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Abaqus Topology and Shape


Optimization Module

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Contents

Introduction
Optimization workflow
Supported functionality
Examples

Topology and Shape Optimization

Topology optimization:

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Modify stiffness (by modifying material)


Good for evolving optimum shape

Shape optimization:
Moves nodes
Good for fine tweaking of shape

Both support:
Contact
Geometric non-linearity
Nonlinear materials:
o Within the design area: *plastic, *hypoelastic, most *hyperelastic
o Outside design area: all

Manufacturing restrictions

Export smoothed shape to STL or INP


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Optimization Workflow
Topology optimization
Modify stiffness

Shape optimization
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Move nodes

5-50 solver iterations


is typical
Afterwards, run
Smooth, then export
INP or STL to CAD
Currently
Abaqus/Standard only
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ATOM Workflow: Setup

The flow chart on the left shows


the user actions required to setup
the optimization
Each user action is associated
with a manager in the
Optimization module accessible
from the Optimization Module
Toolbox or the Model Tree
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ATOM Workflow: Execution and Monitoring


Once an Optimization Task is setup, an Optimization Process needs
to be defined to execute the optimization
Users may have multiple Abaqus models and optimization tasks
defined. An optimization process refers to a unique Model and Task
combination.
Right-click on the optimization process to access: Validate, Submit,
Restart, Monitor, Extract and Results postprocessing

ATOM Workflow: Results


The Abaqus Visualization module allows for
convenient visualization of optimization results
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Postprocessing will be discussed in detail in subsequent lectures

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ATOM Workflow: Extraction

Optimization
results can be
smoothened and
extracted as
Abaqus input files
or STL files

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Supported functionality overview


Design Responses provide variables for the optimization
solver
Objective Functions define how those
Design Responses should be used
(sum/min/max/formula/etc)
Constraints determine bounds for the optimization solver
Geometric Restrictions provide for manufacturing
Stop conditions

Supported Functionality
Design Responses

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Single or multiple terms


Region based
Operators:

Sum
Minimum
Maximum
Deviation from Max
Number of values

Select the step to extract


results from or load cases
e.g: sum the element
strain energy

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Supported Functionality

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Objective Functions

Uses already defined Design Responses


Allow combining
multiple Design
Responses
Targets:
Minimize
Maximize
Minimize the maximum
weighted difference from
the maximum

E.g: minimize Design Response 1

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Supported Functionality

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Constraints

Uses already defined Design


Responses
Allows constraining the Design
Response to:
Greater than
Greater than a fraction of the initial
value
Less than
Less than a fraction of the initial value

E.g: Constraint the volume to be less than 35% of the original


volume

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Supported Functionality
Geometric Restrictions

The following geometric restrictions are available:


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Frozen areas
Member Size
o Min, max, envelope

Cyclic symmetry
Planar, Point and Rotational Symmetry
Demolding

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Supported Functionality

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Job control

New job super-type (similar to


Adaptivity or Co-execution)
Once a job is submitted, CAE
can be closed.
Restarting a failed analysis run
is supported
Allows control on
maximum number of
jobs, results ODB
merge, etc
Queues from CAE
are supported
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Supported Functionality

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Post processing

Standard post-processing of results


Additional support for viewing the generated iso-surface
Extraction of the results surface to STL or Abaqus input file
Allows export to CAD or back to
Abaqus/CAE for rerunning with
ATOMs Shape Optimization

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ATOM Example : Pull Lever on a Press

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Lever is redesigned to reduce stresses, with minimum weight

Initial volume

Validate
FEA model

Design
Proposal

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ATOM Example: Bracket with Loads

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Bracket with loads, some torsion and press fits


Final result is sensitive to applied loads/etc

Original Geometry

Demold
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Demold with thickness


control

SIMULIAs Design Exploration and


Optimization Tools
Six Sigma
Test Data
Match

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ATOM

Taguchi RD

Isight
Optimization

Topology optimization

Monte Carlo
DOE
Shape optimization

ATOM

Exploration

Isight

Tuned for topology and shape


optimization

A general purpose design exploration and


optimization package

Non parametric

Parametric

Can handle a very large number of design


variables. (~100K-1000K)

Meant for small number of design


variables(~10-100)

Multiple objectives are summed up to


single objective

Multi-objective, multi-discipline
optimizations possible
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Demo- Topology Optimization of a Gear

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More on Topology Optimization

Topology Optimization
clamped
end

Load

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uout

Consider a beam structure clamped at one end


Typically the goal of a topology optimization is to produce a landscape
that minimizes an objective given a certain amount of material removal
In this case we want to minimize the tip displacement of this beam

Therefore, we define our Objective and Constraint


Objective: Minimize displacement uout
Constraint: Reduce mass by a given amount

Design domain: All elements in the beam structure


Design variables: Relative density of each element in the design domain

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Problem Statement
The problem statement is the following:
clamped
end

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Load

uout

where:
ve is the element volume

e is the element relative density


n is the number of elements in the optimization domain

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Topology Optimization as an Integer


Value Problem

It is indeed possible to solve the


integer value problem
However, such approaches are quite
expensive computationally and
therefore impractical
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clamped
end

uout

clamped
end

The design variables can only take the values 1 or


0
This results in voids and fully dense elements
only, which is favorable.

Load

clamped
end

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The Topology optimization problem can


be posed as an integer value problem

Load
clamped
end

In order to apply gradient-based optimization techniques


(which can be more efficient), the integer value problem is
relaxed
The design variables (relative densities) are assumed to be
continuous

uout

clamped
end

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Continuous Design Variables

How do we interpret the intermediate density elements?


