HANDOUTS Morph&Optimization

ANSA Morph & Optimization
Training handouts
www.beta-cae.com
Contents
 Direct Morph Terminology ……………………………………………………………....................... page 06
 Features recognition and handling ……………….……………………….………………............ page 07

 Create part from cross sections…………………………………………….................................... page 15
 Cross section modifications .............................……………………………………………............. page 20
 Adapt Flanges…………………………....…………………………………………............................ page 23
 Direct morphing - Constraining regions’ morphing……………...………………………………...... page 24
 Relocating members ……………....………………………………………….................................. page 28
 Reinforcing an area………………….…………….......................................................................... page 29
 DFM morphing…………………………....…………………………………………............................ page 31
 Form - Bend…………………..…………………....…………………………………………............... page 38
 Form – Twist………………………………………....…………………………………………............ page 39
 Form – Taper & Extend………………….…………………....……………………………………….. page 40
 Spotweld Morphing – Spotweld Groups…………………………………………………………………………………………….. Page 41
 3D Morph Terminology………..…………………………………………………............................. page 44
 2D/1D/Cylindrical Morph Terminology………………………………………………………………… page 45
 Morphing with 3D Morphs…………….….………………..………………………………………......... page 46
ANSA Morphing & Optimization 2 www.beta-cae.com

Contents
 Cylindrical Morphs………..…………………………………………………………....................... page 64
 Morphing with 2D Morphs……………………………………………….……………………............ page 71

 Morphing with 1D Morphs…………………………………………………………............................ page 76
 Linked Morphs…………………………………………………………………………………… page 79
 3D Morph - Constraining regions’ morphing.………………………………………............. page 81
 History Tool…...…………………………....…………………………………………............................ page 83
 Geometry morphing with 3D Morphs…..……………………………………............................ page 85
 Optimization Tool - Introduction….……....…………………………………………........................ page 86
 Pre-processing setup…………...……....…………………………………………............................ page 92
 Solver setup……………………………....…………………………………………............................ page 99
 Post-processing setup….……………....…………………………………………............................ page 100
 Design of Experiments setup…...…………………………………………............................ page 102
 ANSA responses………………………………………………………………………………. page 104
 DOE constraints…….…………………....…………………………………………............................ page 107
 DOE simulation & execution……..….………………..………………………………………......... page 110

Contents
 Response Surface Models setup….…….….………………..……………………………........... page 112
 Optimization…………..………………………………………………………………………………. page 115
 Results – Data Analysis..………………………………….………………………………………… page 117
 SOL200 Shape Optimization….………………………………………………................................ page 119
 SOL200 Size Optimization…………………………………………..…………………………….. page 125
 SOL200 Topology Optimization……………………………………………………………………… page 132

Morph – “What - Where”
Optimization Tool
Morphs Creation/Deletion
Morph Entities in
DataBase Browser
Manipulation of
Control Points,
Edges & Hatches
Modification of Morphs
(If Morphing Flag is Active, the
loaded Entities are Morphed)
Direct Modifications
Various Checks
Box Draw Visibility Toolbar
Morphing flag

Direct Morph Terminology
Control
Entities
Morphed
Entities
Bounds
Form Entities
Constraint
Fixed
Transition Entities

Feature recognition and handling – Feature Manager DFM_neon.ansa
Some Design actions are available through the Feature manager, facilitating the morphing of specific features.
Activate the Feature Manager tool and press the Parameters button, to recognize the features.
Select the Holes 2D and Stamps features and press Recognize.

Feature recognition and handling – Feature Manager
Selecting a Hole or Stamp, it is possible to perform Design Actions; Remove, Move, Copy or change the size of the
Feature, (Diameter for holes or Width/Height of Stamp through Scale mode).

Feature recognition and handling – Feature Manager
Select Stamps and select to change the size of a bead using Design Actions>Move.
Enable the Scale mode. Pick an axis tab and change the Width and Height of the bead

Feature recognition and handling – Feature Slide DFM_neon.ansa
1. Select Design Change> Feature [Slide] and select any feature from the model, like beads, holes, embosses,
etc.
2. Confirm the selection. An interactive coordinate system appears on the selected area.
3. Select an axis or arc in order to move the feature to the desired direction. Pressing the space button, a user
defined value can be applied. Multiple movements are possible. The area is reconstructed at both initial and
final affected areas if selected in the Feature Slide window.
4. There is also the ability to copy the selected feature in multiple steps.
1 2 3 3

Feature recognition and handling – Feature Copy
1. Select Design Change> Feature [Copy] and select any feature from the model, like beads, holes, embosses,
etc.
2. Confirm the selection. An interactive coordinate system appears on the selected area.
3. Set the steps to 2 to copy twice the feature and select the Follow path Movement type. Select a path on the
model and confirm. Enable the Preview and select to Reconstruct 2 zones around the copied features.
4. Select the x axis, move the mouse to the new position and left click. Middle click to confirm the position.
5. Confirm with middle click to reconstruct the area.
1 2 3 4

Feature recognition and handling – Holes 2D
HOLES_subframe.ansa
1. Recognize Holes 2D from Feature Manager.

Feature recognition and handling – Holes 2D
2. Select automatically or manual openings (Select in range) of any shape according to their diameter and press
Next
3. Set the value 4 in the field and press the Refresh button to change the holes’ diameter
4. Select to switch between the initial and final state to inspect the change.
A Morphing Parameter of
HOLES type can automatically
be created, using the “Save>As
parameter” button

Feature recognition and handling – Create
DFM_neon.ansa
1. Select Direct Morphing> Create[Bead]
2. Select the type of the Bead, here Curved Rounded and Flat Bottom for cross section shape, enter the
specifications for the depression and the mesh details
3. Define the bead by selecting Nodes or Curves, where this is possible.
4. Next, it is possible to move the new feature at a new place across the surface.
5. Select to Reconstruct the affected areas and pick Finish to complete the action

Create part from cross sections - Extrude
MODELLING_door_side.ansa
1. Select Direct Morphing> Modeling> Extrude
2. Select a cross section to extrude. Activating the Chain selection checkbox to select the entire cross section in
a single step
3. Extrude geometry in one direction by setting the extrusion distance to 50,
4. Set the distance -50, to extrude geometry in the other direction by 50, the taper factor to 1.2 and the twist
angle to 5
5. Select to generate new geometry faces and middle click to complete the action
2
3
Extrude directly a cross
4 section in a specific direction,
by left clicking on it and
5 dragging and dropping it in a
2 specific distance.

Create part from cross sections - Sweep
1. Select Direct Morphing> Modeling> Sweep [New]
2. Select a cross section to sweep along a guide curve and middle click to confirm. Activate the Chain selection
checkbox to select the entire cross section in a single step
3. Select the guide curve
4. Set a 1.2 taper factor and a 15 degree twist angle
5. Select to generate new geometry faces and click OK to complete the action
2 3

Create part from cross sections - Sweep
1. Select Direct Morphing> Modeling> Sweep [Wrap]
2. Hover the mouse cursor over an existing part and left click to define a starting position. The tool automatically
recognizes the cross section
3. Select more positions
4. In the Options List, select to create new geometry faces based on the recognized cross sections
2 3

Create part from cross sections - Loft
1. Select Direct Morphing> Modeling> Loft [New]
2. Select a starting cross section. Its curves are added under the first chain
3. Select a second cross section. A second chain is added under the first group
4. Continue and select all cross sections. When finished, activate the preview button
5. In the options, you can select the group matching method, as well as the tangencies for the start, intermediate
and end cross sections. Select to create new geometry faces and click OK.
2 3 4

Create part from cross sections - Loft
1. Select Direct Morphing> Modeling> Loft [Wrap]

2. Hover the mouse cursor over an existing part and left click to define a starting position. The tool automatically
recognizes the cross section
3. Select more positions
4. In the Options List, select to create new geometry faces based on the recognized cross sections. Middle click
to generate the geometry
2 3 4

