© Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

Inspire for Structural Analysis and Optimization, v2020

INSPIRE FOR STRUCTURAL ANALYSIS AND OPTIMIZATION - V2020

CH7 - TOPOLOGY OPTIMIZATION

1
 © Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Inspire for Structural Analysis and Optimization, v2020

Chapter 7 - Topology Optimization

• Introduction to Topology Optimization • Exercise 7A: Running a Topology

• Design Space Optimization

• Shape Controls • Exercise 7B: Re-Analyze and Compare

Results
• Displacement Constraints
• Questions & Answers
• Minimum Gauge for Topology Optimization
• Run Optimization - Topology
• Shape Explorer - Topology
• Maximize Stiffness Results
• Minimize Mass Results
• Post-Processing Results
• Analyzing and Comparing Topology Results
• Exporting Results

2
 © Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Inspire for Structural Analysis and Optimization, v2020

Introduction to Topology Optimization

Topology Optimization

• The topology optimization process carves material

away from design spaces, creating the lightest structure
capable of withstanding the forces you apply to your
model.
This approach is ideal for maximizing the stiffness of
components while trying to achieve a desired mass target.
It can also be used to minimize the mass of a model,
depending on your objective.

• If you maximize the stiffness of a design space, the

resulting shape will resist deflection, but may be heavier
as a consequence.
If you minimize mass, the resulting shape will be light but
may deflect more.

3
 © Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Inspire for Structural Analysis and Optimization, v2020

Design Space
• By default, all parts are Non-Design Space.

• To change this, select the part and set to Design Space.

• To do this, on the part, use the Property Editor or Model Browser.

4
 © Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Inspire for Structural Analysis and Optimization, v2020

Shape Controls
Draw Direction

Applied when you intend to manufacture the model in a specific type of way.

• Draw directions can be applied to any plane, global or translated/rotated.

• Only one draw direction can be applied to a Design Space.

Structure ribbon > Setup group > Shape Controls > Apply Draw Directions

• 4 types of draw directions are available:

• Single Draw

• Split Draw

• Extrusion

• Overhang

5
 © Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Inspire for Structural Analysis and Optimization, v2020

Shape Controls
Draw Direction

• 4 types of draw directions are available:

• Single Draw

• Split Draw

• Extrusion

• Overhang

Note: Stamping can only be selected from the micro-dialog.

6
 © Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Inspire for Structural Analysis and Optimization, v2020

Shape Controls
Symmetry (Optimization)

Generate symmetric shapes, even under asymmetric conditions, by

defining symmetry planes in the design space.

Don’t always get a perfectly symmetric shape but get a result that is very
nearly symmetric.

Structure ribbon > Setup group > Shape Controls > Apply Symmetric Controls

• 3 different symmetries:

• Symmetric

• Cyclic

• Cyclic Symmetric

Note: Symmetry planes are valid for optimization but not analysis.

7
 © Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Inspire for Structural Analysis and Optimization, v2020

Displacement Constraints
Displacement constraints can be applied to limit deflections in desired locations and directions.

Structure ribbon > Setup group > Disps > Apply Displacement Constraints

• Can be applied to a cylindrical hole, a face, an edge or a point.

• Should be applied only to Non-Design Spaces.

• Recommended to use with stress constraints.

• Can have upper bound, lower bound or both.

Apply the displacement constraint in one direction or all directions.

Enter a magnitude or upper and/or lower bound for the displacement

constraint.

Connect a displacement constraint placed at a distance to the model

using connectors.

Translate or rotate the displacement constraint using the Move tool.

Align the displacement constraint to an axis or normal to the face.

8
 © Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Inspire for Structural Analysis and Optimization, v2020

Minimum Gauge for Topology Optimization

• When running Topology Optimization on a surface, Minimum Gauge
constraints are used to avoid holes in the optimized part and help show
where rib structures should be placed.

• Use the Property Editor to define a minimum gauge:

1. Define the Thickness of the part

2. In Optimization section enable Use Base Thickness and insert the

value of Base Thickness.

9
 © Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Inspire for Structural Analysis and Optimization, v2020

Run Optimization
Topology

1. Objective – Can be toggled to either Maximize Stiffness or 1

Minimize Mass. Maximize Stiffness produces a result that will
resist deflection, essentially giving you load paths for a 2
particular analysis. On the other hand, Minimize Mass
produces the lightest resulting shape.

2. Mass Targets – When the Optimization Objective is set to

maximize stiffness, mass targets are used to specify the
amount of material to keep. This target can be defined either
as a percentage of the total volume of the design space, or as
the total mass of the entire model. If you have more than one
design space, you can set targets for each design space
individually. When the Optimization Objective is set to minimize
mass, a global stress constraint can be set.

