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Optimization of a bearing angle Dipl.-Ing. (FH) Andreas Veiz

Sensitivty Analysis, Optimization and Robust Design with optiSLang and ANSYS Workbench (ANSYS v13). Optimization of a bearing angle Dipl.-Ing. (FH) Andreas Veiz Dynamic Software and Engineering GmbH, Weimar, Germany Seminar 23.-24.5.2011, Weimar. Agenda. 1. Model background

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Optimization of a bearing angle Dipl.-Ing. (FH) Andreas Veiz

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  1. Sensitivty Analysis, Optimization and Robust Design with optiSLang and ANSYS Workbench (ANSYS v13) Optimization of a bearing angle Dipl.-Ing. (FH) Andreas Veiz Dynamic Software and Engineering GmbH, Weimar, Germany Seminar 23.-24.5.2011, Weimar

  2. Agenda • 1. Model background • 2. ANSYS workbench simulation • Parametrization of the Geometry Values • Setting boundary conditions in ANSYS Workbench • Meshing in ANSYS Workbench • Solver settings in ANSYS Workbench • Parametrization of simulation results • ANSYS Parameter Manager • 3. Introduction in optiPlug • Workaround optiPlug and optiSLang • File system in optiSLang created by optiPlug • Exporting the simulation to optiSLang • Default settings • Special features of optiPlug Sensitivity analysis, optimization and robust design with optiSLang and ANSYS Workbench

  3. Agenda • 4. Performing of a sensitivity analysis (DoE) • Checking the parametrization in optiSLang • Updating the parameter range • Starting a new Design of Experiments • Postprocessing of the sensitivity study • 5. The Metamodel of optimal prognosis (MoP) • 6. Optimization of the model • Reducing the number of necessary parameters • Defining an suitable obective function • Optimization of the model with the method of adaptive response surfaces • Read-in the best design in ANSYS Workbench • Introduction in other optimization algorithms • 7. Basics of a robustness analysis • Stochastic scatter of parameters • Write out a new robustness task with optiPlug • Update the parametrization for a robustness analysis • 8. Summary and conclusion Sensitivity analysis, optimization and robust design with optiSLang and ANSYS Workbench

  4. 1. Model background • The bearing angle is part of a test bench for chains. • In this test bench, a load of 12.6 kN is set on chains. • The load is set in longitudinal direction. • A load cell is fixed to the angle. This measures the load and send it to the computer system • Therefore the whole load of 12.6 kN is set on the winding, where the load cell is fixed to the bearing angle • Thus, the problematic variables are the v.Mises stress in the whole structure and especially at the connection between the rib and the angle short below the winding. Sensitivity analysis, optimization and robust design with optiSLang and ANSYS Workbench

  5. 1. Model background • Workflow of a robust design optimization Basic design Sensitivity analysis Optimization Robustness analysis Is the design robust ? No Yes Robust design Sensitivity analysis, optimization and robust design with optiSLang and ANSYS Workbench

  6. 2. ANSYS Workbench simulation • 1. Model background • 2. ANSYS workbench simulation • Parametrization of the Geometry Values • Setting boundary conditions in ANSYS Workbench • Meshing in ANSYS Workbench • Solver settings in ANSYS Workbench • Parametrization of simulation results • ANSYS Parameter Manager • 3. optiPlug • 4. Sensitivity analysis • 5. Optimization • 6. Robustness analysis • 7. Summary and conclusion Sensitivity analysis, optimization and robust design with optiSLang and ANSYS Workbench

  7. 2.1 CAE Integration within ANSYS Workbench Sensitivity analysis, optimization and robust design with optiSLang and ANSYS Workbench

  8. 2.1 Overview – Parametrization in ANSYS Workbench • The basic of the parametrization in ANSYS is the Parameter Set on the project page: • Geometryparameters(from CAD or Design Modeler) • Materialparameters/Simulationparameters • Simulationresults Sensitivity analysis, optimization and robust design with optiSLang and ANSYS Workbench

  9. 2.1 Overview – Parametrization in ANSYS Workbench • The Parameter section summarizes the Parameters of each component • CAD Parameters:CAD System (external)or ANSYS Design Modeler • Material Parameter:Engineering Data • Simulation results:Simulation Sensitivity analysis, optimization and robust design with optiSLang and ANSYS Workbench

  10. 2.2 Parametrization of the geometry • Start a new project in ANSYS Workbench • Create a new „Static Structural (ANSYS)“ analysis Sensitivity analysis, optimization and robust design with optiSLang and ANSYS Workbench

  11. 2.2 Parametrization of the geometry • Attach the geometry file „angle.agdb“ to the project • The geometry is already prepared but not yet parametrized Sensitivity analysis, optimization and robust design with optiSLang and ANSYS Workbench

