The Concept behind modeFRONTIER

The concept behind modeFRONTIER Some conceptual fundaments for introducing the modeFRONTIER design environment

modeFRONTIER® is a registered product of ESTECO srl Copyright © ESTECO srl 1999-2007

For more information visit: www.esteco.com or send an e-mail to: [email protected]

Defining modeFRONTIER

modeFRONTIER is a multi-objective optimization and design environment, written to allow easy coupling to almost any computer aided engineering (CAE) tool, whether commercial or in-house.

2



The concept behind modeFRONTIER The Black Box: Generates the outputs accordingly to the inputs Input Variables: Entities that define the design space. Output Variables: Measures from the system



The input variables Variables: Variables are the free parameters, i.e. the quantities that the designer can vary or the choices the designer can make.

Continuous variables: • point coordinates • process variables


Discrete variables: • components from a catalogue • number of components


The Black Box The black box can be: • A set of solvers that models and solves in a numerical manner the design problem (e.g. CAD/CAE tools) • A set of experiments that produces some data

Multi-disciplinary Scenario CAD

CFD

(CATIA, UGS, PROE)

(StarCD, Fluent, CFX)

FEM

Others

(Nastran, Ansys, Madymo, etc)

(In-House codes, MATLAB, Excel)



The output variables

The output variables are a measure of the system response and/or performance, i.e.:

acceleration, speed, consumption, confort,… deformation, stress, mass, volume,… lift, drag,… defects, number of failures, cost,… ….

6



Input Variables: Entities defining the design space.

The Black Box: (ANSYS, FLUENT, Workbench, MatLab, etc…)

Constraints

Output Variables: Measures from the system

Objectives

Optimization means to find a set of system configurations (input variables) that meets the objectives and satisfy the constraints 7



INPUT

The optimization can be multiobjectives

Many softwares can be used to describe the behavior of the system under exam

OPTIMIZER CAE1

CAE2

Black box

OBJECTIVES CONSTRAINTS OUTPUT

8



Multidisciplinary Optimization - MDO

Discipline 1

x1

Discipline …

Objective 1

Objective 2

x2 … xn

Discipline 2

Discipline 5

Discipline 3

Discipline 4

…

…

Objective k Multiobjective optimization, Approximation methods, Sensitivity Analysis, Space exploration, Multivariate Analysis



EMO and its fields*

Leisure & Sport

aerospace & defence appliance automotive chemical construction electronics healthcare equipment industrial equipment marine & offshore materials & processes others

*On a database of 148 real world applications modeFRONTIER® is a registered product of ESTECO srl Copyright © ESTECO srl 1999-2007


Leisure & Sport Applications • Study of innovative solutions of a cycle wear crotch pad for Campagnolo • The optimization considered the ergonomic level of the crotch pad function of both geometry and materials.



Innovation – HOW ? Objective: Product innovation for high performances

Technologic issue (cost) – appearance/ Marketing – performances

Simplified product analysis Alternative materials Ergonomic/Marketing Ergonomic improvement modeFRONTIER® is a registered product of ESTECO srl Copyright © ESTECO srl 1999-2007

Decrease in cost

Stiffness and energetic absorption Independence by anthropomorphic features Shape and thickness modification


Parametric models carrying out Objective : Ergonomic improvement

Shape change, thickness, material

Assessment of the critical zone

A B

C



Parametric models carrying out Objective: Ergonomic improvement


Shape, thickness, weight change


Geometric parameters Simulation CAD parameters. These parameters have been implemented in modeFRONTIER.



Optimization process Workflow Excel node

Objectives

Ansys node - WorkBench

Independent variables modeFRONTIER® is a registered product of ESTECO srl Copyright © ESTECO srl 1999-2007

Dependent variables For more information visit: www.esteco.com or send an e-mail to: [email protected]

Optimization process

The optimization process: •

Input variables: Geometry, materials mechanical properties

•

Objectives: Minimization of back and front cushions volume, minimization of pressure distribution and its maximum value.