10
 © Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Inspire for Structural Analysis and Optimization, v2020

Run Optimization
Topology

3. Stress Constraints – When the Optimization Objective is set

to minimize mass, the mass target parameter is replaced with
the stress constraint parameter. Inspire analyzes the materials
3
used in the model to determine which has the lowest yield
stress, then divides the lowest yield stress by the user
designated minimum safety factor. Inspire ensures stress will 4
not go above this value.

4. Frequency Constraints – Allows the user to control the

frequency at which an optimized part vibrates. You may 5
choose to either maximize frequencies or set a specific minimum
frequency.

5. Thickness Constraints – Control of wall thicknesses and the

diameters of beam-like members in a shape. Default maximum
thickness = 2 * minimum thickness. Directly correlates to run
times.

11
 © Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Inspire for Structural Analysis and Optimization, v2020

Run Optimization
Topology

6. Speed/Accuracy – The Faster setting is sufficient to obtain

good conceptual designs. The More Accurate setting is only
necessary when a great degree of accuracy is required for
frequency constraints.

7. Contacts – Sliding only option allows you to run the model

faster, but the results will not be as accurate. If you select the
Sliding with separation option, the model will run slower, but will
6
better represent the actual physics.

7
8. Gravity – Yes or No
If the weight of a structure is a significant portion of the load
8
it is bearing, then you should include gravity when running an
analysis or optimization.

12
 © Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Inspire for Structural Analysis and Optimization, v2020

Run Optimization
Topology

9. Load Cases – Allows you to toggle which load cases you

would like to run an optimization for. As for Analysis, you can
also control Inertia relief.

10. Restore – Restores the default values of any previous

optimization you ran during your saved session.

11. Export – Allows you to export your optimization as a .fem file

for further analysis.
9

12. Run – Launches the optimization.

10 11 12

13
 © Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Inspire for Structural Analysis and Optimization, v2020

Shape Explorer
Topology

Use the Topology slider on the Shape Explorer to analyze the quality of your results.

• If the topology of your shape doesn’t change much when you move the slider, this
means you’ve arrived at a good solution and may even be able to make your design
targets a bit more aggressive.

• If the topology changes significantly when you move the slider, you should consider
relaxing your design targets and re-running optimization until the topology remains
consistent when the slider is moved.

• The topology slider serves different functions depending on if you are running a
Maximize Stiffness or a Minimize Mass optimization.

14
 © Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Inspire for Structural Analysis and Optimization, v2020

Shape Explorer
Topology

• Maximize Stiffness – When your optimization objective is to maximize stiffness, the

optimal shape is generally found near the center of the slider marked by the star.
Increasing or decreasing your mass target can have a significant effect on the
point on the slider at which all structures are connected.

• Minimize Mass – When your optimization objective is to minimize mass, the optimal
shape is often found to the far right of the slider. Once all structures are
connected, you have an optimal design that is sized according to your stress
constraint.

15
 © Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Inspire for Structural Analysis and Optimization, v2020

Maximize Stiffness Results

Maximize Stiffness

• Bad design: since regions are shown that have structure

beginning to form while the topology slide is near the middle,
Inspire needs more design space to work with to complete the
particular load path. Increasing the Mass Target by 5-10%
should resolve this issue.

• Good design: all structures are complete while the topology

slider is near the middle. When moving the topology slider to
the right only thickens the created structures, you know you
have arrived at a good solution.

16
 © Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Inspire for Structural Analysis and Optimization, v2020

Minimize Mass Results

Minimize Mass

• With Minimize Mass, a good design is one in

which all structures are connected,
regardless of what position the topology slider
is in.

• It is typically good practice to begin the design

process with a maximize stiffness run. Then,
once you have well defined loads, run a
minimize mass optimization to compare
results.

17
 © Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Inspire for Structural Analysis and Optimization, v2020

Exercise 7A - Running a Topology Optimization

File Name and Location

..\STUDENT-EXERCISE\Ch7\Exercise_7A.stmod

Exercise Goals
1. Open the model
2. Set Design Space and Shape Controls
3. Run optimization with Minimize Mass Objective
4. Run optimization with Maximize Stiffness Objective
5. Explore results in the Shape Explorer.

18
 © Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Inspire for Structural Analysis and Optimization, v2020

Exercise 7A - Running a Topology Optimization

Step 1: Open the Model

a) File > Open > ..\STUDENT-EXERCISE\Ch7\Exercise_7A.stmod

Step 2: Set Design Space and Shape Controls

a) Model Browser > Design part > > check Design Space box

b) Structure ribbon > Setup group > > Apply Symmetric Controls
c) Select a Design Space and using Property Editor activate only XZ as a Planar Symmetry.

