Optimisation
Several optimisation steps usually lie between the first draft and the final design of a product. Existing products are optimised too — to reduce cost, for example, or to withstand changed loads. When designing a component, one goal is to use the material as uniformly as possible while using as little of it as possible. Optimisation may be carried out for reasons such as:
- reducing material cost or weight
- eliminating (potential) weak points
- finding alternative geometries and design approaches with equal or better function
- and much more
We have various approaches and specialised software packages available for this. Defining the parameters of an optimisation, interpreting the results and turning the optimisation output into a manufacturable, production-ready design all require considerable experience on the part of the user. We specialise in the use of state-of-the-art software packages and have many years of wide-ranging experience in optimising components and assemblies.
Variant studies
Variant studies are the simplest form of optimisation. Several variants of a component or assembly are analysed and the simulation results compared. This approach is useful, for example, when several design principles are to be compared or local geometry variations investigated. The models are usually assessed comparatively, which makes evaluating the variants straightforward.
Topology optimisation
Topology optimisation is used to arrive at an idea for a design with ideal material utilisation. First, the available design space is defined. This design space is then divided into fixed regions and variable regions — those the optimisation algorithm may change. The loads and the optimisation objective are defined, along with any constraints. In each iteration the algorithm modifies the variable region and checks the objective function and the constraints. Put simply, material is added where loading is high and removed where it is low. Manufacturing constraints can also be specified, such as minimum and maximum wall thicknesses, draw directions or symmetries.
The result of a topology optimisation is a design proposal — one that must then be translated into a production-ready CAD model in a subsequent step.
Bead optimisation
Bead optimisation is used to optimise sheet-like structures for stiffness and vibration behaviour. Optimisation algorithms generate a bead pattern that maximises stiffness. Manufacturing constraints such as bead width or bead height can be specified.
Parameter optimisation
Parameter optimisation exploits the parametric modelling of 3D CAD models. Individual parameters or dimensions are varied and the change in the objective function observed. The optimal parameter combination is identified — the one that gives the best result (e.g. minimum mass at permissible stresses). If several parameters are variable, statistical methods such as design of experiments (DoE) can be used to determine the influence of individual parameters and parameter combinations on the objective functions.
Parameter optimisation is also used for tolerance studies, to assess the robustness of a system.
