Chapter 14

Design Optimization

Contents
14.1

?
What is Design Optimization?

14.2

ANSYS
Design Optimization with ANSYS

14.3

:
Example: Shape Optimization of a Fixed-ends Beam

14.4

:
Example: Design of a Triangular Plate

14.5

Other Optimization Tools

2/33

 14.1
?
What is Design Optimization?

3/33

14.1.1 Mathematical Model

Mininize
f (x )
Subject to SiL s i ( x ) SiU , i 1, 2, ..., m
X Lj x j X Uj ,
j 1, 2, ..., n

4/33

14.1.2 Optimization Variables

Mininize
f (x )
Subject to SiL si ( x ) SiU , i 1, 2, ..., m
X Lj x j X Uj ,
j 1, 2, ..., n

Design variables
State variables
Objective function
5/33

14.1.3 Design Space and

Design Sets

Design space
Design set
Feasible design
Optimal design
Best design

6/33

 14.2
ANSYS
Design Optimization with ANSYS

7/33

14.2.1 A Design Optimization

Procedure Using ANSYS
Organize ANSYS procedure into two
files:
Optimization filedescribes
optimization variables, and trigger the
optimization runs.
Analysis fileconstructs, analyses,
and post-processes the model.
8/33

14.2.2 Typical Commands in

an Optimization File
01
02
03
04
05
06
07
08
09
10
11
12
13

/CLEAR
...
/INPUT, ...
/OPT
OPCLEAR
OPVAR, ...
OPVAR, ...
OPVAR, ...
OPTYPE, ...
OPANL, ...
OPEXE
OPLIST, ...
...

!
!
!
!
!
!
!
!
!
!
!
!
!

Clear model database

Initialize design variables
Execute analysis file once
Enter optimization phase
Clear optimization database
Declare design variables
Declare state variables
Declare objective function
Select optimization method
Specify analysis file name
Execute optimization run
Summarize the results
Further examining results

9/33

14.2.3 Typical Commands in

an Analysis File
01
02
03
04
05
06
07
08
09
10
11
12

/PREP7
...
FINISH
/SOLUTION
...
FINISH
/POST1
*GET, ...
*GET, ...
...
FINISH

! Build the model using the

! parameterized design variables

! Apply loads and solve

! or /POST26
! Retrieve values for state variables
! Retrieve value for objective function

10/33

14.2.4 ANSYS Optimization

Algorithms
Two built-in algorithms in ANSYS:
First order method
Subproblem approximation method
(Zero order method)

11/33

 14.3
:
Example: Shape Optimization of a Fixed-end Beam

12/33

14.3.1 Problem Description

F = 100,000 N

p =15,000 N/m
h

b = 100 mm

6m

13/33

14.3.2 Modeling Consideration

Mininize
TVOLUME
Subject to 100 Mpa SMAX 100 Mpa
100 Mpa SMIN 100 Mpa
100 mm H1 800 mm
100 mm H 2 800 mm
100 mm H 3 800 mm
C
L
H1

1.5 m

H2

1.5 m

H3

14/33

14.3.3 ANSYS Procedure

Optimization File
01
02
03
04
05
06
07
08
09
10
11
12
13

FINISH
/CLEAR
/TITLE, Design of Beam (SI)
H1 = 0.4
H2 = 0.4
H3 = 0.4
/INPUT, BEAM, TXT
/OPT
OPCLR
OPVAR, H1, DV, 0.1, 0.8

