Topology Optimization of Triangular Bracket - ANSYS Workbench

Topology optimization is a mathematical method which spatially optimizes the distribution of material within a defined domain, by fulfilling given constraints previously established and minimizing a predefined cost function. Main aim of this tutorial is optimizing and decreasing the material density of the triangular bracket as 50% by topology optimization.

  1. Step 1: Overview



  2. Step 2: Analysis Procedure

    • As a very first step, the triangular bracket has been analyzed to obtain the maximum deformation, maximum stress (point of interest) and minimum safety factor.
    • As the 2nd step, structural (topology) optimization analysis has been implemented to decrease the material density.
    • As the last step, the optimized geometry has been reworked on SpaceClaim and analyzed once more.



  3. Step 3: Engineering Data (Material Model)

    • The default material which is Structural Steel have been used in this tutorial:




  4. Step 4: Geometry (SpaceClaim Model)

    • The triangular bracket has been designed on SpaceClaim could be seen below:


  5. Step 5: Meshing Operations (Default Geometry)

    • The default mesh with 0.6mm of Element Size has been created:


    • The mesh refinement on point of interest (the area which has the maximum stress) has been refined until the stress value difference between two adjacent nodes is less than 10%.
    • The first refinement on point of interest have been implemented as Body Sizing / Sphere of Influence with 1.5mm of Sphere Radius and 0.11mm of Element Size:





    • The second refinement has been implemented as Inflation with 3 Layers and 1e-002mm:


  6. Step 6: Boundary Conditions (Default Geometry)

    • The Boundary Conditions have been implemented as below figure:


    • Cylindrical Support has been implemented on 2 Faces with Free Tangential option:




    • The Bearing Load has been implemented as seen below:




  7. Step 7: Results (Default Geometry)

    • Total Deformation:




    • Equivalent (von-Mises) Stress:




    • Minimum Safety Factor:


  8. Step 8: Topology (Structural) Optimization

    • Firstly, the engineering data, the geometry, the model and the results from Static Structural must be connected with Structural Optimization Analysis:




    • Analysis Setting of Structural Optimization could be seen below:



    • The Exclusion Regions (bearing load and cylindrical support areas) and Topology Region could be seen below:




    • Material Density (Response Constraint) Reduction with 50% Mass has been determined:



    • The result of the Topology Optimization could be seen below:



  9. Step 9: The Geometrical Optimization of Resulted Geometry

    • The resulted geometry from Topology Optimization results have been optimized according to new geometry boundaries:





  10. Step 10: Results (Optimized Geometry)

    • The analysis results for optimized geometry with the same boundary conditions could be found below.


    • Total Deformation:


    • Equivalent (von-Mises) Stress:



    • Minimum Safety Factor:


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