•

DOE: Sobol (50 designs initial population )

•

Optimisation algorithm: MOGA II



Optimization process

1810



Optimization – Assos F13

Assos F13

Comparison between initial configuration and optimal points

Des. 1810

http://www.campagnolosportswear.com/ modeFRONTIER® is a registered product of ESTECO srl Copyright © ESTECO srl 1999-2007


Example of Applications: Biomechanics

Graph of relative drag difference between a cyclist using a rear wheel with and without a disk in a range of crosswinds



Example of Applications: Biomechanics



Constructions - Brenner Railway Base Tunnel • München

• • • •

Two single track railway tunnels connecting Fortezza (Italy) and Innsbruck (Austria). Tunnel section: 72,4 m2 Length: 56 km Up to 1650 m under the Alps Tunnels about 70 apart, connecting galleries every 330 meters

Innsbruck

The problem: • Uncertainities of data on the mechanical behaviour of Bozen

• •

the rock mass Passing from south to north, the tunnel will be drilled throug granite, paragneiss, schist, gneiss, marble, phylite. It also crosses the Periadriatic Seam, caused by the collision of the African plate and the European Continent

Verona modeFRONTIER® is a registered product of ESTECO srl Copyright © ESTECO srl 1999-2007


Examples – Constructions - Transportation Time and Cost Reduction modeFRONTIER tasks

• • •



Reliability analysis (general) – and documentation Reliability analysis with respect to rock models (behaviour of the mass during borging) Senario and decion on the best excavation method.

Automotive Application

Courtesy of Fiat

The aim of this activity is to OPTIMIZE CONFLICTING ASPECTS in terms of Handling performances as well as Ride&Comfort performances.

Stability and response of the vehicle

Comfort for driver and passengers

Understeer Side-slip angle Rolling Yaw speed

Peak accelerations Time of dissipation after impact RMS of low frequency accelerations on uneven road, highway, obstacles

The study results in a set of vehicle set-up, concerning suspension vertical and longitudinal stiffness, elasto-cinematic behavior, optimizing both aspects without forgetting the robustness of the solution. modeFRONTIER® is a registered product of ESTECO srl Copyright © ESTECO srl 1999-2007


Full-vehicle MSC.ADAMS/Car Models Assembly Handling

Assembly Comfort

Front Suspension (incl. flexible subframe) Rear Suspension Steering Antirollbar Conceptual Driveline Front&Rear Tires Rigid Body

Front Suspension (incl. flexible subframe) Rear Suspension Steering Antirollbar Engine Front&Rear Tires Rigid Body

Front Suspension

Rear Suspension modeFRONTIER® is a registered product of ESTECO srl Copyright © ESTECO srl 1999-2007


Definition of Input variables Vehicle parameters able to influence both the Ride-Comfort and Handling performance

VERTICAL STIFFNESS AND ROLLING STIFFNESS

Input variables: Spring Stiffness and preload Bumpstop clearance and characteristics Anti-roll-bar diameter Damper characteristics Bushing characteristics

VERTICAL DAMPING

LONGITUDINAL STIFFNESS AND DAMPING

ELASTO-CINEMATIC CHARACTERISTICS modeFRONTIER® is a registered product of ESTECO srl Copyright © ESTECO srl 1999-2007


Objectives and Constraints Constraints:

Objectives:

- Ride height in various load conditions

- Key synthesis Handling parameters (understeer, sideslip curve, yaw, rolling - gains, time delays)

- Feasibility of the components for .ex. rate between axial and radial bushing stiffness, damper characteristics, bumpstop length and characteristics etc.

- Key synthesis Comfort parameters (peak accelerations, time dissipations, RMS/RMF) frequency response - yaw rate / steering angle 80 km/h 0.45g

frequency response - side slip angle / steering angle 80 km/h 0.45g

0.0180 - lateral acceleration / steering angle 0.500 response siderate slip/ angle / steering frequency response frequency response - yaw steering angle angle 263 Muletto calcolo pneumMule (195 "Stilo") frequency km/h - 0.4 g 80 km/h 0.45g 80100 km/h 0.45g 223 sperim pneumMule (195 "Stilo") 0.450

frequency 0.0600 response - side slip angle / steering angle 263 Muletto calcolo pneumMule (195 "Stilo") 80 km/h 0.45g