14
15
16
17
18
19
20
21
22
23
24
25
26

OPVAR,
OPVAR,
OPVAR,
OPVAR,
OPVAR,

H2, DV, 0.1, 0.8

H3, DV, 0.1, 0.8
SMAX, SV, -100E6, 100E6
SMIN, SV, -100E6, 100E6
TVOLUME, OBJ,,, 0.0001

OPTYPE, SUBP
OPANL, BEAM, TXT
OPEXE
OPLIST, ALL
PLVAROPT, TVOLUME
PLVAROPT, SMAX, SMIN
PLVAROPT, H1, H2, H3

15/33

14.3.3 ANSYS Procedure

Analysis File (1/2)
01
02
03
04
05
06
07
08
09
10
11
12
13
14

/PREP7
ET, 1, PLANE42,,, 3
R, 1, 0.1
MP, EX, 1, 200E9
MP, NUXY, 1, 0.3
MP, DENS, 1, 7800
K,
K,
K,
K,
K,
K,

1,
2,
3,
4,
5,
6,

0,
0
1.5,
0
3.0,
0
0, -H1
1.5, -H2
3.0, -H3

16
17
18
19
20
21
22
23
24
25
26
27
28
29
30

L, 1, 2
L, 2, 3
L, 1, 4
L, 3, 6
SPLINE, 4, 5, 6,,,,,,, 1, 0, 0
A, 1, 2, 5, 4
A, 2, 3, 6, 5
ESIZE, 0.1
MSHAPE, 0, 2D
MSHKEY, 1
AMESH, ALL
EPLOT
FINISH

16/33

14.3.3 ANSYS Procedure

Analysis File (2/2)
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46

/SOLU
NSEL, S, LOC, X, 0
D, ALL, ALL
NSEL, S, LOC, X, 3
DSYM, SYMM, X
NSEL, S, LOC, Y, 0
SF, ALL, PRES, 15000
NSEL, R, LOC, X, 3
F, ALL, FY, -50000
NSEL, ALL
ACEL,, 9.81

48
49
50
51
52
53
54
55
56
57

/POST1
ETABLE, VOLUME, VOLU
SSUM
*GET,TVOLUME,SSUM,,ITEM,VOLUME
ETABLE, STRESS, S, X
ESORT, ETAB, STRESS
*GET, SMAX, SORT,, MAX
*GET, SMIN, SORT,, MIN
FINISH

SOLVE
FINISH

17/33

14.3.3 ANSYS Procedure

The Optimization Design
23
24
25
26

OPLIST, ALL
PLVAROPT, TVOLUME
PLVAROPT, SMAX, SMIN
PLVAROPT, H1, H2, H3

SMAX
SMIN
H1
H2
H3
TVOLUME

(SV)
(SV)
(DV)
(DV)
(DV)
(OBJ)

(FEASIBLE)
0.94292E+08
-0.92123E+08
0.25608
0.10153
0.18085
0.43822E-01

18/33

14.3.3 ANSYS Procedure

Optimization History
23
24
25
26

OPLIST, ALL
PLVAROPT, TVOLUME
PLVAROPT, SMAX, SMIN
PLVAROPT, H1, H2, H3

19/33

 14.4
:
Example: Design of a Triangular Plate

20/33

14.4.1 Problem Description

T1

30o

30o

Dimension: mm

R = FIL

30o
30o

40

INRAD
200

30o
30o

21/33

14.4.2 Modeling
Consideration
1/6 model is used, due to the symmetry
of the geometry and loading.

22/33

14.4.3 ANSYS Procedure

Optimization File (1/2)
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
16
17
18
19

FINISH
/CLEAR
/TITLE, Optimal Design of a hexagonal plate
! UNITS: N-mm-s
T1 = 30
FIL = 10

! Thickness
! Fillet radius

/INPUT, TRIPLATE, TXT

/OPT
OPCLR
OPANL, TRIPLATE, TXT
OPVAR,
OPVAR,
OPVAR,
OPVAR,

T1, DV, 20, 40

FIL, DV, 5, 15
SMAX, SV,, 150
VTOT, OBJ,,, 1

! DVs: Thickness
!
Fillet radius
! SV: Max equ. Stress
! OBJ: Total volume

23/33

14.4.3 ANSYS Procedure

Optimization File (2/2)
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37

OPKEEP, ON
OPTYPE, SUBP
OPEXE
OPLIST, ALL
PLVAROPT, T1, FIL
PLVAROPT, SMAX
PLVAROPT, VTOT
FINISH

! Save best design

! Plot the best design

/POST1
RESUME,, BDB
FILE,, BRST
SET
PLNSOL, S, EQV

24/33

14.4.3 ANSYS Procedure

Analysis File (1/6)
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25

/PREP7
*AFUN, DEG
INRAD = 200*COS(30)-20

! Inner radius

CYL4,-200,0,INRAD,-30,INRAD+T1,30
CYL4,200*COS(60),200*SIN(60),INRAD,-90,INRAD+T1,-150
CYL4,200*COS(60),200*SIN(-60),INRAD,90,INRAD+T1,150
APLOT
AADD, ALL
ADELE, ALL
! Delete area, keep lines
LPLOT
!

