Appendix Thirteen

Shape Finder
Shape Finder

Chapter Overview Training Manual

In this chapter, using the Shape Finder in Simulation will be

ANSYS Workbench Simulation

covered.
In Simulation, performing shape optimization is based on a
linear static structural analysis.
It is assumed that the user has already covered Chapter 4
Linear Static Structural Analysis prior to this section.

The capabilities described in this section are generally

applicable to ANSYS DesignSpace Entra licenses and
above.
Some options discussed in this chapter may require more
advanced licenses, but these are noted accordingly.
Other type of analyses are covered in their respective
chapters.

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Shape Finder

Basics of Shape Optimization Training Manual

Requesting the Shape Finder performs shape or topological

ANSYS Workbench Simulation

optimization
Shape Finder is an optimization problem, where the energy of
structural compliance is minimized based on a volume reduction
constraint
Another way to view this is that the Shape Finder tries to obtain
the best stiffness to volume ratio. The Shape Finder tries to find
areas where material can be removed without adversely affecting
the strength of the overall structure.
The Shape Finder is based on a single static structural
environment
The Shape Finder cannot be used for multiple environments
The Shape Finder currently cannot be used for free vibration, thermal,
or other analyses
Although based on a single static structural analysis, because it is an
optimization, many iterations will be performed internally, so it can be
computationally expense.

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 Shape Finder

Basics of Shape Optimization Training Manual

In the example below, a simple assembly has supports and

ANSYS Workbench Simulation

a bolt load. The Shape Finder allows the user to determine
where material may be removed for the given loading
condition, if weight reduction was sought.
Shape optimization is useful for conceptual designs or
performing weight-reduction on existing designs

Model shown is from a sample Inventor assembly. March

Shape Finder

A. Shape Optimization Procedure Training Manual

The shape optimization procedure is very similar to

ANSYS Workbench Simulation

performing a linear static analysis, so not all steps will be
covered in detail. The steps in yellow italics are specific to
shape optimization analyses.
Attach Geometry
Assign Material Properties
Define Contact Regions (if applicable)
Define Mesh Controls (optional)
Insert Loads and Supports
Request Shape Finder Results
Set Shape Finder Options
Solve the Model
Review Results

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 Shape Finder

Geometry and Material Properties Training Manual

Unlike linear static analyses, only solid bodies can be used

ANSYS Workbench Simulation

for shape optimization
Line or surface bodies cannot be used with the Shape Finder

For material properties, Youngs Modulus and Poissons

Ratio are required
If acceleration (and other inertial loads) are present, mass
density is also required
If thermal loading is present, coefficient of thermal expansion
and thermal conductivity are also required

ANSYS License Availability

DesignSpace Entra x
DesignSpace x
Professional
Structural
Mechanical/Multiphysics
x
x
x
March
 Shape Finder

Contact Regions Training Manual

Any type of face-to-face contact may be included with

ANSYS Workbench Simulation

Shape Finder
Because shape optimization requires multiple iterations, if
nonlinear contact is present, the overall solution will take
longer

Since line and surface bodies are not supported in Shape

Finder, edge contact and spot welds cannot be used.

ANSYS License Availability

DesignSpace Entra
DesignSpace x
Professional
Structural
Mechanical/Multiphysics
x
x
x
March
 Shape Finder

Mesh Controls Training Manual

The density of the mesh affects the fidelity of the solution

ANSYS Workbench Simulation

As with other analyses, this is also true for shape
optimization. A finer mesh will be computationally more
expensive, but the areas where material can be removed will
be much more clearly defined, as shown in the example
below:

ANSYS License Availability

DesignSpace Entra x
DesignSpace x
Professional
Structural
Mechanical/Multiphysics
x
x
x
Model shown is from a sample Unigraphics assembly. March
 Shape Finder

Loads and Supports Training Manual

Any loads and supports may be used with the Shape Finder

ANSYS Workbench Simulation

Because the Shape Finder tries to minimize volume and
maximize stiffness based on the loads and supports, the loads
and supports are very important and will influence the results.
The Shape Finder will generally keep material where loads are
present and where supports are reacting to the load.
Different load and support conditions will create different load
paths, so the Shape Finder results will differ.
The Compression Only support is nonlinear. Because Shape
Finder is an optimization problem, a nonlinear support may
increase solution time considerably.
Thermal loads may also be used (if supported by license).
However, note that the Shape Finder results may be unintuitive in
cases where thermal strains are large. In these situations, it may
be advisable to run two environments, one with and another
without thermal loads to compare the differences.
ANSYS License Availability
DesignSpace Entra x
DesignSpace x
Professional
Structural
Mechanical/Multiphysics
x
/
x
March
 Shape Finder