19
 © Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Inspire for Structural Analysis and Optimization, v2020

Exercise 7A - Running a Topology Optimization

Step 3: Run optimization with Minimize Mass Objective

a) Structure ribbon > Run group > Run Optimization

b) Run optimization with Minimize Mass Objective and
Minimum safety factor of 1.5.
c) click on the run name when appears the green flag

20
 © Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Inspire for Structural Analysis and Optimization, v2020

Exercise 7A - Running a Topology Optimization

Step 4: Run optimization with Maximize Stiffness Objective

a) Run optimization with Maximize Stiffness Objective.
b) click on the run name when appears the green flag
c) Optional: Run optimization with Maximize Frequency Objective.

21
 © Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Inspire for Structural Analysis and Optimization, v2020

Exercise 7A - Running a Topology Optimization

Step 5: Explore results using Shape Explorer

a) Review the shape obtained and click on Compare Results.
b) Use the Topology slider on the Shape Explorer to analyze the quality of your results.

22
 © Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Inspire for Structural Analysis and Optimization, v2020

Topology Optimization
Post-Processing Results

Topology optimization results are a STL mesh. The following operations

can be performed:

• Re-analyze optimized shape to confirm performance.

• Export results as an STL and use STL file as a guide in your CAD
software.

Auto-PolyNURBS is used to optimize your PolyNURBS design.

• Rebuild smooth geometry in Inspire using PolyNURBS

(see PolyNURBS Chapter).

• Rebuild thick plate models with 2.5D sketching

(see 2.5D sketching Chapter).

23
 © Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Inspire for Structural Analysis and Optimization, v2020

Analyzing and Comparing Topology Results

1. Analyze the Optimized Shape - Performs an analysis on the generated shape.

The results will allow you to quickly gain insight into the performance of the optimized shape.

To perform this operation, the user can select the Analyze icon in the Shape Explorer.

2. Compare results - Allows optimization results to be compared in a table.

3. Select the Smooth Results check box on the Shape Explorer to smooth the results of a
topology optimization. This option is enabled by default.

4. Click to change the smoothing method:

• Maintain Part Volume While Smoothing:

Drag the slider to modify the smoothness of the results

• Ignore Part Volume While Smoothing:

Material may appear thin or be removed entirely in some regions.

• Smoothing Iterations:
The greater the number of iterations, the smoother the result will be.

24
 © Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Inspire for Structural Analysis and Optimization, v2020

Compare Results
Compare the results of multiple analysis runs

The Compare Results button is located at the bottom of the Analysis Explorer.

• Compare results across all runs and load cases for the selected result type.

• Compare result types at a point of interest where you have placed a callout.

25
 © Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Inspire for Structural Analysis and Optimization, v2020

Exporting Results
Once a concept has been generated, the user has the ability to do the following with the results:

• Export results as an STL  File > Save As > STL (*.stl) – gives the user a raw,
unsmoothed result file that can then be viewed in typical CAD software.

• Fit PolyNURBS – fits a smooth surface over the generated shape. The result appears in the
Model Browser with the name PolyNURBS Fit and you are placed in PolyNURBS editing
mode. New geometry can be exported (most CAD systems).

• Crease break angle: any break angle above

the value entered will have high sharpening
applied to the edge.

• Element density Factor: Lowering the Element

Density Factor will increase the size of the
PolyNURBS cages but will capture less detail.

• Auto creasing: high sharpening will automatically

be applied based on Crease break angle

26
 © Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Inspire for Structural Analysis and Optimization, v2020

Exercise 7B - Re-analyze and Compare Results

File Name and Location

..\STUDENT-EXERCISE\Ch7\Exercise_7B.stmod

Exercise Goals
1. Open the model
2. Show optimization results
3. Analyze and compare results

27
 © Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Inspire for Structural Analysis and Optimization, v2020

Exercise 7B - Re-analyze and Compare Results

Step 1: Open the model

a) File > Open > ..\STUDENT-EXERCISE\Ch7\Exercise_7B.stmod

Step 2: Show optimization results

a) Structure ribbon > Run group > Show Optimization Results
to display the Shape Explorer.
b) Click on Analyze to run an analysis on the shape
c) click on the run name when appears the green flag

28
 © Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Inspire for Structural Analysis and Optimization, v2020

Exercise 7B - Re-analyze and Compare Results

Step 3: Analyze and compare results

a) Show the results using Analysis Explorer

b) Use Compare Results to check optimized design
vs original design performance.

Note: Higher stress occur near the fixations. Those are

local stress that will be addressed later in the design
cycle. You can use the filter to check areas where
Safety Factor is below 1.5.

29
 © Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Inspire for Structural Analysis and Optimization, v2020

Questions & Answers

30