Cross section modifications – Modeling Update
1. The entities described and created previously are saved in the Database Browser, under MODELING, as
PM_EXTRUDE, PM_SWEEP and PM_LOFT entities.
2. Select a PM_LOFT entity, right click on it and select Geometry> Load … to load FE entities by hand
3. Select the elements between the first and last cross sections and middle click to continue
4. Use the saved morph parameter to modify the height of a cross section participating in this PM_LOFT. Right
click > Morph, enter a value of 15 and confirm twice with middle click
5. The cross section is morphed
1 2 3
4 5

Cross section modifications – Modeling Update
6. Go back to the PM_LOFT entity and this time right click and select Geometry> Update
7. The model is updated based on the new cross section
8. Loft also recognizes fillets as PM_ARC entities. Open the 3 rd arc entity card, change the radius to 8 and click
OK. The fillet in the cross section is updated
9. Switch back to the PM_LOFT entity and update it again. The model is updated
6 7 8
8 8 9

Cross section modifications – Design Change DFM_neon.ansa
1. Select Design Change> Cross-Section and select entities to change their cross section. Select the Transition
area, these entities will adapt to the movement of the Action area. The Fixed edges are automatically defined,
but can be modified.
2. To select a Cross Section, that will give the movement to the shell elements, select an from existing or create
one by selecting two or three points.
3. In the Coordinates step the automatically defined Height and Width axis need to be aligned correctly.
4. In the Height and Width definition, Rigid segments need to be selected, that will give the movement to shells.
Optionally Frozen segments can be defined, to maintain their position.
1
2 4

Adapt flanges – Hat Flange HAT_FLANGE_floor.ansa
1. Select Direct Morphing> Hat flange and select the flange entities to adapt to an underlying surface. Then
middle click to continue
2. Select the contact entities, which are the elements of the underlying surface
3. Select the transition entities, the entities that will absorb the deformation caused by the flange adaptation.
Middle click to continue. The bounds are recognized automatically
4. Select a vector along which the flange will be adapted. Select two nodes of the model
5. Enter a distance in the offset field and activate the Preview to see the result. Middle click to confirm and exit
1 2 3 4
5
The Add/Remove
neighbours functionality 4
can be particularly useful
while selecting transition
entities. Also, mesh
improvements are
available after exiting. 5

Direct morphing - Constraining regions’ morphing DFM_neon.ansa
For Direct Morph actions, in case the result is not optimum for areas like, holes, curvatures, stamps, or flat areas,
Morph Constraints can be added in the direct morph actions, to improve the result.
A planar Constraint can be used, to keep a flat plane, when a direct actions create a curvature on the morphed
entities.
In this case, a DFM Edge Fit is used and the result is causing the flat area to deform.

Direct morphing - Constraining regions’ morphing
1. Apply Direct Morphing> Constraints [Planar] to create a Planar Constraint. Select the top area as Planar Entities
and a few neighboring areas as Transition. The Fixed areas are automatically defined.
2. Activate the available Constraint in the Constraints Item of the DFM parameter.
3. Morph the DFM parameter.
1 2

A Path follower Constraint can be used, to maintain a model’s curvature when a direct morph action moves the
morphed entities away from the correct shape.
In this case, a DFM Translate is used and the result is causing the top rail area to deform.

1. Apply Direct Morphing> Constraints [Path Follower] to create the Constraint. Select the entire top area as Path
Follower Entities. These will only follow the path and not the vector set by the DFM.
2. Select the path that will constrain the movement of the Path Follower Entities.
3. Select a few rows of neighboring elements on the b pillar, and press Finish in the Fixed Entities step
4. Once the Path follower constraint is defined, modify the contents of the DFM function, to include the constraint.
5. Once the DFM parameter is applied, the shape of the top rail is maintained.
1 2 3
4 5

Relocating members – Design Change Position DFM_neon.ansa
1. Select Design Change> Position and select a PID from the model that will change position as Action Area.
Select the movement Direction at the second step and press Finish. The DC position is ready.
2. To add a Flange constraint, create a new constraint from the Constraints Tab .
3. Select the Flanges, the contact area and gap, the Transition and the Fixed entities. Once the constraint is
ready, activate it and confirm.
4. Apply a Distance value to move the PID while the Flanges maintain the gap from the contact area.
1 3 3
3 3 4

Reinforcing an area – Bulkhead bulkhead.ansa
1. Select the Plugins> Bulkhead tool. Select the Hat cross section type and press the add button to select the
PID of the part to be reinforced. Select the PID and middle click. Press Next.
2. Press the add button to select two grids that will define the flanges direction. Select the grids and middle
click. Set the offset flanges value to 2 and press Next.
3. Set the bulkhead thickness, select the Spot Line as connection entity and to Create a DFM Translate parameter.
4. Press Next to create the bulkhead.
1 2
3 4 Remove automatically
curved areas of the
Flanges by selecting the
Remove Action.

Reinforcing an area – Bulkhead
5. Press the pick button to select areas of the bulkhead’s flanges to cut. Select the areas and middle click. Press
Next and then Finish to generate the connection entities and DFM parameter
Swapping the Flanges is

available in the Edit
options.
The creation of Fillet or

Chamfer is possible via
the respective Bend Type
options.

DFM morphing - Translate DFM_neon.ansa
1. Activate the Direct Morphing> DFM function and pick the Translate mode. Select the Control Entities (here three
green areas) that should be translated, as rigid bodies and the respective translation Vectors
2. In the next step, select Morphed Entities that should be morphed, following the translation of the previously
selected areas
3. Next, the Bounds of Morphing are automatically defined by ANSA. However, the user can manually modify them
1 3 Bounds
2
The Translate mode of DFM
function can also be performed
as a Morphing Parameter :
CONTROLS> Parameters [New]
> DFM (Translate)

DFM morphing - Translate
Upon confirmation, the user can view all the Direct Items that were defined, and modify (if needed) the specified
Values. Press Apply button, in order to proceed with Morphing
After Applying, there is the option to Save> As parameter or see the Initial and
Final position
The translation groups (green)
are moving along the defined After Morphing, reconstruction
vectors, keeping the original of the Mesh, can instantly be
shape, while the selected performed by selecting the
entities (magenta) are morphed relative button.
Areas translated Reconstructed mesh

DFM morphing - Rotate DFM_beta_cc.ansa
1. Activate the Direct Morphing> DFM function and pick the Rotate mode. Select the Control Entities (green area) that
will be rotated as rigid bodies and the respective rotation vector
2. In the next step, select the Morphed Entities that should be morphed (magenta area), following the control entities’
movement
3. Next, the Bounds of Morphing are automatically selected by ANSA. However, the user can modify them manually
2 1
3 Use the embedded radio

buttons in order to define the
type of entities, needed to
select, (e.g. FE Entities)
The Rotate mode of DFM

function can also be performed
as a Morphing Parameter :
CONTROLS> Parameters [New]
> DFM(Rotate)

DFM morphing - Rotate
Upon confirmation, the user can view the Direct Items that has already defined, and
modify (if needed) the specified Values (degrees of rotation). Press the Apply button
to proceed with Morphing.
The rotation group (green) is

moving around the defined
vector, keeping the original
shape, while the selected
entities (magenta) are
morphed
12º -12º
Defined
vector

DFM morphing - Edge Fit DFM_EDGE_FIT_Geometry_beta_cc.ansa
1. Activate the Direct Morphing> DFM function and pick the Edge Fit mode. Select pairs of Source (green) and
Target (orange) Curves
2. In the next step, select the Morphed Entities that should be morphed following the fitting of the curves, that were
previously defined
3. Finally, the Bounds are automatically selected by ANSA. However, the user can modify them manually
Target
Curves
1 3
Origin Bounds
Curves 2
2
3 1

DFM morphing - Surface Fit DFM-SUR-FIT_door_c.ansa
1. Activate the Direct Morphing> DFM function and pick the Surface Fit mode. Select the Source Surface (green),
confirm and then the Target Surface (orange)
2. Next, select (at least three) Pairs of Nodes from the Perimeters of the Origin and Target areas. Pairs of Nodes
from any internal perimeters can be selected as well
3. In the next step it is also possible to select and pair inner feature lines
4. Next, select the Morphed Entities (magenta elements) that should be morphed following the fitting of the surfaces,
that were previously defined
5. Finally, the Bounds are automatically selected by ANSA. Here, no Bounds are needed.
2
4
1 1’
2’
1
2
Target Source Morphed Entities

Surface Surface

DFM morphing - Offset BOXES_neon.ansa
Activate the Direct Morphing> DFM function and pick the Offset mode. Select the Control Entities (green) and confirm
1. Select an Offset Value
2. Select the Morphed Entities (magenta elements) that should be morphed following the movement of the Control
Entities
3. Finally, the Bounds are automatically selected by ANSA.