0.0160

0.0080 0.0060 0.0040

0.0060 0.0020 0.0040 0.0000 0.0020

0

0.5

1

1.5

2

2.5

3

3.5

frequency (Hz)

0.0000 0.5

1

1.5

2

2.5

3

3.5

4

4.5

0.0300 0.200

0.250 0.200 0.150

263 Muletto calcolo pneumMule (195 "Stilo")

0.100

223 sperim pneumMule (195 "Stilo")

0.150 0.0200

263 target 263 Muletto calcolo pneumMule (195 "Stilo") 0.050 263 "Stilo") 7q rev4 pneumMule (195 "Stilo") 223 sperim pneumMule (195 0.100 0.000 0.0100 263 target 0.050 4 4.5 0 0.5 1 1.5 2 2.5 3 263 7q rev4 pneumMule (195 "Stilo") frequency (Hz) 0.000 0.0000 00 0.50.5 1 1 1.5 1.5 2 2 2.5 2.5 3 3 3.5 3.54 44.5

frequency (Hz)

0.15

0

-0.15 -0.2

1

0 0

0.5

1

1.5

2

2.5

3

1.5

2

2.5

3

3.5

4

4.5

-0.05

1

263 7q rev4 pneumMule (195 "Stilo") 0.0300

0.0200

0.0200

0.0100

0.0000

4

4.5

0

0.5

1

1.5

2.5

3

3.5

4

0.5

1

1.5

2

2.5

3

3.5

4

1

1.5

2.5

3

3.5

4

4.5

2

2.5

3

3.5

4

4.5

0

0.5

1

1.5

2

2.5

3

1.5

2

2.5

3

3.5

4

4.5

3.5

4

4.5

0

0.5

1

3500

StdA

3000

Minimo realizzabile per 263 con ammortizzatore attuale

2500

MT104

2000 1500

-0.05

0 1.5

4000

ISO SMORZANTE 223

frequency (Hz) 2

Tarature ammortizzatore posteriore 263 confronto con tarature X250

4.5

0 0.5

P.C.

4.5

REAR_MV muletto validato CRF

0

4.5

2

frequency (Hz)

1000 500

0.05

-0.1 -0.15

3.5

-0.04 4 -0.06

-0.08

-0.05

-0.04

-0.06

-0.08

-0.1

-0.1

-0.12

-0.12

-0.14

-0.2 -0.25

4.5

PSIP/DVOL - phase (s)

0.5

263 target

0.0000

BETA/DVOL - phase (s)

-0.1

0.5

-0.02

PSIP/DVOL - phase (s)

0

AY/DVOL - phase (s)

0 -0.05

3.5

0.1

0.05

0.0400

0.0100

-0.02 0

0.1

0.0300

- Performance constraints

263 target 263 Muletto calcolo pneumMule (195 "Stilo") 263 "Stilo") 7q rev4 pneumMule (195 "Stilo") 223 sperim pneumMule (195

0 0

0.15

0.0400

0.0500

frequency frequency (Hz) (Hz)

0.2

0.2

0.0500

frequency (Hz)

-0.25

-0.15 -0.2

0 -3000

-0.15

-2000

-1500

-1000

-500

0

500

1000

1500

2000

2500

3000

-1000

101

-1500

-0.2

-2000

100

velocità [mm/s^2]

-0.25

-0.25

-0.3

-0.3

-0.35

-0.35

-0.4

frequency (Hz) -0.4

frequency (Hz)

-2500

-500

frequency (Hz) -0.14

frequency (Hz)

-0.1

-0.1

frequency (Hz)

Efficienza ammortizzatore [%]

0

0.300 0.0400 0.250

0.300

223 sperim pneumMule (195 "Stilo")

BETA/DVOL - gain (deg/deg)

0.0080

0.0100

Option 2

BETA/DVOL - phase (s)

0.0100

0.0120

Option 1

0.350

BETA/DVOL - gain (deg/deg)

