Optimization Analysis

Design Online Academy

ABOUT THE INSTRUCTOR

•B.Sc in mechanical engineering, design and production engineering

department, faculty of engineering, Ain Shams University (year 2007).

•M.sc in the CAD/CAM/CNC field /design and production engineering

department, Faculty of Engineering, Ain Shams University (Oct2007-
Oct2010).

•PhD in the virtual simulation field/design and production engineering

department, Faculty of Engineering, Ain Shams University (May2011-
May2015).

•Currently, Assistant Professor in ASU.

•Founder of Design Online Academy (1st March2017).

Background VIRTUAL PROTOTYPING

From CAD to CAE

Need modifications
Need modifications
Static analysis
Normal mode
Frequency response
Transient response
Solids
DESIGN
SIMULATION
APPROACH
PRODUCT
Analysis

PROCESS
results

Fluids
Thermodynamics

Approved design
Aerodynamics
Fluid mechanics
Heat transfer

CAM/CNC

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Background

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Background
Fully Stressed Design (FSD) method.
• This used the observed fact that for a
determinant structure, the minimum volume
could be achieved by forcing the stresses at
all points to be simultaneously at the
required upper limit.
• At the same time it was recognized that all
loading cases must be catered for
simultaneously. This method is a
similar approach to
• The method has definite disadvantages
when used in non-determinant structures
much later topology
and it can be shown that it is far from optimization
optimum in many cases.

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Background

Mathematical programming • By Increasing computing power and using

higher efficiency solving techniques, other
• Gradient based method is the dominant. methods appeared like:
• Methods like: • Design of experiments
o Linear programming • Neural network
o Integer programming • Genetic algorithm
o Nonlinear programming • Fuzzy logic
o Quadratic programming

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OPTIMIZATION PROBLEM STATEMENT
• Design variables: {X1, X2,….,Xn}
• Objective function:
Minimize or maximize f{X}
• Subject to:
• Inequality constrain: g(x) ≤ 0
• Equality constrain: h(x)= 0 Example
• Gage constrain: XLi ≤ Xi ≤ XUi • Design variables: {X, U, W, r, V, t}
• Objective function: Minimize Weight.
• Inequality constrain: σ≤ 300Mpa
• Equality constrain: r= 20

• Gage constrain: 10 ≤ X,U≤ 30

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OPTIMIZATION PROBLEM STATEMENT

• If there is one design variable, x and an
objective function f(x).
• We can find the unconstrained optimum x*
with a numerical search
After putting in an upper constraint g(x)
and forcing the optimum to sit against the
constraint ‘barrier’, this is now a
constrained optimization problem

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Example
In practice there is no one dimensional ( one design variable)
problem, there may be hundreds or thousands of design variables in
a real problem.
For simplicity, imagine a problem with two design variables (B & H).
Objective function: Minimize the volume of the cantilever.
Subject to:

The design space in 2d

• Variables H and B
• Objective function contours
• Constraint Boundaries

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GRADIENT APPROACH
Optimization process is like climbing the hill with a corresponding map.
The objective function is like trying to reach the mountain top.
The challenge is:
• There are constrains like those barriers that opposes your climbing.
• Actually the map is not clear or the weather is foggy.
Here comes the main approach called GRADIENT APPROACH, that most
methods used in internal FE-solver optimizers rely on it.
• Common expression called “STEEPEST DECENT OR ACCENT” appears.

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GRADIENT APPROACH

One drawback of gradient approach is uncertainty of local or global max/min .

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 DESIGN OF EXPERIMENT
• A set of FEA solutions with random design
variables are used to create large body of results.
• The response of all constraints, objective function
etc. can be surface fitted in n-dimensional space
against the design variables.
• A search can then be made in design space for a
minimum feasible solution.
• The method is used as a supplement to gradient
based.

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Design Explorer

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Optimizers

For copyrights: http://www.endeavos.com/services/design-optimization/

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 TYPES of OPTIMIZATIONS

Size Opt. Shape Opt. Topology Opt.

• Changing physical properties of
the elements – plate thickness,
rod area, etc.
• Keeping mesh constant
• Distorting the element mesh to
change the geometric shape
• Keeping mesh topology
constant
• Eroding elements from a mesh
• Overall mesh topology and shape is
constant.
• Remaining elements form the new
shape.

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OTHER RESPONSE TYPES

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REAL LIFE APPLICATIONS

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