Form – Bend FORM_floor.ansa
1. Activate the Direct Morphing> Form function and pick the Form entities, elements that will be bent, twisted,
tapered and extended
2. Include the defined flange constraint
3. A coordinate systems has appeared in the middle of the Form entities. Use its handlers to set the position of the
bending axis
4. Use the green arrow-pointed arc to bend the entities. The dashed line is a preview of the neutral line. Activate the
Preview button to see the result
5. Move the central coordinate system along the neutral line to modify the bending
6. Same thing can be done with the other two coordinate systems. Use the red axis to slide the handlers
1 2 3 4
4 5 6 6

Form – Twist
1. The red quadrant handler can be used to twist the entities around the neutral line
2. Switch to the Twist tab and enter a value in the Negative Angle field. Use the button next to the field to reset the
change
1 2
The Move to CoG button can be

used to move the central
Activate the Link button to
coordinate system back to the
move both ends of the entities
center of gravity of the Form While moving the handlers,
simultaneously.
entities and the Align to principal press the spacebar to enter a
to align it to the global axes. specific numeric value.

Form – Taper & Extend
1. The cube-pointed green and blue axes can be used to taper the entities. Enter values of 1.33, that will cause an
increase in size of 33%
2. Drag and drop the red sphere to extend the entities
3. Use the Save Button on the bottom of the menu to save the current Form selections
1
Switch the Interpolation to

Quadratic in order to get a After Morphing, mesh
smoother deformation between improvements can be
3 the elements on the central and performed by selecting
the end point coordinate the relative button.
systems.

Spotweld Morphing – Spotweld Groups SPOTWELDS.ansa
During morphing, spotwelds may need to retain their density.
The Spotweld Groups can be used, both in direct and box morphing, to retain their density regardless of the shape
modification.
Moreover, those groups can be used to alter the density by a factor, setting a specific number of spotwelds or equal
spacing between them and to parameterize those alterations.
In this case, a DFM Translate is used. The spotwelds’ density is not retained.

Spotweld Morphing – Spotweld Groups
1. Open Controls> Spotweld Groups to create connection chains. Select New> Box and select the connections to
be added in a connection chain that will control their density. A connection chain in defined.
2. Repeat the same, on the other side of the model
3. Open Controls> Parameter and Morph the stored parameter which has spotwelds included as control and
morphed entities by 150.
1 3

Spotweld Morphing – Spotweld Groups
Select a connection chain and Design Actions to modify or parameterize its density, by a factor, a specific number
or equal spacing.
Equal spacing can be forced via a

parameter also in case of density
changes by factor or number of
spots

3D Morph Terminology
Frozen Control User Defined
Frozen Hatch Point Central Tangency
Point
Double
Hatch
Free Hatch
Loaded Elements
Internal Control
Control Morphing Point
Point Edge Tangency
Constraint
Intersecting
Elements

2D/1D/Cylindrical Morph Terminology
2D Morph
Nested
Element
Cylindrical
Morph
Linked Morph 1D Morph Inner

Concentric
Split

Morphing with 3D Morphs BOXES_neon.ansa
The aim here is to translate the B-pillar forward or rear, according to a specified
distance. The B-Pillar must slide smoothly on the feature lines of the model

Morphing with 3D Morphs – Creating Morph Boxes/3D Morphs
The first step is to create 3D Morphs around the areas that will be influenced by the movement
1 1. Select the Boxes> New[Ortho] function to
create a new Hexahedral 3D Morph around
selected entities. Select the appropriate
Elements
2. Using the same function create a second

3D Morph
3. Select the Boxes> New[Points]
function, pick the Hatches option and
then the hatches of two neighboring
Hatches, in order to create a new 3D
Morph, pasted to the existing ones
2 3

At the upper side, we need some 3D Morphs that will follow the curvature of the model
1. Activate the WORK PLANE visibility flag to make visible the existing Working Planes
2. Select the Boxes> New[Adapt>Bounds] function to create a new 3D Morph adapted to the shape of the
selected elements. Select the appropriate elements and confirm
3. Select, optionally, two working planes that will serve as bounds for the new 3D Morph
1 3
Orange Control Points (frozen)

2 appear here due to intersection
between 3D Morphs and loaded
Elements. It is suggested to avoid
moving such points during
Morphing. Later it is shown how
we can get rid of them

1. In the same way create another 3D Morph adapted to the upper side
2. Connect the two 3D Morphs, as previously, using the Boxes> New[Points] function
3. Possibly, one Edge of the new 3D Morph, intersects the model. To eliminate this intersection, move the
appropriate Control Points, using the Box Morphing> Slide[On Edges] function. Select the appropriate Control
Points and confirm. Then select the respective Edges and confirm again. Slide the cursor until no intersection
appears anymore
1 2 3
Be sure that the Morphing flag of

the Options List is de-activated to
avoid Morphing during this steps

4. Create a new 3D Morph around the B pillar, by connecting two 3D Morphs with the Boxes> New[Wrap] function.
5. Set the section Offset distance to 10 in the Options List.
6. Hover over the Morph hatch at the bottom of the B pillar until it becomes yellow and click on it.
7. Move the cursor along the B pillar and click on various positions to wrap a box around it. Finally hover over and
click on the hatch at the top of the pillar. Middle click to create the 3D Morph.
5 6 7

Morphing with 3D Morphs
1. Once there are no elements intersecting with any box faces, select the Boxes> Load[Visible] and select all the
3D Morphs to load all the elements in them
2. Activate the Morphing flag from the options list and then select the Box Morphing> Slide[On Edges] function and
select the top and bottom control points of the B pillar ,
3. and the edges they will slide on with the Opposite tool of the Selection toolbar, and confirm.
4. Apply a value (100mm) to move the b pillar.
1 2 3

Morphing with 3D Morphs – Fitting 3D Morphs
1. There are still some frozen Control Points remaining due to intersections. The only accepted frozen Points are
those at the single boundaries of the 3D Morphs where no movement is needed. To eliminate the rest of the
frozen Control Points, some manual adjustments are needed.
2. Activate the Box Morphing> Slide[On Edges] function, select the appropriate Control Points, confirm, pick the
relative Edges and confirm. Slide the points along the Edges till the Frozen Control points turn to green.
3. Do the same wherever else it is needed.
1 2
Accepted Frozen
Points
Make sure that the Morphing

flag, in the Option List, is de-
activated, in order to avoid
Morphing during this steps

Morphing with 3D Morphs – Offset & Move PARAMETERS_hook.ansa
1. Activate the Box Morphing> Offset function. Pick the Morph faces that need be offset and confirm. Set the
appropriate relative modification value in the window that appears.
2. For more detailed movements of specific Control Points, the Box Morphing> Move function can be used. There
are several moving types available in this function (translate, rotate, align etc.). Pick here the Translate tab. Select
the appropriate Control Points and confirm. Define the moving vector or axis (here dz:) from the relative window
and set the desired distance (Dist.) and press Apply
1 2

Morphing with 3D Morphs - Parameters
Activate the Controls> Parameters function to create a new PARAMETER. You can choose a type of MORPH and
save it as a PARAMETER. By creating a Morph PARAMETER the user is able to:
• Save the selection and apply multiple modifications at once

• Undo and preview MORPHING actions
• Parameterize MORPHING actions
• Control the Morphing action through the Optimization Tool.
Translation
Vectors

Morphing with 3D Morphs - Angle PARAMS_SLIDE_fin.ansa
Activate the Box Morphing> Angle function. First pick the Morph Edge that is needed to retain its position and
confirm. Next pick a neighboring Edge that needs to be moved and confirm again. Set the appropriate (relative)
modification value in degrees.
More than one pair of Edges

can be selected at the same
modification.
During Morphing, the same A Morphing parameter of type
relative modification value is ANGLE can be used in order to
added to all these pairs save the selection for the
ANGLE function

Morphing with 3D Morphs - Edge Fitting
EDGE-FIT_neon.ansa
The goal here is to Fit the front feature line of the roof, to the
Target 3D Curve. The rest of the model will follow smoothly.