  12. 2.2 Parametrization of the geometry • To complete the parametrization, right-click on the geometry and select „Edit“ Sensitivity analysis, optimization and robust design with optiSLang and ANSYS Workbench

  13. 2.2 Parametrization of the geometry • Mark the single parameters by clicking in the checkbox. • The parameter dialog opens. • Insert a reasonable parameter name. Sensitivity analysis, optimization and robust design with optiSLang and ANSYS Workbench

  14. 2.2 Parametrization of the geometry • Parametrized dimension appear yellowin you model • After defining the parameter name,a „D“ appears in the checkbox • Repeat this also for extrusions and blends Sensitivity analysis, optimization and robust design with optiSLang and ANSYS Workbench

  15. 2.2 Parametrization of the geometry • Repeat this procedure for all of your desired parameters: • XY_plane sketch 2: • H14: DS_Rib_length • H5: DS_Blade_thickness_vertical • H6: DS_Blade_length_horizontal • V7: DS_Blade_thickness_horizontal • V8: DS_Blade_length_vertical • XY_plane sketch 3: • V12: DS_Rib_height • Extrude1: DS_Blade_breadth • Extrude2: DS_Rib_breadth • Outer_blend: DS_Outer_Blend • Blend_Fixing: DS_Blend_Fixing • Blend_Bore: DS_Blend_Bore • Rib_Blend: DS_Rib_Blend • Edge_Blend: DS_Edge_Blend Sensitivity analysis, optimization and robust design with optiSLang and ANSYS Workbench

  16. 2.2 Parametrization of the geometry • For the blade and Rib-breadth we have to do a modification, because of symmetry • 1. Open the parameter section of the Design Modeler • 2. Double the value of the parameter „ DS_Blade_breadth“ and „ DS_Rib_breadth“ in „Design Parameters“ Sensitivity analysis, optimization and robust design with optiSLang and ANSYS Workbench

  17. 2.2 Parametrization of the geometry • 3. Now click on „Parameter/Dimension Assignments“: Here, you can modify each of the parameters so that they depend another parameters. You may also insert formulas here. • 4. Modifiy the dimension assignment so that the value of the parameter is divided by 2. • 5. You can check your parametrization easily by clicking on „Check“. • Save the project as Angle_v12 locate in a local directory. Sensitivity analysis, optimization and robust design with optiSLang and ANSYS Workbench

  18. 2.3 Simulation and parametrization of the results • Close the design modeler and start a new simulation by click RMB on „Model“ and select „Edit“. • See the „Parameter Set“ Box. This indicates that you are working with parameters in ANSYS Workbench. Sensitivity analysis, optimization and robust design with optiSLang and ANSYS Workbench

  19. 2.3 Simulation and parametrization of the results • Make sure that the units are switched to „mm, kg, N, °C, s“ • Insert a Refinement with a ratio of 2 on the shown faces. • The highest stress level is expected here. Sensitivity analysis, optimization and robust design with optiSLang and ANSYS Workbench

  20. 2.3 Simulation and parametrization of the results • Set the other Mesh settings like shown below • Generate the Mesh Sensitivity analysis, optimization and robust design with optiSLang and ANSYS Workbench

  21. 2.3 Simulation and parametrization of the results • Now, stet up the static structural analysis settings • Put a fixed support on the 4 holes. Sensitivity analysis, optimization and robust design with optiSLang and ANSYS Workbench

  22. 2.3 Simulation and parametrization of the results • In addition to that set a displacement of „0“ in Y-Direction on the ground plate. This prevents the structure to lift from the imaginary bearing Sensitivity analysis, optimization and robust design with optiSLang and ANSYS Workbench

  23. 2.3 Simulation and parametrization of the results • Set a force in negative X-direction with a magnitude of12.6 kN on the winding • As results, we need the total deformation and the equivalent Stress click solve Sensitivity analysis, optimization and robust design with optiSLang and ANSYS Workbench

  24. 2.3 Simulation and parametrization of the results Stress: 133.44 MPa Deformation: 0.0836 mm Sensitivity analysis, optimization and robust design with optiSLang and ANSYS Workbench

  25. 2.3 Simulation and parametrization of the results • For the following analysis we need 3 simulations parameters: • Mass (material: structural steel) • Maximum deformation • Maximum equivalent stress • Parametrization just by clicking in the checkbox in the outline tree.A „P“ indicates a successful parametrization Sensitivity analysis, optimization and robust design with optiSLang and ANSYS Workbench

  26. 2.3 Simulation and parametrization of the results • Save the project and close the mechanical simulation. • Check the parametrization by opening the parameter section by doubleclicking on „Parameter Set“ Sensitivity analysis, optimization and robust design with optiSLang and ANSYS Workbench