We dont! We use an approach that penalizes
intermediate density elements so that they are not
favorable in the final solution.

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SIMP

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How do we avoid intermediate density elements in the final


solution?
By using the Solid Isotropic Material with Penalization method (SIMP) for
material interpolation
This popular method represents the stiffness matrix as:

where:
Ke is the element stiffness matrix at the global level

min is a small relative density


e is the element relative density
p is a penalty term
N is the number of elements in the domain

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SIMP

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SIMP serves several functions:


1. Material interpolation
o

Assigns stiffness to intermediate density elements

2. Penalization of intermediate elements


o

Makes the intermediate density elements unfavorable in the optimization by making the
stiffness of the intermediate density elements small compared to the volume

3. Avoids singular stiffness matrices


o

Doesnt allow the stiffness matrix to become singular by introducing a very small
amount of minimum relative density

Note: min need not be introduced in SIMP (next slide)


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SIMP for Nonlinear Analysis

The basic statement for equilibrium in a nonlinear analysis is that the


external forces P and the internal forces I must balance each other
(within a tolerance) at every node; i.e., P I = 0
That is, equilibrium is established when the force residual R is zero

We can write the topology optimization problem as:


The material tensor is scaled by SIMP
For simple material models, such as linear elasticity, the
scaling would be the following:
This scaling becomes more complicated for advanced material
models; please see the ATOM documentation for a list of
supported materials.
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RAMP

RAMP (Rational Approximation of Material Properties) is


an alternative to SIMP
RAMP also penalizes the intermediate density elements

where:
Ke is the element stiffness matrix at the global level

min is a small relative density


e is the element relative density
p is a penalty term
N is the number of elements in the domain

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The Sensitivity Based Optimization


Algorithm

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Gradient-based optimization algorithms are preferable for solving


this class of problem.
They are efficient
But they can get trapped in local optima

In particular, the Method of Moving Asymptotes (MMA) is preferred


This method, like SLP and SQP, works with a sequence of approximate sub-problems to
arrive at the optimum solution
It is appropriate for problems with very large numbers of variables

Gradient-based methods require sensitivity information


Calculated by adjoint methods
Optimization performs a linear perturbation to calculate sensitivity
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Stiffness and Controller Based


Topology Optimization

Stiffness

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Often the goal of Topology optimization is to find


the stiffest possible structure given a certain
amount of material removal.
For example, assume you are trying to reduce the weight of the
component shown on the right.
o You know your structure is going to be more compliant as a result of the
material removal.
o You want to find out what landscape will give you the most stiffness (or
least compliance) given the material removal, and evaluate if this new
landscape is stiff enough to do the job your component was designed to
do.
o You can use controller-based topology optimization to produce this new
landscape (bottom right)

Note: You may also use sensitivity-based optimization to minimize compliance


(max stiffness) but the controller-based approach
has certain advantages (discussed later)

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Stiffness

We have a scalar measure of the compliance of a structure


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Compliance is given by UTKU


o Here K is the global stiffness matrix and U is the global displacement vector

Thus, we may write the stiffness optimization problem as:

Note: In ATOM, compliance is selected as the sum of the strain


energies of the elements in the design area
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Controller Based Optimization for


Stiffness Optimization

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The controller in ATOM is an extension to the optimality


criteria method for topology optimization
Optimality criteria methods have been shown to
efficiently produce good results for stiffness optimization
(with volume constraints)
TIP: when solving a complex topology optimization
problem, try the controller based optimization (of the
reduced problem) first.
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Controller Based Optimization vs


Sensitivity Based Optimization
Controller Based

General Sensitivity Based

Objective: Strain energy

Objective: Strain energy, Volume, Weight,

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Displacement, Rotation, Eigenfrequency, Reaction


force, Reaction Moment, Internal force, Internal
moment, Center of gravity, Moment of Inertia

Constraint: volume

Constraint: Strain energy, Volume, Weight,


Displacement, Rotation, Eigenfrequency, Reaction
force, Reaction Moment, Internal force, Internal
moment, Center of gravity, Moment of Inertia

Solution is guaranteed for a stiffness


problem

Solution is not guaranteed for objectives


other than stiffness

Doesnt need to perform a linear


perturbation step for sensitivity
calculation

Needs to perform a linear perturbation


step for sensitivity calculation

Needs around 15~20 iterations for most


problems

Needs around 50~80 iterations for most


problems

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