In order to modify a feature line of the model, a Morphing Edge must 1
be fitted on it. Then, this Edge will be fitted to the target Curve,
carrying the model’s feature line as well. The nearby elements of the
feature line should be moved smoothly. Thus, it is also needed to
create 3D Morphs around the feature line.
1. Select Boxes> New[Ortho] to create a big 3D Morph that includes

all the area of interest. In the New Morph window, choose FE
Entities and the Ortho Box type. Select the desired elements and
confirm
2. Select Box Morphing> Offset to increase the 3D Morph’s height

Apply Boxes> Split[User] to split the initial 3D Morph along the selected positions. Split the 3D Morph on the
appropriate positions in order to create an Edge, fitted to the Feature Line of the roof

1. Apply Box Morphing> Fit[To Edges] to fit specific Morph Edges, to the model’s Feature lines. Select the
appropriate Morphing Edge and confirm.
2. Pick the roof’s feature line.
3. Activate the relative flag, in order ANSA to add Control Points and thus fit the Edge to the curved feature line.
Press Apply to proceed with fitting.
4. Do the same for the rest Morphing Edges around the roof.
1 2
Be sure that the Morphing flag
of the Option List is de-
activated to avoid Morphing,
during this step
3 4

Morphing with 3D Morphs - Load Entities
1. Apply Boxes> Load[Visible] to all 3D Morphs. Before proceeding with Morphing, load all the Entities (that need to
be morphed), to the 3D Morphs.
2. If the Freeze Check flag of the Options List is activated, Frozen Control Points are Highlighted in orange. Here,
frozen Control Points are not a problem, since they are located at the outer boundaries of the 3D Morphs, that will
not be moved.
1 2
During Loading, activate in the

Options List, the appropriate
Entity categories, that should be Frozen Controls Points appear to
included to the loading Morphing Faces that intersect any
of the loaded entities

1. Activate the Morphing Flag in the Options List window. Now all the modifications of 3D Morphs are followed by
the respective Morphing of the Loaded Entities .
2. Apply Box Morphing> Fit [To Edges]. Pick the roof’s front Morph Edge, confirm, select the Target Curve and
confirm again. Press Apply in order to proceed with the fitting.
2
Be sure that the Morphing flag, in

the Option List, is activated, in
order to apply Morphing during
this step

Morphing with 3D Morphs - Highlight deformed Entities
The Morphing effect can be better visualized, if the Fringe> N.Deformation option is activated in from the Drawing
Styles toolbar.
1. Once Morph Points are moved, select the Fringe> N.Deformation draw style, in order to quantify in color scaling,
the deformation of the affected elements.
1 2
The N.Deformation
option is available
only when the
Morph points move.

Morphing with 3D Morphs - Edge Fitting through Parameter
1. The Edge Fitting modification can be saved & applied through the relative Morph Parameter
2. Activate the Controls> Parameters[New] and pick the EDGE FIT parameter type. Select the Morph Edge and
one or more Target Curves. Press the Save button to create the Parameter .
3. Pick the Parameter and activate the Controls> Parameters[Morph] in order to morph by fitting the selected
Edge to one of the Target Curves.
2
Target 3D
Curves
Target 3D Curves

Cylindrical Morphs - Creation CYLIND_manifold.ansa
Cylindrical Morphs can be easily created around cylindrical or conical models.
Additionally, they offer manipulation of Radius dimensions, both for inner or outer circular Features.
Apply Boxes> Cylindrical[Curves|Points] to create Cylindrical Morph based on selected Curves (If the axial curve is
not available use Boxes> Cylindrical[Middle]). Select the Axial curve and confirm. Define the Radii of the two
Cylinder’s Bases. In the same way define Morphs along the whole axial Edge.
Axial Edge
Be sure that the Morphing flag, in Radius

Initially set a common Radius
the Option List, is de-activated, in
value for all Cylindrical Morphs.
order to avoid Morphing during
In the next steps the radii will
the next steps
be modified accordingly.
Create the appropriate splits near

the nodes of the axial Edge, using
the Boxes> Split[Project] function

Cylindrical Morphs - Modification
1. Apply Box Morphing> Cylindrical[Outer Radius] to fit the Morphs to the model. Select the appropriate Circular
Edges, confirm and set the desired, new radius (26 & 47mm)
2. Select Boxes> Load[Visible] to load entities to the selected Morphs.
3. Select Box Morphing> Slide[On Edges] to extend the length of the Morphs, in order to include exceeding
elements and Load again the visible entities.
1
2 3

Cylindrical Morphs – Modify Radius
Activate the Morphing flag and apply Box Morphing> Cylindrical[Outer Radius] to modify external dimensions of
cylindrical model.
Outer radius
Be sure that the Morphing flag of

the Option List is activated, to
apply Morphing during this step

Cylindrical Morphs – Concentric splits creation
CYLIND_wheel.ansa
In order to manipulate concentric features of cylindrical models, it is needed to create concentric splits
1. Activate the Edges> Concentric[Project] function. Pick a node (between the tire and the rim) and confirm. Then
select the Cylindrical Morph and confirm again.
2. The MORPH card appears which contains all the useful information for the Cylindrical Morph.
1 2
Inner split

Cylindrical Morphs – Modify Outer Radius
1. Apply Boxes> Load[Visible] again
2. Apply Box Morphing> Cylindrical[Outer Radius] to modify external dimensions of cylindrical models
Outer radius
When the Move all inners flag

is activated :
the modification of outer
radius, affects the inner radius
accordingly
When the Move all inners flag

is de-activated :
the modification of outer
radius, does NOT affect the
inner radius at all.

Cylindrical Morphs – Modify Inner Radius
Apply Box Morphing> Cylindrical[Inner Radius], select the inner split and confirm.
Type the new radius value (50mm) in the relative field, in order to modify the internal split of the model
Inner radius
The Move all inners flag

ensures that the Morphing
action is applied to all the inner
splits

Cylindrical Morphs – Convert to 3D Morphs
1. Activate the Boxes> Convert function and select all Cylindrical Morphs.
2. Confirm. New 3D Morphs are created in place of the Cylindrical ones. However, the user has the option to keep
or delete the original Cylindrical Morphs.
1 2 3
3. Now we can move peripheral Control Points independently, destroying

the initial circular shape.
4. However, ANSA has automatically created all the needed Morphing
Parameters that control inner & outer radii, the length and spinning of
the old Cylindrical Morphs.

