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PERMAS-OPT + PERMAS-TOPO: Multi-Modal Optimization

Manufacturing process
Rolling, blanking, and beading to achieve the stiffest sheet metal.

In the development of sheet metal parts various production processes like rolling (to get thickness variations), blanking (to cut out the final sheet), and beading (to generate beads for higher stiffness) are very important. In order to optimize sheet metal parts for weight and stiffness, these production processes have to be represented by suitable model modifications. The integration of this optimization in Finite Element (FE) analysis facilitates the direct identification of the necessary production steps.

To this end, the rolling is implemented by the optimization method called free sizing to achieve variable sheet thicknesses. This method works like topology optimization and modifies the thickness of shell elements in a wide range to get the desired part properties.

The blanking process is implemented by topology optimization, where an unambiguous selection of required elements is generated.

For the stiffening of the sheet metal part, bead generation by shape optimization is available, where the nodes of the shell mesh are moved normal to the sheet to get the stiffening effect.

By applying the Multi-Modal Optimization (MMO) approach in PERMAS, all these previously mentioned methods can be combined in one single optimization.

The adjoining example of a simple shell model under torsional loading shows the effect of the three combined optimization methods. The stiffest structure under a given weight and symmetry conditions is the corresponding objective. The results of the different production steps and the final result of the optimization are shown.

An animation of the shape changes over all iterations of the optimization is available here.

Multi-Modal Optimization
Multi-Modal Optimization of a cylindrical shell.