Chapter 36: Wheel Topology Optimization

36 Wheel Topology Optimization

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Summary 549
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Introduction 550
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Solution Requirements 550
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Modeling Tips 552
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Input File(s) 552
 CHAPTER 36 549
Wheel Topology Optimization

Summary
Title Chapter 36: Wheel Topology Optimization
Topology optimization Cyclical symmetry constraints
features
Geometry

Material properties Young’s Modulus = 1.0x107 Pa, Poisson’s ratio = 0.3, density = 1.0
Boundary conditions Fixed at some points
Applied loads Force = 1000.0 N in direction of gravity
Element type HEXA, RBE3
Topology result Material distribution
)
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CHAPTER 36

Introduction
A wheel model shown in Figure 36-1 is used to demonstrate MD Nastran topology optimization cyclical symmetry
capabilities. The wheel is modeled with six-sided solid elements (118156 CHEXA). The wheel outer layers and bolts
are nondesignable. One load case is considered. The structural compliance is minimized (i.e., minimize the total strain
energy of the structure) with a mass target 0.1 (i.e., remove 90% of the material). Although the load is not cyclically
symmetric about the Y-axis, the design is required to be cyclically symmetric about the Y-axis with five segments.

Figure 36-1 Wheel FE Model

Solution Requirements
Design Model Description

Objective: Minimize averaged compliance

Topology design region: PSOLID (blue)
Constraints: Constraints: Mass target = 0.1 (i.e., mass savings 90%)
The design is forced to be cyclical symmetry about the Y-
axis with five segments.

This solutions demonstrates:

• By using cyclical symmetry constraints in topology optimization, a rotational symmetric design can be
obtained regardless of the boundary conditions or loads.
• CASI solver provides a major speed up for large 3-D problems in static analysis.
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Wheel Topology Optimization

Optimization Solution
The input data for this example related to topology optimization model is given in Listing 8. The coordinate system
(CORD2R = 1) is created to be used to specify cyclical symmetric constraints. The field CS (cyclical symmetric axis)
on the SYM line is Y-axis with NCS (number of cyclical symmetric segments) = 5. It is noticed that SMETHOD=
ELEMENT is used to select CASI iterative solver. The CASI iterative solver released in MD R1 Nastran can provide a
major speedup in the solution of large static analyses.

Listing 8 Input File for Wheel

DESOBJ = 10
DESGLB = 1
ANALYSIS = STATICS
SMETHOD = ELEMENT
SUBCASE 1
SPC = 2
LOAD = 2
BEGIN BULK
CORD2R 1 10.512 33.3312 12.9921 -22.209833.3312 4.88385
28.388 33.3313 -19.7297
DCONSTR 1 2 .1
TOPVAR 1 PSOLID PSOLID .1 2
SYM 1 Y 5
DRESP1 2 FRM FRMASS
DRESP1 10 COMP COMP
Figure 36-2 shows the topology optimized result that is smoothed by using MD Patran. It is noticed that cyclical
symmetry is obtained even though the loading is not cyclically symmetric.

Figure 36-2 Wheel Topology Design

552 MD User’s Guide - Application Examples
CHAPTER 36

Modeling Tips
• CASI solver is limited to compliance minimization topology optimization problem only.
• The cyclical symmetry constraints can also be used for rotational parts <60°. In addition, the starting surface
must be XY plane for cyclical symmetric CS=X, YZ plane for CS=Y; ZX plane for CS=Z, respectively. The
cyclical symmetric segment (NCS) must also be defined in 360 for this case. For example, a 90° rotational
part has three segments, NCS must be set to NCS=12 in 360°.

Input File(s)
File Description
nug_36.dat Cyclical symmetry constraints