2D-MORPH_bonnet.ansa
In many cases, 2D Morphs are more suitable for Morphing. Additionally, they offer a much more simpler view of
the 2D Morph structure.
target FE-surface
bonnet
Here, a sheet metal part (yellow bonnet),

needs to be fitted to a target surface (red
bonnet). Simultaneously, the bonnet
bonnet reinforcement
reinforcement should follow the movement

Morphing with 2D Morphs - Creating 2D Morphs
1. Apply Boxes> 2D Morph[Curves] to create a 2D Morph based on four Curve-Groups. Select groups one by one
and confirm after each selection .
2. Select Boxes> Info to visualize the active space of the 2D Morph. This value is controlled by the respective field
in the MORPH card.
1
3D Curves
2
The Default 2D
thickness value
can be set by
Tools>
Settings>
Settings>
Morph/
2D thickness Optimization

Morphing with 2D Morphs - Splitting 2D Morphs
Apply Boxes> Split[Parametric] to split the 2D Morph at a specific position. Set the appropriate parameter (0.5) in the
relative field and proceed.
Specify the
appropriate
parameter (here 0.5) After the first split, do
in order to split the not exit the function.
Right click to apply Apply the
2D Morph at an HATCHES>
exact parametric splits quickly, at the
same parametric JOIN function
position to revoke a
position
split

Morphing with 2D Morphs - Fitting the 2D Morph to the Initial model
Although the 2D Morph is fitted to the bounds of the bonnet, the internal splits are not fitted on the FE (yellow)
surface. Thus, it is needed to apply…
1. Box Morphing> Fit[To Surfs] to fit the internal Morph Edges to the bonnet surface. Select the inner split, as
Edges, confirm and select the bonnet PID as FE Entities. Define the projection vector (Normal or User Defined)
and press OK .
2. In the confirmation step use Refine or Coarsen to add points to improve the fitting and press Finish.
3. After the final 2D Morph fitting apply Boxes> Load[Visible] to load visible entities to the 2D Morphs.
Be sure that the Morphing

flag, in the Option List, is de-
activated to avoid Morphing
during this step
Bring also to visible the
reinforcement part, in
order to load it as well
BETA CAE Systems - ANSA Morphing & Optimization training handouts 74 www.beta-cae.com
Morphing with 2D Morphs - Fitting the 2D Morph to the Target surface
The morphing of the model will be achieved in two steps. First, the bonnet boundaries will be fitted to the target
curves and second, the inner splits will be fitted to the target FE-surface.
1. Box Morphing> Fit[To Edges] : select sequentially Morph Edges and respective Target Curves. Confirm each
group selection, using the middle mouse button.
2. Box Morphing> Fit[To Surfs] : select the inner splits and confirm. Select the PID of the Target (red) surface,
define the projection vector and press OK.
1
Group 1 Group 2
Group 4
Group 3
2
Be sure that the Morphing flag
of the Option List, is activated
so that Morphing is applied
during this step

1D-Morph_race_car.ansa
1D Morphs provide a fast and convenient way of morphing due to quick

definition of 1D Morphs and flexible selection of morphing area. In many
cases 1D Morphs can be more suitable due to ease of use and time saving.
Use Boxes> 1D Morph[Curves|Points] and select Points or Curves to define
the 1D Morph. The curve or the line connecting the points will become the 1D
Morph. In the card define a load radius (30) in which all elements will be
loaded and morphed according to control points movement.
Load Radius

Morphing with 1D Morphs – Load entities & Bounds
The usual functions also apply on 1D Morphs. The Boxes> Load has an extra step just for 1D Morphs.
1. After selecting an appropriate Load radius for each 1D Morph, select Boxes> Load , the 1D Morphs and the
entities to be loaded and confirm
2. Select to Auto update or Keep the auto-defined bounds or in this case select the Manual update button to add
more bounds,
3. Select the Bound edges that will retain their position after morphing and confirm.
2 3
Bounds

The usual functions also apply on 1D Morphs.
1. Activate the Box Morphing> Move[Translate] function and select control points to move and confirm.
2. Select two grids to define the movement vector and enter 100 in the Dist field.
3. Finally use the Control Points Movement window to Apply morph or Save> As parameter.
1 2

Linked Morphs – Symmetry Plane BOXES_neon.ansa
1. Activate Boxes> Links[Create] function, select the existing Morphs (half car) and confirm. In the window that
appears pick the Symmetry tab and keep the Default Symmetry Plane option. Press Apply to create Linked
Morphs. Control Points on the Symmetry Plane are colored in Blue, which means that their movements are
restricted on the Symmetry Plane.
2. All Modifications applied to the parent Morphs, are automatically applied to the Linked ones.
When the Tangency flag is set

to default in the Options List:
Tangency constraints are
automatically applied between
the Original and Linked Morphs
Symmetry
Linked Morphs

Linked Morphs - Creation 2D-LINKED_fan.ansa
1. Activate Boxes> Links[Create], select the existing 2D Morph and

confirm. In the window that appears pick the Rotate tab and
define the appropriate Rotation Vector. Set the number of Steps
to 5 and the Angle to 60 degrees. Press Enter to create Linked
Morphs.
2. All Modifications applied to the parent Morph, are automatically

applied to the Linked Morphs.
1 2
Rotate Linked
Morphs

3D Morph - Constraining regions’ morphing NESTED.ansa
1. Apply Controls> Nested[New] to create Nested Elements. Select the appropriate nodes and confirm. Optionally,
pick a node to become the Center of the Nested Element or skip this step. In the latter case, the Center of Gravity
of the selected nodes, is the center of the Nested Element.
2. In the NESTED Card that appears, enter the Degrees of Freedom that need to be constrained. Type all six Degrees
(123456), to create a Frozen Nested Element (highlighted in blue), or leave it empty to create just a rigid nested
element that moves to all Degrees of Freedom.
3. Apply Boxes> Load[Visible] to ensure that the Nested Elements are also loaded in the Morph.
1 3

3D Morph - Constraining regions’ morphing DFM-SUR-FIT_door_c.ansa
Nested Elements satisfy the need of freezing or moving as
not deformable, a specific area during the Morphing procedure. In the NESTED_ZONES_side.ansa
first case, the nested is called frozen while in the second, rigid.
1. Nested Elements work both in Box and Direct Morphing.
2. Smoothing zones around the Nested Elements guarantee the Mesh continuity after Morphing
3. Rbe2tonested function in the Nested List can convert existing RBE2 elements to Nested, maintaining the RBE2
DOF.
Rigid
Element
Smoothing
Zones
Frozen
Element

History Tool – Record History HISTORY_neon.ansa
1. Apply Controls> Parameters[Morph], to Morph the roof shape. Modify the Roof Height & Width, by changing the
existing Morph Parameters one by one.
2. During Morphing, record the History States using the Rec.State button in the Confirmation window, after each
modification. Alternatively, use the same button of the History window.
1 2 3 4
History
states
1
2
3
4

History Tool – Moving through History States
1. Select the desired History State and press Apply to move to the specific History state. Thus, it is possible to
UNDO any of the Morphing actions and return back to one of the previous States.
2. Select two or more States and apply the Create.. Morph linear function. The relative Par field and the sliding bar,
are activated. Now it is possible to move smoothly through the History States.
3. Select two or more States and apply the Curved Deform function. A new Curved Deform Parameter is created.
The Control Points of this parameter will follow a curve created from the selected Morphing states. In a similar
manner you can create a Deform Parameter. Automatically, a Deformation parameter is created, which help us to
move parametrically between two History States. Extrapolation is also possible for this type of parameter.
Deformation
Vectors-
Deformation
Parameter

Geometry morphing with 3D Morphs GEO_CHECK_BrakeCaliper.ansa
1. Apply the Checks> Geometry check function. During this check, all the loaded Geometrical Faces are cut along the
Morph splits that intersects them and they are distributed to the appropriate Morphs
2. The Geometry Morph Window appears, listing the “Conflict” Faces, that cannot be distributed by ANSA, to the
appropriate Morphs.
3. Sort the list by the “FACE’’ column and isolate problematic Faces using the Show Only button
4. Set the “conflict” faces to the appropriate Morphs using the available pull down menu.
5. As soon as all the “Conflict” faces are fixed, press the Next button. Here ANSA checks if there are any Faces that
are Out of all Morphs (outside check). If not, press the Finish button. We are now ready to Morph the Geometrical
model, using the already known functionality.