Fillets on inner slot

LSEL,, RADIUS,, INRAD+T1

L1 = LSNEXT(0)
L2 = LSNEXT(L1)
L3 = LSNEXT(L2)
LFILLET, L1, L2, FIL
LFILLET, L2, L3, FIL
LFILLET, L3, L1, FIL
LSEL, ALL
LPLOT

! Select inner arcs

25/33

14.4.3 ANSYS Procedure

Analysis File (2/6)
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45

Keep only symmetric portion

WPROT,, 90
LSBW, ALL
WPROT,,, 60
LSBW, ALL
WPCSYS
WPSTYLE
CSYS, 1
LSEL, U, LOC, Y, 0, 60
LDELE, ALL,,, 1
LSEL, ALL
KSLL
KSEL, INVE
KDELE, ALL
KSEL, ALL
LPLOT

! Delete unnecessary keypoints

26/33

14.4.3 ANSYS Procedure

Analysis File (3/6)
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62

Create missing lines and combine right edge lines

KSEL,, LOC, Y, 0
K1 = KPNEXT(0)
K2 = KPNEXT(K1)
LSTR, K1, K2
KSEL,, LOC, Y, 60
K1 = KPNEXT(0)
K2 = KPNEXT(K1)
LSTR, K1, K2
ALLSEL
CSYS, 0
LSEL,, LOC, X, 100
LCOMB, ALL
ALLSEL
LPLOT

27/33

14.4.3 ANSYS Procedure

Analysis File (4/6)
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78

Create the area

AL, ALL
APLOT
! MESHING
ET, 1, PLANE82,,, 3
R, 1, 10
! Thickness
MP, EX, 1, 2.07E5
! Young's modulus, MPa
MP, NUXY, 1, 0.3
SMRTSIZE, 3
AMESH, ALL
EPLOT
FINISH

28/33

14.4.3 ANSYS Procedure

Analysis File (5/6)
80
81
82
83
84
85
86
87
88
89
90
91
92

/SOLU
CSYS, 1
LSEL,, LOC, Y, 0
LSEL, A, LOC, Y, 60
DL, ALL,, SYMM
CSYS, 0
LSEL,, LOC, X, 100
SFL, ALL, PRES, -50
ALLSEL
LPLOT
SOLVE
FINISH

Symmetry b.c.

Pressure load (MPa)

29/33

14.4.3 ANSYS Procedure

Analysis File (6/6)
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108

/POST1
PLNSOL, S, EQV
/DSCALE,, OFF
/EXPAND, 6, POLAR, HALF, 0, 60
/REPLOT
!

Retrieve maximum equivalent stress and volume

NSORT, S, EQV
*GET, SMAX, SORT,, MAX
ETABLE, EVOL, VOLU
SSUM
*GET, VTOT, SSUM,, ITEM, EVOL
FINISH

30/33

14.4.3 ANSYS Procedure

The Optimum Design
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37

OPKEEP, ON
OPTYPE, SUBP
OPEXE
OPLIST, ALL
PLVAROPT, T1, FIL
PLVAROPT, SMAX
PLVAROPT, VTOT
FINISH

! Save best design

! Plot the best design

/POST1
RESUME,, BDB
FILE,, BRST
SET
PLNSOL, S, EQV

31/33

14.4.3 ANSYS Procedure

Optimization History
25
26
27

PLVAROPT, T1, FIL

PLVAROPT, SMAX
PLVAROPT, VTOT

32/33

14.5 Other Optimization Tools

Provided by ANSYS

Single Iteration Design Tool

Random Design Tool
Gradient Tool
Sweep Tool
Factorial Tool

33/33