  27. 2.3 Simulation and parametrization of the results • The parameters are listet like in an Excel Sheet Sensitivity analysis, optimization and robust design with optiSLang and ANSYS Workbench

  28. 2.4 Summary Simulation • The geometrie has been opened and parametrized • Static-structural analysis with parametrized results • Calculation time is about 1.5 min • Check of the parametrization in the parameter set • Save now the project. Sensitivity analysis, optimization and robust design with optiSLang and ANSYS Workbench

  29. 3. optiPlug • 1. Model background • 2. ANSYS workbench simulation • 3. optiPlug • 3.1. Introduction • 3.2. File system optiPlug - optiSLang • 3.3. Export an ANSYS project to optiSLang • 3.4. Export the project bearing angle to optiSLang • 4. Sensitivity analysis • 5. Optimization • 6. Robustness analysis • 7. Summary and conclusion Sensitivity analysis, optimization and robust design with optiSLang and ANSYS Workbench

  30. 3.1 Introduction • Bidirektional Interface between optiSLang and ANYS Workbench. • Extraction of results and input of external input-parameters to the ANSYS parametermanager • Starting of the Workbench using Python-skripts (ANSYS v12/13), former by Java-scripting (ANSYS v11) • optiPlug is now located on the project page in ANSYS Workbench, therefore it is now possible to cope with different simulation types in one optiSLang project! • Basic feature is to write the optiSLang input and output file and generates pre-defined basic workflows. • optiPlug generates the complicated starting script for starting the workbench automatically by optiSLang Sensitivity analysis, optimization and robust design with optiSLang and ANSYS Workbench

  31. 3.1 Introduction Preparings in ANSYS workbench: • Definition of all parameters (design-, material-, simulation parameters) in ANSYS Workbench • Save your project. Settings in optiPlug • Choose the analysis type (optimization / stochastic) • Default settings optiSLang • Modification of the variation space • Definition of objectives and constraints • Execution of the desired optimization / analysis runs Sensitivity analysis, optimization and robust design with optiSLang and ANSYS Workbench

  32. 3.2 File system optiSLang - optiPlug • optiPlug saves the files into a subdirectory of your ANSYS-project directory: • bin – folder: here is the starting script located • opti_problems: here is the input and output file and the problem file located • workflows: here you can find all the executed workflows in XML format • logfiles: logfiles of optiSLangruns • The projectfile *.fgpr Sensitivity analysis, optimization and robust design with optiSLang and ANSYS Workbench

  33. 3.2 File system optiSLang - optiPlug • Files in the folder opti_problems: • Angle_v12_doe.pro: problemdefinition In the subfolder: • Angle_v12_doe.dat :all input variables are saved in an ASCII format text file • Angle_v12_doe.dat :all output variables are saved in an ASCII format text file • The name is according to yourANSYS project file name Sensitivity analysis, optimization and robust design with optiSLang and ANSYS Workbench

  34. 3.3 Export an ANSYS project to optiSLang • Start optiPlug by clicking on the „optiPlug“ Button on the project page. • Then, the optiPlug dialogue opens. Sensitivity analysis, optimization and robust design with optiSLang and ANSYS Workbench

  35. 3.3 Export an ANSYS project to optiSLang • Overview optiPlug Dialogue: • Write or read • Problem type • Stochastic • Optimization • Start Variations space • Modify/overwrite of anexisting optiSLang pro-ject • Save ANSYS Data* • Show ANSYS GUI * If you choose this option, makesure that you have enogh space on your harddrive for storaging a large amount of data Sensitivity analysis, optimization and robust design with optiSLang and ANSYS Workbench

  36. 3.3 Export an ANSYS project to optiSLang • Default settings: • Parameter range defaults: • +/- 20% for Optimizationproblems,(suitable for first basicsimulations) • Coefficient of variation of 5% for stochastic analysis, standard deviation 1σ • Update mode:- Warn if the optiSLang files already exist- Update the existing files- Overwrite everything Sensitivity analysis, optimization and robust design with optiSLang and ANSYS Workbench

  37. 3.4 Export the project bearing angle to optiSLang • Click on the optiPlug Button to export the project. • The export dialogue opens. • You do not need to make any changes here. • Confirm the export with OK. Sensitivity analysis, optimization and robust design with optiSLang and ANSYS Workbench