Optimization Tool - Introduction ( Workflow tab )
The Optimization Tool in ANSA is used for the definition, set-up and
solutions of Design of Experiments (DOE) or Optimization cases preparing an ANSA model to connect
with an optimization software.
The optimization tool contains five tabs:
1. Workflow: Area where the process is defined and overviewed. The Optimization Task is the Item that contains all
the actions and parameters of the Optimization definition that will be executed sequentially.
a. Pre-Processing Item: All the pre-processing actions are defined. Typically this item contains
i. Design Variables, that describe the parameters of the Optimization problem
ii. User script, that may automate any custom pre-processing actions
iii. Responses, that can be various ANSA entities of the model (e.g. measurements’ changes)
iv. FE output, that produces the ready-to-run solver file
The Pre-Processing Item contains all the

pre-processing functions
Morphing & ANSA Parameters can be

connected to the Optimization Task through
the relative Task Items
User Scripts and Responses can be added in

the pre-processing item
The FE output Task Item refers to the path

where the output file will be located

Optimization Tool - Introduction ( Workflow tab )
b. Solver item: Following the definition of the pre-processing, a solver file is created. With the solver item, a
selected solver is invoked to run the analysis
c. Post-Processing item: META is called to use the solver results and provide analysis responses.
• The Working directory is defined at the lower part of the window. All files are referring to this directory.
• The right side of the Workflow tab contains the Design Variables list, presenting in detailed mode their types and
bounds.
• Bellow, the Responses Ansa & Meta list presents the respective responses from ANSA entities or responses
extracted from META.
The Solver Item contains a solver command

and uses the FE output file to run the
analysis
The Post-Processing item uses the results

from the analysis and a user defined session
file, to create responses to describe the
behavior of the model

Optimization Tool - Introduction ( DOE setup tab )
2. DOE setup: Area where a Design of Experiments process is defined.
• The Design Variables are listed at the top left side of the window for overview.
• A DOE Algorithm can be selected from the available options in the respective drop menu and a specified number
of Designs can be Generated based on the selected algorithm and the Design Variables’ bounds.
• The Experiments are listed at the right of the window.
• The Constraints button is used to create user-defined constraints for responses or design variables.
• Several Run Options are available at the lower left side of the window that control the DOE process.
• The Simulate button will run each experiment (applying morphing, changing values, running scripts) and provide a
preview of each experiment.
• The Start button will initiate the DOE process, running each experiment one by one.

Optimization Tool - Introduction ( RSM setup tab )
3. RSM setup: Area where Response Surface Models (RSM) can be created or loaded from the connected DM.
• The New RSM button is used to train a new RSM with the DV based prediction algorithm.
• The Contents area lists all existing RSMs that are saved in the DM.
• The tables in the right side of the window show information about each selected RSM.
• The Update DM Signature button is used to specify the Simulation Model that will be used

Optimization Tool - Introduction ( Optimizer tab )
4. Optimizer: Area where a design optimization study can be set-up and solved. This study can be either RSM-based
or solver-based (Direct optimization). There are two available algorithms: IPOPT and Simulated Annealing.
• The New Optimization Study button is used to initiate the set-up process of a new optimization problem.
• The Start button is used to initiate the solution process of a specified optimization study.
• The Contents area lists all existing optimization studies.
• The area on the right shows information about any selected study from the Contents area.

Optimization Tool - Introduction ( Results tab )
5. Results: Area where Results from the DOE and Optimization analysis can be processed.
• The Results are automatically loaded from the working directory or DM, on condition that the directories Prefixes
are the same as the ones in the DOE tab.
• The New table field can be used, in order to load additional custom results.
• Point ,Line and Parallel coordinates charts along with Histograms can be created from the available buttons,
selecting values among Design Variables and responses.

Pre-processing setup – Shape Optimization example
OPT_TOOL_biw.ansa
1. To create a New Optimization Task : Tools > Optimization

2. Right click on the Workflow and select Optimization task>New. This action creates a default Optimization task
3. The default items are not correctly defined so warning icons appear one their left.

Pre-processing setup – Automatic DV generation
The appropriate Direct morphing Parameters that change the sub-frame's members width and height, are
already defined.
4. To automatically create Design Variables from the existing morphing parameters, open the Parameters list
Controls>Parameters select the parameters and from the right click menu, select Assign DV.

Pre-processing setup – Items creation & Manipulation
5. The 1st Design variable is empty, while the rest are linked with the morphing parameters. Delete the empty
Design Variable.
6. To create Design variables that will control field values (property thickness, material, material properties, etc.)
right click in the workflow and select Design Variables> from Entities. Select two properties from the model and
confirm. Select to control the Thickness value (T) and next select to create one Design Variable for each
property

7. Two new Design Variables have been defined that control the thickness of the selected properties. Click on their
name to rename them.
8. To assign two parameters to one Design Variable, expand the item, and “Drag and Drop” the morphing
parameter to a different Design Variable. Then rename the variable and delete the empty one.
9. From the Design variables list, modify the range and values as needed.

10. The two items that need attention are the DV file and the FE Output. Right click on the DV file and select Edit, to
define a name and optionally an absolute path for the text file that contains all the information regarding values,
type and bounds of the Design Variables. This is the key file when the process is defined for parametric
Optimization with an external optimizer.
11. Double click on the FE Output file to define the Solver, name and optionally an absolute path for the solver file to
be output.
12. Once the FE Output item is completed, the icon of the Optimization task disappears and it is ready to run.

Pre-processing setup – DV(Design Variable) file
Initially, the DV file contains the ranges and values of the design variables as set by the user. When the process is
handled by a parametric Optimization software, it modifies the current values of this file at each iteration and then
ANSA reads and applies these values to the model through the Optimization Task.

Pre-processing setup – Baseline run
The Optimization task is ready to run if there are no warnings. At this point the model is ready to be used in an
optimization analysis connecting ANSA with a third party parametric optimizer.
To check if the definition is correct, the Baseline run button will run the optimization task (apply morphing/ values,
run scripts, etc.). A “Baseline run” folder will be created in the Working directory, that will contain all the files used/
created by the optimization task.

Solver setup
To continue the process and define a full DOE study or a Direct optimization analysis (from the Optimizer tab), a
solver item needs to be defined.
Right click on the Optimization Task item and select New>Solver.
The Solver item reads the existing FE Output Item and auto-selects the correct Solver. If the solver commands is
written in the ANSA defaults, it appears in the Command field. If not, the user is called to type the command in the
field or in the ANSA defaults.

Post-Processing setup
Continuing, a Post-Processing item needs to be inserted that provides key responses from the analysis. Thus, a
session file should be defined to serve this purpose.
Right click on the Optimization Task item and select New>Post-Processing.
In the Post-Processing item, the Command field is auto-completed, based on the METAPOST command from the
ANSA defaults. The session file needs to be created, in order to get responses at each iteration. In case a session file
is not available, pressing the METAPOST icon, will launch META to start creating a new one.
The Responses file is created from the session file, which contains the extracted responses.

Post-Processing setup
All META responses are listed in the Responses ANSA & META table.
The Workflow for the DOE analysis is completed.
The next step is to switch to the DOE setup tab, to define the parameters of the DOE.

Design of Experiments setup
Switch to the DOE setup tab, to define the parameters of the DOE.
The Design Variables are listed here for overview. Select the Uniform Latin Hypercube from the DOE Algorithm
options to generate the experiments. Specify the number of Designs and Seed (depending on the Algorithm). Press
Generate, to generate the Experiments.

Design of Experiments setup
The experiments are created and listed in the respective table. It is possible to modify anything from the list. To
reduce the number of decimals, select columns and right click on the column title and reduce the Column Decimals.
In Run options it is possible to define what items of the workflow will run during the DOE. It is possible to save the
modified ANSA database at each experiment directory, set up if and when the DOE should Terminate if there is an
error, and define Animation settings.
The Directory and Experiment prefix will be used for the new directories that will contain the runs and experiments.

ANSA responses
A Response Item can be added in the workflow that exploits some measurements from the model.
Use the Measure Tool in ANSA to create measurements and Store them.
Select to measure the mass of PID 700001, that also has a thickness variable. Additionally, measure the distance
between the two rails of the same PID 700001.
The two measurements appear in the Database browser.

ANSA responses
Right click on the Pre-Processing item and select New>Response Item. Select the two measurements from the
Measurement window and then select the field value of the measurement that will used.
An item called Responses.txt is created in the Task, along with the specified measurement. Right click on it and
select Edit to specify a name and optionally an absolute path where the text file that contains all ANSA responses
will be saved.

