2) P1 STRESS ZONE 4 < ST1 (TREHOLD 1) P1 STRESS ZONE 3 < ST2 (TREHOLD 2) P1 STRESS ZONE 5 < ST3 (TREHOLD 3) Topological, shape and multidisciplinary combined optimization for fixed crossbeam in hydraulic press 16
Phase II: TOPOLOGY AND SHAPE OPTIMIZATION 8 OBJECTIVE MINIMIZE COMPLIANCE CONSTRAINTS DISP X < DT1 (TREHOLD 1) MINDIM: 300 VOL FRAC = 0.30 4 SHAPE CHANGE DISP Y > DT2 (TRESHOLD 2) P1 STRESS ZONE 4 < ST1 (TREHOLD 1) P1 STRESS ZONE 3 < ST2 (TREHOLD 2) P1 STRESS ZONE 5 < ST3 (TREHOLD 3) BEST RESULT (with few Stress Violation) Topological, shape and multidisciplinary combined optimization for fixed crossbeam in hydraulic press 17
Phase III: SECOND ORDER OPTIMIZATION WITH HYPERSTUDY FILLET ENLARGEMENT FOR STRESS REDUCTION GLOBAL SHAPE CHANGE ELEMENT DENSITIES DISTRIBUTION IN SECOND ORDER OPTIMIZATION THE CONTINUOUS RANGE OF ELEMENT DENSITIES WAS REDUCED TO 0 OR 1 IN ORDER TO DISTINGUISH PHYSICALLY THE REMAINIG PORTION OF MATERIAL Topological, shape and multidisciplinary combined optimization for fixed crossbeam in hydraulic press 18
Phase III: SECOND ORDER OPTIMIZATION WITH HYPERSTUDY IN HYPERSTUDY WE SET A DOE ANALISYS (FULL FACTORIAL) ELEMENT DENSITIES DESIGN VARIABLE CONTINUOUS BETWEEN 0 1 MAX P1 STRESS ARE CALCULATE IN FILLET AND MULTIPLIER ZONES RESPONSES PERFORMANCE OF RESPONSES (STRESS) VS DENSITY BEST SOLUTION MEANS DENSITY AROUND 0.65 0.7 Topological, shape and multidisciplinary combined optimization for fixed crossbeam in hydraulic press 19
NEW CAD EXPORT NEW CAD BY OSSMOOTH EXPORTED A IGES FILE WITH THE BASE FEATURES FOR DRAW A NEW CAD AND Topological, shape and multidisciplinary combined optimization for fixed crossbeam in hydraulic press 20
FROM FEM TO REALITY NEW HYDRAULIC PRESS SERIES 2000 Topological, shape and multidisciplinary combined optimization for fixed crossbeam in hydraulic press 21
CONCLUSIONS The use of OptiStruct allowed to SACMI to find easily an efficient and alternative design; Stiffness and Stress results reached the desired targets; Topology Optimization allowed to reduce the design time and save material. Topological, shape and multidisciplinary combined optimization for fixed crossbeam in hydraulic press
THANKS THANK YOU FOR YOUR ATTENTION Topological, shape and multidisciplinary combined optimization for fixed crossbeam in hydraulic press 23