Designing for Manufacturing: Topology Optimization in Ansys Discovery

In today’s competitive design world, efficiency, material savings, and performance enhancement are more important than ever. Enter topology optimization—a process that not only refines your design by removing unnecessary material but also creates organically evolving forms that echo natural evolution. In this post, we’ll discuss the fundamentals of topology optimization using ANSYS Discovery and share best practices.

What is Topology Optimization?

Topology optimization is a computational technique used to determine the most efficient material layout within a given design space, subject to specific loads, support conditions, and performance requirements. By iteratively removing material that contributes less to the overall structural efficiency, the process results in shapes that are lean, durable, and innovative.
One of the most fascinating aspects of topology optimization is how the resulting geometries often appear “organic.” Much like evolutionary processes in nature, where structures adapt over time to optimize strength and function, topology optimization evolves a design through a series of iterations. The computer algorithm “selects” material regions to keep or discard based on simulated stress distributions, leading to results that mimic the smooth curves and complex forms found in natural systems. This organic quality doesn’t only make for visually compelling designs—it also offers structural benefits, such as efficient load distribution and reduced stress concentrations.

Best Practices 1: Defeaturing

Defeaturing is the process of removing unnecessary geometric details from your model before running optimization. These features, while sometimes important for aesthetics or minor assembly considerations, can complicate the simulation and lead to less clear optimization results. By simplifying your model, you ensure that the optimization focuses solely on the critical load-bearing structures.
Tips for effective defeaturing:- Simplify complex parts: Remove small holes, fillets, or intricate patterns that don’t contribute significantly to structural performance.- Focus on function: Retain only the features that directly affect how loads are transferred or distributed.- Clean geometry: Ensure your model is free from irregularities that might disrupt the simulation process.

Best Practices 2: Defining Protected Areas

While simplification is key, there are areas in your design that must remain unchanged—these are your protected areas. Protected areas may include interfaces for mating parts, connection points, or regions that serve as load transfer points. By designating these areas as off-limits during optimization, you can ensure that key functional or assembly-related features are preserved.
Key steps to properly define protected areas:- Identify critical features: Pinpoint areas essential for assembly or integration with other components.- Set constraints: In your simulation software, mark these regions to prevent material removal.- Balance optimization with functionality: Aim for the best overall design while safeguarding the elements that make your model work in the real world.

Best Practices 3: Validation

Even though topology optimization often produces innovative and efficient structures, it’s still essential to simulate the optimized design under actual operating conditions. A validation simulation helps you:- Confirm Structural Integrity: Ensure that the optimized design safely carries the anticipated loads.- Identify Potential Weaknesses: Reveal any areas that might be subject to high stress or failure.- Refine the Design: Provide insights into adjustments that might be needed before moving to production.

Designing for Manufacturing

Optimized designs often require a thoughtful approach to ensure they can be practically manufactured. Ansys Discovery offers settings that allow you to incorporate manufacturing constraints directly into your optimization process. While topology optimization with correct settings can yield an efficient structure, the result might not still be directly ready for production. Instead, consider the optimized design as a baseline—a starting point for further refinement.