ANSA responses
The Responses items are defined and the two ANSA responses are visible in the Responses Ansa & Meta list.
These responses can be used in order to set up Constraints for the DOE.

DOE constraints
In the DOE setup tab, press the Constraints button to open the Constraints editor and press the + button to create a
new constraint.
Constraints can be defined for Responses or Design Variables.
Optionally, the Value/Expression for the Limit of the constraints can defined through the constraints editor, pressing
on the Edit icon.

DOE constraints
If the constraints are applied on design variables, the violating experiments are identified in the DOE setup window
and can be disregarded.

DOE constraints
If the Constraints are applied on responses, the violated experiments are identified and shown in the Results tab,
after the DOE is completed.

DOE simulation & execution
Before starting the DOE, it is possible to press the Simulate button, to preview the models without actually using the
solver. This can work on all, or selected experiments.
Once the button is pressed, the optimization task will be executed for each experiment and will bring in visibility the
model and the Simulate experiments window, to navigate through each experiment.
This way it is possible to see if there are intersections, violating elements or other issues with the model at specific
experiments. By pressing the Remove experiment button, the experiment is deleted from the list.

DOE simulation & execution
Press the Start button to start the DOE process. This will freeze ANSA while the optimization task runs for each
experiment. The solver and post-processor will run in the background to provide results.
If the process runs without any problems, a DOE_Run structured folder will be created in the working directory and no
Error messages will appear in the information window.

Response Surface Models setup
Besides DOE, the Optimization Tool can create/load Response Surface Models (RSMs) that can be used in
Optimization Studies. An RSM is trained based on a DOE that is saved in the DM as Simulation Runs.
Connecting to a DM before running the DOE is a prerequisite. This can be done in two ways:
1. Use Set DM Paths option to point to a specified DM.
2. Use the Enable RSM-Optimizer button from the Workflow tab to automatically create a new DM.
Switch the Working directory mode to Save in DM.
1 2
home/documents/biw_DM

Switch to the RSM setup tab. In case any RSMs exist in the DM they will be listed in the Contents area.
To train a new RSM, press the New RSM button. Follow the steps of the Train new RSM window that opens. Once its
definition is finished, the training process will start automatically.

The newly created RSMs are shown in the Contents area and are saved in the DM. Multiple groups can be listed,
each one being able to include multiple RSMs.
Click on an RSM to show the respective information in the right side of the window.

Optimization
Switch to the Optimizer tab to set up and solve an Optimization Study. This study can be RSM-based or direct
optimization-based, and it can be solved with either of the two available algorithms: IPOPT and Simulated Annealing.
Press the New Optimization Study button to start setting-up the problem.
In the New Optimization Study window, name the new study and define the Algorithm and Method that it will be
based on. Depending on those parameters, follow the respective steps within the window until the study’s definition
is finished.

Optimization
The new Optimization Study along with any existing studies are listed in the Contents area.
Click on a study to show the respective information in the right side of the window.
Select the Optimization Study and press the Start button to initiate the solution process.
As the Optimizer runs, each optimization iteration is saved in the DM as Simulation Runs. Once it converges to the
optimal solution, a Verification Run can be executed in order to apply the optimal values to the model.

Results – Data Analysis
Switch to the Results tab, to see the results of the DOE/Optimization Study.
The values of the design variables and the responses are presented for each experiment. The Gray columns signify
the Responses. Clicking on the Column name, sorts the experiments accordingly.
To better visualize the results, it is possible to create a Point /Line 2D/3D chart, a Parallel coordinates chart or a
2D/3D Histogram.

Results – Data Analysis
The charts are listed in the Charts and Graphs area and can be dragged and dropped in the right area of the window.
Optionally, right click on a chart’s definition to edit or delete it, or right click inside the chart to make modifications or
save it.

SOL200 Shape Optimization - Introduction
For Shape Optimization, ANSA and EPILYSIS use the Manual Grid Variation method which requires the definition of
displacement vectors for the grids of the design space. These vectors prescribe the allowed movement of the grids
and are defined manually by the user with the aid of the DVGRID keyword. The creation of the DVGRIDs is automated
by the use of the Morphing functionality.
The Task Manager is used to set up the study in an guided way. Pre-defined items which are edited by the user are
provided to shape, solve and post-process the Shape Optimization study.
The Pre-Processing item contains all Task

items related to the set up of the Shape
Optimization problem.
The Start Optimization Task item is used to

initiate the solution process.
The Post-Processing item contains all Task

items related to post-processing the solver’s
results.
The Validation Task item is used to update

and validate the final model’s integrity.

Pre-Processing setup – DVGRIDs & DESVARs
SHAPE_OPT_initial.ansa
DVGRID entities are created from Morph Parameters. Three DESVARs will be created.
1. Select one by one the pocket_depth and middle_curvature parameters and click on the Create>Dvgrids option.
2. Taper of the piston rod is controlled by two morphing parameters. Use the History tool to record the initial and
morphed state (morph taper1 param. by 1 and taper1_auxiliary by -1.1). Select both the Initial_State and the
Taper states, click on Create>DVGRIDs and choose to create a new DESVAR. After finishing, select the
Initial_State and click on Apply to return back to the initial model shape.
3. Correct the bounds of all three DESVARs, from the XINIT, XLB and XUB fields in the Database Browser..
1 2 3

SOL200 Shape Task – Pre-Processing
1. Open the Task Manager and select SOL200 Task>SHAPE.
Right-click on the Initial Model, select Load>SOL200. Right-
click also on the SOL200 NASTRAN SHAPE TASK item to
specify the solver (NASTRAN).
2. Right-click on the DESIGN VARIABLEs>Add from List and
select all three existing DESVARs.
2
3. Create two Design Responses by right-clicking on the
RESPONSE>New>DRESP1>New. Create a VOLUME
response and a STRESS response for the set with ID 2
(ATTA field =13).
4. Create a new stress constraint by right-clicking on the
CONSTRAINTs>New>DCONSTR. In the RID field browse the 3
stress response and in the UALLOW field type the value
42.5. 4
Design Variables
Design Responses
Design Constraint

SOL200 Shape Task – Pre-Processing
5. Right-click on PARAMETERs>New>DOPTPRM and double-
click on the new DOPTPRM entity to edit the optimization
parameters. Activate the DESMAX field and type the value
30.
6. Double-click the OBJECTIVE_FUNCTION to edit it. Select
MIN to define a minimization study and in the Response Id
field browse the volume response.
7. Create a new SOL200 Header based on the existing
SOL101 one by double-clicking on HEADER and following
the steps of the wizard. In the created header, change the
DESGLB command with DESSUB.
8. Finally, double-click on the OUPUT item to define the
NASTRAN output file.
Optimization
Parameters 5
Design Objective
6
7
8
Solution Header
Solver Output

SOL200 Shape Task – Start Optimization
Double-click on the RUN task item to specify the path of the solver’s executable file and any necessary run option.
Right-click on the RUN item and select Run to initiate the solution process.

SOL200 Shape Task – Post-Processing
Double-click on the VIEW task item to define the path for the META executable file.
Then, right-click on the VIEW item and select View to open META automatically. Load the *.op2 file and select the
Shape Change option of the results in order to visualize the optimized shape of the various optimization cycles.

SOL200 Size Optimization - Introduction
Size optimization uses the desired property characteristics of a model as design variables.
provided to shape, solve and post-process the Size Optimization study.

items related to the set up of the Size


results.