  38. 4. Sensitivity analysis • 1. Model background • 2. ANSYS workbench simulation • 3. optiPlug • 4. Sensitivity analysis – Design of Experiments (DoE) • 4.1 Introduction – Sensitivity analysis • 4.2 Import the project bearing angle • 4.3 Modification of the parameter settings • 4.4 Sampling • 4.5 Performing a sensitivity analysis • 4.6 Postprocessing of a sensitivity analysis • 4.7 Summary • 5. Optimization • 6. Robustness analysis • 7. Summary and conclusion Sensitivity analysis, optimization and robust design with optiSLang and ANSYS Workbench

  39. 4.1 Introduction – Sensitivity analysis Sensitivity analysis Analysis of parameter sensitivity means investigating the effect of variability of certain parameters on the variability of design-relevant response quantities.Using stochastic sampling methods such as plain Monte Carlo simulationlatin hypercube samplingwith statistics to evaluation for sensitivity calculation:histogram, anthill plotslinear and quadratic correlation coefficientscorrelation matrix, confidence intervalsprincipal component analysisdetection of most sensitive/relevant input variables Sensitivity analysis, optimization and robust design with optiSLang and ANSYS Workbench

  40. 4.2 Import the project bearing angle • Start optiSLang • To import the project that you created with optiPlug, clickon „flowGuide“ and choose the „Project manager“ Sensitivity analysis, optimization and robust design with optiSLang and ANSYS Workbench

  41. 4.2 Import the project bearing angle • Now, choose „Import project“ • Browsen for the project by clicking on the button • Choose the flowGuide project file xyz.fgpr in the defined directory and confirm the selection with „Select“ • Conform the creation of the project with „Apply“ and close the Project Manager with „Close“ Sensitivity analysis, optimization and robust design with optiSLang and ANSYS Workbench

  42. 4.3 Modification of the parameter settings • Now, we have to modify the variation space of each Parameter. • To do this, choose the current project and double-click on „Parametrize_problem“ then choose the predefined „…_modify_1“ workflow. • Confirm with „Start“ to start the parametrization. Sensitivity analysis, optimization and robust design with optiSLang and ANSYS Workbench

  43. 4.3 Modification of the parameter settings • Unfold the parameter treeby clicking „Tree“  „Unfold Tree“ • To modify a parameter, double-click on it in the unfolded parameter tree • Alternative: right mouse buttonon one parameter and select „Show Dialog“ Sensitivity analysis, optimization and robust design with optiSLang and ANSYS Workbench

  44. 4.3 Modification of the parameter settings • In the „Parameter Settings“-dialogueall of parameter settings are listed • Modify at „Optimization“ the lower and upper bounds for the parameter as shown below • Format type and parameter type are already correctly predefined. • Click on „OK“ to close the „Parameter Settings“-dialogue. • „Go to parameter“ causes a jump of a marker to the parameter in the input / output file. Sensitivity analysis, optimization and robust design with optiSLang and ANSYS Workbench

  45. 4.3 Modification of the parameter settings • Modify the lower and upper bounds of all parameters according to the tabular. • The variation of the blends will remain on the defaultsetting of +/- 10% as predefined with optiPlug • We have got 13 design paramters to deal with in our sensitivity analysis Sensitivity analysis, optimization and robust design with optiSLang and ANSYS Workbench

  46. 4.3 Modification of the parameter settings • To close the parametrization, click on „File“  „Exit“ • Confirm the following dialogue boxes with „Yes“ and „OK“ Sensitivity analysis, optimization and robust design with optiSLang and ANSYS Workbench

  47. 4.3 Modification of the parameter settings • Finally, you get a table of all you parameters and lower and upper bounds. • Please check your parametrization carefully. • You can also make final changes here • Close the table with „OK“. • Now the parametrization is finished. Sensitivity analysis, optimization and robust design with optiSLang and ANSYS Workbench

  48. 4.4.3 Sampling Summary • State-of-the-art of today is to generate the samples by Latin Hypercube Sampling in a DoE! • In our case, we have about 50-75 Samples for a DoE • Because of the future meta modeling, we’ll choose 75 designs Sensitivity analysis, optimization and robust design with optiSLang and ANSYS Workbench

  49. 4.5 Performing a sensitivity analysis • The Workflow of a sensitivity analysis has been predefined by optiPlug • Already filled in: • Worflow Identificator (Name) • Problem specification file (Parametrization) • Start script (by optiPlug) • Start the DoE by clicking on“Start” • Now the DoE dialogue opens Sensitivity analysis, optimization and robust design with optiSLang and ANSYS Workbench

  50. 4.5 Performing a sensitivity analysis • Choose “advanced latin hypercube” as samplingmethod • Definine the desirednumber of designs to calculate (e.g. 75) • Confirm with “Apply”Then, all of the designswill be created • Start the DoE with“OK” 75 Sensitivity analysis, optimization and robust design with optiSLang and ANSYS Workbench

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