Requesting Results Training Manual

For shape optimization, only the Shape

ANSYS Workbench Simulation

Finder results are valid
Under the Solution branch, the Shape Finder result(s) can be
requested
No other type of result can be requested. If a stress analysis is
desired, duplicate the Environment branch, then request
displacement and stress/strain results.
For Shape Finder, simply specify the target reduction amount
(default is 20% reduction)
Note that too much reduction of material will result in a truss-like
structure

ANSYS License Availability

DesignSpace Entra x
DesignSpace x
Professional
Structural
Mechanical/Multiphysics
x
x
x
March
 Shape Finder

Solution Options Training Manual

The solution branch provides details on the type of analysis

ANSYS Workbench Simulation

being performed
For a shape optimization, none of the options in the Details
view of the Solution branch usually need to be changed.
Solver Type or Weak Springs can be changed, if needed, per
the guidelines in Chapter 4 for static structural analyses.
Large Deflection is not applicable to shape optimization.
The Analysis Type will display
Shape for the case of shape
optimization. If thermal loads are
also present, then Thermal Shape
will be shown. Note that this refers
to a thermal-stress analysis, not a
purely thermal analysis.

ANSYS License Availability

DesignSpace Entra x
DesignSpace x
Professional
Structural
Mechanical/Multiphysics
x
x
x
March
 Shape Finder

Solution Options Training Manual

For the Shape Finder, the following is performed internally:

ANSYS Workbench Simulation

The Shape Finder procedure corresponds to topological
optimization in ANSYS.
In Simulation, only a single stress analysis is supported (whereas
in ANSYS, modal analysis and multiple load cases are supported)
If thermal loads are present, a thermal analysis is performed
first.
A thermal analysis is only performed once, at the start of the
simulation. This means that the thermal loading does not account
for redistribution of temperatures due to changes in shape

Advanced ANSYS Details March

 Shape Finder

Solution Options Training Manual

For bodies that results are scoped to (see next Chapter), these

ANSYS Workbench Simulation

elements will have element type 1 as SOLID95.
18x elements, such as SOLID186 and 187 are not used.
SOLID92 is not used. If only tetrahedral elements exist, SOLID95 is
used in degenerate tetrahedral form.
All other solid elements (as well as surface effect, contact, or
spring elements) will have element types greater than 1. In
topological optimization in ANSYS, only material for element type 1
is removed.
Support of other non-solid elements, such as SURF154,
CONTA174, TARGE170, and COMBIN14 in topological optimization
is undocumented.

Advanced ANSYS Details March

 Shape Finder

Solution Options Training Manual

The TOxxxx family of topological optimization commands are

ANSYS Workbench Simulation

not used. Instead, the older, undocumented TOPxxx
commands are used, although the functionality is very similar
TOPDEF defines the problem statement
Similar to TOCOMP, TOVAR
TOPDEF,vol_reduction,load_case, accuracy:
where vol_reduction is percent volume reduction, based on
input in Details window. Other arguments are internally
specified
TOPEXE runs the topological solution
Similar to TOEXE
TOLOOP or TOPITER are not used. A *DO loop is used
internally loop through multiple topological iterations
Besides the output file (solve.out), a summary of the last
shape optimization run can be found in the compliance.out
ASCII file located in the Solver working directory.

Advanced ANSYS Details March

 Shape Finder

Solving the Model Training Manual

After setting up the model, one can perform the shape

ANSYS Workbench Simulation

optimization just like any other analysis by selecting the
Solve button.
A shape optimization is several times more computationally
expensive than a single static analysis on the same model
because many iterations are required.
If a Solution Information branch is added to the Solution
branch, detailed solution output, including how many shape
optimization loops have been performed, will be provided:

ANSYS License Availability

DesignSpace Entra x
DesignSpace x
Professional
Structural
Mechanical/Multiphysics
x
x
x
March
 Shape Finder

Reviewing Results Training Manual

After solution is complete, the Shape Finder results can be

ANSYS Workbench Simulation

viewed
As indicated in the legend, orange denotes material which can
be removed, and beige is marginal
The details view compares the original and final mass of the
structure (including the marginal material)

ANSYS License Availability

DesignSpace Entra x
DesignSpace x
Professional
Structural
Mechanical/Multiphysics
x
x
x
March
 Shape Finder

Reviewing Results Training Manual

Animations are also quite helpful in visualizing where

ANSYS Workbench Simulation

material could be removed and what the resulting shape
may look like.

ANSYS License Availability

DesignSpace Entra x
DesignSpace x
Professional
Structural
Mechanical/Multiphysics
x
x
x
March
Shape Finder

B. Workshop A13 Training Manual

Workshop A13 Shape Finder

ANSYS Workbench Simulation

Goal:
Use the shape optimization tool to indicate potential geometry
changes that will result in a 40% reduction in the mass of the
model shown below.

March