SOL200 Size Task – Pre-Processing SIZE_OPT_property_init.ansa
1. Open the Task Manager and select SOL200 Task>SIZE.
Right-click on the Initial Model, select Load>SOL200. Right-
click also on the SOL200 NASTRAN SIZE TASK item to
specify the solver (NASTRAN).
2. Right-click on the DESIGN VARIABLEs>New>DESVAR
from>Entity and select all PSHELL properties. In the Available
2
fields window activate the T option that stand for property
thickness. After creating the DESVARs, modify their default
bounds (XLB=0.5 and XUB=3).
3. Create two Design Responses by right-clicking on the
RESPONSE>New>DRESP1>New. Create a FREQ response
(ATTA=5) and a WEIGHT response (ATTA=ATTB=3). 3
4. Create a new frequency constraint by right-clicking on the
CONSTRAINTs>New>DCONSTR. In the RID field browse the
4
frequency response and enter the values 75 and 120 in the
LALLOW and UALLOW fields respectively.
Design Variables
Design Responses
Design Constraint

SOL200 Size Task – Pre-Processing
5. Double-click on the DOPTPRM entity to edit the optimization
parameters. Activate the DESMAX field and type the value
15. Activate also the METHOD, P1, P2 fields and insert the
values 4, 1 and 15 respectively.
field browse the weight response.
7. Create a new SOL200 Header based on the existing SOL103
one by double-clicking on HEADER and following the steps
of the wizard. In the created header, change the DESGLB
command with DESSUB and the value of NASPRT to 1. Add
also the following keywords: TIME=1000000,
ANALYSIS=MODES, BEGIN BULK.
NASTRAN output file.
5
Optimization
Parameters
6
Design Objective
7
8
Solution Header
Solver Output

SOL200 Size Task – Start Optimization

SOL200 Size Task – Post-Processing
Then, right-click on the VIEW item and select View to open META automatically.
The general functionality of META can be exploited for reading and post-processing the results.

SOL200 Size Task – Post-Processing
Besides META’s general functionality, a dedicated toolbar for SOL200 Optimization can be used.
Select User Toolbars>Optimization>SOL200 Plot, browse the *.f06 file and create plots based on the available
options.

SOL200 Size Task – Model Update
In order to update the nominal model with the optimized values, the UPDATE Thicknesses task item is used.
Right-click on it, select Edit, pick the update_fe_model(pch_filename) and confirm.
Right-click on the same task item again and select Run. Browse the *.pch file, select all DESVARs and click Apply.

SOL200 Topology Optimization - Introduction
Topology optimization is used to achieve the optimal material distribution of a model.
provided to shape, solve and post-process the Topology Optimization study.

items related to the set up of the Topology


results.
The Smooth item contains all Task items

used to update the model with the optimal
results.


SOL200 Topology Task – Pre-Processing TOPOLOGY_OPT.ansa
1. Open the Task Manager and select SOL200
Task>TOPOLOGY>New. Right-click on the Initial Model,
select Load>SOL200. Right-click also on the SOL200
NASTRAN TOPOLOGY TASK item to specify the solver
(NASTRAN).
2. Double-click on the DESIGN AREA and specify the property
with ID 6 as the design volume. Also, browse the 2
coordinate system with ID 1 in the CID field and type a
name in the LABEL field. Right-click on the DESIGN AREA
and select New>MANUFACTURING_CONSTRAINTS to
3
create three new manufacturing constraints. Right-click on
the newly created task item and select
New>EXTRUDE/CASTING. Create a new Cast constraint
and specify SINGLE, X, YES in the respective fields. Create
also a MEMBERSIZE_CONTROL constraint with a TVMIN
value of 8. Finally, create a SYMMETRY_CONTROL and
select MIRROR and ZX in the respective fields.
3. Create three Design Responses by right-clicking on the
RESPONSE>New>DRESP1>New. Create a COMP response,
a DISP response (ATTA=1, ATTI_TYPE=NODE ID,
ATTI=1181) and a FRMASS response.
Design Volume &

Design Responses
Manufacturing Constraints

SOL200 Topology Task – Pre-Processing
4. Create a new frmass constraint by right-clicking on the
CONSTRAINTs>New>DCONSTR. In the RID field browse
the frmass response and enter the value 0,3 in the
UALLOW field. Create also a displacement constraint with
a different DCID value and enter the values -2.5 and 1 in the
LALLOW and UALLOW fields respectively.
5. Double-click on the DOPTPRM entity to edit the
optimization parameters. Activate the DESMAX field and
Design Constraints
type the value 60. Activate also the P1 and P2 fields and
insert the values 1 and 0 respectively.
field browse the compliance response. 4
7. Create a new SOL200 Header based on the existing
SOL101 one by double-clicking on HEADER and following 5
the steps of the wizard. In the created header, add the
6
DESGLB command for the frmass constraint, the
PARAM,TOPSYM with the value 1 and the BEGIN BULK 7
keyword. Change also the value of NASPRT to 1 8
NASTRAN output file. Optimization
Parameters
Design Objective Solution Header Solver Output

SOL200 Topology Task – Start Optimization

SOL200 Topology Task – Post-Processing
Then, right-click on the VIEW item and select View to open META automatically.
The general functionality of META can be exploited for reading and post-processing the results.
The Topology Optimization toolbar opens automatically while the results are already read. Define a Threshold Value
of 40 and export the shown Isofunction.

SOL200 Topology Task – Model Update
In order to update the nominal model with the optimized values and create a smooth and continuous shell surface,
the SMOOTH task item is used.
Double-click on the SMOOTH task item and browse the *.nas file.
Double-click on the GENERATE_ISOSURFACE and browse the *.des file. Specify also an Isosurface threshold value
of 40. Then, right-click on the same item and select run in order to create the isofunction.nas file.
Double-click on the SMOOTH_SURFACE icon and browse the previously created isofunction. Then right-click on the
same item to generate the final, optimized model.
Optionally, right-click on the VOLUME_CREATION item and select RUN to generate a solid mesh out of the shell
model.

SOL200 Topology Task – Validation
The VALIDATION task item is used to output and solve the optimized model using the initial header aiming to
structurally compare the initial and the optimized model.
Double-click on the VALIDATION OUTPUT to define a directory for the output NASTRAN file. Optionally, specify any
necessary NASTRAN output parameters.
Then, right-click on the same item, select Run to generate the output file and then select the existing sol_101 header.
The output database is ready to be solved in EPILYSIS.

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ANSA Morph & Optimization

 Features recognition and handling ……………….……………………….………………............ page 07

 Cross section modifications .............................……………………………………………............. page 20

 Adapt Flanges…………………………....…………………………………………............................ page 23

 Direct morphing - Constraining regions’ morphing……………...………………………………...... page 24

 Relocating members ……………....………………………………………….................................. page 28

 Reinforcing an area………………….…………….......................................................................... page 29

 DFM morphing…………………………....…………………………………………............................ page 31

 Form - Bend…………………..…………………....…………………………………………............... page 38

 Form – Twist………………………………………....…………………………………………............ page 39

 Form – Taper & Extend………………….…………………....……………………………………….. page 40

 Spotweld Morphing – Spotweld Groups…………………………………………………………………………………………….. Page 41

 3D Morph Terminology………..…………………………………………………............................. page 44

 2D/1D/Cylindrical Morph Terminology………………………………………………………………… page 45

 Morphing with 3D Morphs…………….….………………..………………………………………......... page 46

ANSA Morphing & Optimization 2 www.beta-cae.com

 Morphing with 2D Morphs……………………………………………….……………………............ page 71

 Linked Morphs…………………………………………………………………………………… page 79

 3D Morph - Constraining regions’ morphing.………………………………………............. page 81

 History Tool…...…………………………....…………………………………………............................ page 83

 Geometry morphing with 3D Morphs…..……………………………………............................ page 85

 Optimization Tool - Introduction….……....…………………………………………........................ page 86

 Pre-processing setup…………...……....…………………………………………............................ page 92

 Solver setup……………………………....…………………………………………............................ page 99

 Post-processing setup….……………....…………………………………………............................ page 100

 Design of Experiments setup…...…………………………………………............................ page 102

 ANSA responses………………………………………………………………………………. page 104

 DOE constraints…….…………………....…………………………………………............................ page 107

 DOE simulation & execution……..….………………..………………………………………......... page 110

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1. Select Direct Morphing> Modeling> Loft [Wrap]

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Swapping the Flanges is

The creation of Fillet or

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