0.0120

0.0600

0.400

263 "Stilo") 7q rev4 pneumMule (195 "Stilo") 223 sperim pneumMule (195 0.450 0.0600 263 target 0.400 263 7q rev4 pneumMule (195 "Stilo") 0.0500 0.350

(deg/deg) BETA/DVOL (1/s) - gain PSIP/DVOL- gain

0.0140

0.500 0.0700

263 target 263 Muletto calcolo pneumMule (195 "Stilo")

0.0140

AY/DVOL - gain (g/deg)

0.0160

PSIP/DVOL - gain (1/s)

0.0180

Forza [N]

frequency response - lateral acceleration / steering angle 80 km/h 0.45g

- Top mount stiffness for damper efficiency

99 98 97 96 95 94 93 92 0

200

400

600

800

Rigidezza verticale [N]



1000

1200

Coupling modeFRONTIER & ADAMS/Car modeFRONTIER

INPUT MODEL, ANALYSIS, POST-PROCESSING INPUTS

MSC.ADAMS Car Model modifications

COMMAND FILES ADAMS

Results simulation

OUTPUTS => CONSTRAINT CHECK - ANALYSIS, POST-PROCESSING

COMPARISONS OBJECTIVES AND CONSTRAINTS

Example Process includes modifying and launching 3 models (K&C, Assembly Handling e Comfort), 7 analysis (4 K&C, 2 Handling e 1 Comfort). modeFRONTIER is a registered product For more information visit: of ESTECO srl www.esteco.com or send an e-mail to: Every run requires approx. 5min => weekend 2.5ggr = about 800 run Copyright © ESTECO srl 1999-2007 [email protected] ®

DOE Study and Optimization Method Influence Study: 8 Input variables, 4 Targets for example DOE Study Sobol/Full-factorial => Excluding input variables (and constraints/objectives) + Adapting range of study

Optimization with limited numbers of variables, objectives, constraints - real or virtual response surfaces Pareto FRONTIER => Selection of “optimum” solutions related to the particular project vehicle target setting Verification of optimum solutions belonging to Pareto FRONTIER



Aerospace Application The geometric model built-up in Catia V5 has been imported into ANSYS WorkBench 11.0.

Superfici Alari (Skins)

Centine (Ribs) Longheroni a C (Spars)

Courtesy of Alenia Aeronautica modeFRONTIER is a registered product For more information visit: ®

of ESTECO srl Copyright © ESTECO srl 1999-2007

www.esteco.com or send an e-mail to: [email protected]

Geometric model set-up Subdivision of the wing into 6 parts In this way it is possible to reduce the number of skins while getting closer to the tip of the wing (more efficient optimization process) Different values of skin and caps structural parameters between the wing underside and the top surface With the aim to get the best material performances

The input variables values (thickness, skins number, …) are constant within every 6 partsmodeFRONTIER is a registered product For more information visit: ®



Optimization strategy The optimization process has been sub-divided into the 2 following phases: 1. Firstly, the whole design space has been explored with the scope to get the

global optimal solution. This initial search exploited the MOGA-II

2. In a second step, the more important input parameters have been further investigated, while the remaining ones have been fixed to constant values. This approach enabled to get more accurate solutions. In this phase both

MOGA-II and B-BFGS (hybrid approach) have been used. modeFRONTIER® is a registered product of ESTECO srl Copyright © ESTECO srl 1999-2007


Workflow modeFRONTIER

DATA FLOW

LOGIC FLOW

CPU TIME

17 input variables + 67 constants

DOE: 4 best designs fase 1 Optimizer: B-BFGS

Around 680 analyses

29 output variables 1 objectives modeFRONTIER® is a registered product 30 constraints


DOE: 16 best designs B-BFGS Optimizer:ForMOGA-II more information visit: www.esteco.com or send an e-mail to: [email protected]

10’ per run  around 4.5 days

Results The flexural and the total deformation (torsion and flexural) are depicted. In both cases (positive and negative nz) the maximum deformation values belong to the feasibilty domain. “positive nz” Total deformation (torsion < 7°)

Wing tip deflection (1989.3 mm) For more information visit:



The Concept behind modeFRONTIER

The Concept behind modeFRONTIER

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