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STUDY OF THE DESIGN OF A BICYCLE FRAME BY COMPARING DIFFERENT TOPOLOGY OPTIMIZATION SOFTWARE

ÁLVARO CASAS MARTÍNEZ

ÀLEX FERRER FERRÉ

JOSE ANTIONIO TORRES LERMA

Director/Co-director:

Author:

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TABEL OF CONTENTS

Introduction

Motivation
Topology Optimization
Density vs Level Set
Difficulties
Objectives

Methodology

Software
Benchmark problems
Bicycle problem modelling
Final formulation & analysis

Results

Cantilever
Stool
Chair
Bicycle

Conclusions

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INTRODUCTION

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MOTIVATION

Cycling
Structure lightweighting
Topology Optimization

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INTRODUCTION - MOTIVATION

From [1]

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Problem definition:

INTRODUCTION - TOPOLOGY OPTIMIZATION

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INTRODUCTION - DENSITY vs LEVEL SET

Ψ Function

DENSITY

Level Set

From [2]

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INTRODUCTION - DIFFICULTIES

Time vs results

Software

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INTRODUCTION - OBJECTIVES

Test different commercial TO software and compare it with Swan, which is a open-source code
Be able to decide which software is best suited taking into account different variables

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METHODOLOGY

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SOLIDWORKS

Ansys

nTop

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METHODOLOGY - SOFTWARE

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Focused in TO
Redesign existing
Program taking into account the current manufacturing processes

Fusion 360

SOLIDWORKS

nTop

Ansys

Not mainly focused in TO
Design from start to finish

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METHODOLOGY - SOFTWARE

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More than 50 years of expetience
Not focused in TO

Inspire

SOLIDWORKS

nTop

Ansys

Fusion 360

Not focused in TO
Design from start to finish

Focused in TO
Redesign existing
Program taking into account the current manufacturing processes

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Focused in TO
Redesign existing
Program taking into account the current manufacturing processes

Handles 3D modeling, CAD, CAM, CAE and PCB
Simulations runed in the cloud

SOLIDWORKS

nTop

Ansys

Fusion 360

Inspire

Swan

More than 50 years of expetience
Not mainly focused in TO

METHODOLOGY - SOFTWARE

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Aims to do the user experience easier
SimSolid for design
Optistruct for optimization

More than 50 years of expetience
Not focused in TO

SOLIDWORKS

nTop

Ansys

Fusion 360

Inspire

Swan

Handles 3D modeling, CAD, CAM, CAE and PCB
Simulations runed in the cloud

METHODOLOGY - SOFTWARE

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Open-source software
GitHub repository
Constant updates

Handles 3D modeling, CAD, CAM, CAE and PCB
Simulations runed in the cloud

nTop

Ansys

Fusion 360

Inspire

Swan

Aims to do the user experience easier
SimSolid for design
Optistruct for optimization

METHODOLOGY - SOFTWARE

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CANTILEVER BEAM

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Aims to do the user experience easier
SimSolid for design
Optistruct for optimization

Ansys

Fusion 360

Inspire

Swan

Open-source software
GitHub repository
Constant updates

CHAIR

STOOL

METHODOLOGY - SOFTWARE

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CANTILEVER BEAM

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Aims to do the user experience easier
SimSolid for design
Optistruct for optimization

Ansys

Fusion 360

Inspire

Swan

Open-source software
GitHub repository
Constant updates

CHAIR

STOOL

METHODOLOGY - BENCHMARK PROBLEMS

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METHODOLOGY - BENCHMARK PROBLEMS

CANTILEVER BEAM

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CHAIR

STOOL

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METHODOLOGY - BENCHMARK PROBLEMS

CANTILEVER BEAM

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CHAIR

STOOL

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METHODOLOGY - BENCHMARK PROBLEMS

CANTILEVER BEAM

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CHAIR

STOOL

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METHODOLOGY - BICYCLE PROBLEM MODELLING

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��Com analitzarem els problemas volum, displacements i topo, volem veure la rigidesa i que ho fem a través de displacements

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METHODOLOGY - FINAL FORMULATION & ANALYSIS

Topologies
Volume
Displacements

CASE A	CASE B	CASE C
30%	20%	10%

Compliance is a way of measuring the flexibility of the structure. Minimizing compliance stiffness is maximized.

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RESULTS

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CANTILEVER

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RESULTS - CANTILEVER – TOPOLOGIES - 03

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SolidWorks

nTop

Ansys

Swan

Fusion 360

Inspire

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RESULTS - CANTILEVER – TOPOLOGIES - 02

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SolidWorks

nTop

Ansys

Swan

Fusion 360

Inspire

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RESULTS - CANTILEVER – TOPOLOGIES - 01

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SolidWorks

nTop

Ansys

Swan

Fusion 360

Inspire

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RESULTS - CANTILEVER - VOLUME

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RESULTS - CANTILEVER 03 – MAX. DISPLACEMENTS

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	CANTILEVER 03
	SW	nTop	Ansys	Swan	Inspire
Max. Disp. Topology [mm]	5.47	4.82	5.02	8.90	5.00
Max. Disp. Original [mm]	1.96	1.94	1.74	3.90	1.96
Topology/Original	2.79	2.49	2.89	2.28	2.55

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RESULTS - CANTILEVER 02 – MAX. DISPLACEMENTS

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	CANTILEVER 02
	SW	nTop	Ansys	Swan	Inspire
Max. Disp. Topology [mm]	8.87	8.58	9.12	15.00	8.44
Max. Disp. Original [mm]	1.96	1.94	1.74	3.90	1.96
Topology/Original	4.53	4.43	5.24	3.85	4.31

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RESULTS - CANTILEVER 01 – MAX. DISPLACEMENTS

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	CANTILEVER 01
	SW	nTop	Ansys	Swan	Inspire
Max. Disp. Topology [mm]	27.62	22.11	34.10	50.00	27.23
Max. Disp. Original [mm]	1.96	1.94	1.74	3.90	1.96
Topology/Original	14.09	11.41	19.60	12.82	13.91

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RESULTS - CANTILEVER - TIME

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Posar per exemple que inspire no es de fiar (conclusions Finals )

A l’hora d’explicar “recapitular” i centrar a l’espectador

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STOOL

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RESULTS - STOOL – TOPOLOGIES - 03

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SolidWorks

nTop

Ansys

Swan

Fusion 360

Inspire

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RESULTS - STOOL – TOPOLOGIES - 02

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SolidWorks

nTop

Ansys

Swan

Fusion 360

Inspire

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RESULTS - STOOL – TOPOLOGIES - 01

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SolidWorks

nTop

Ansys

Swan

Fusion 360

Inspire

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RESULTS - STOOL - VOLUME

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RESULTS - STOOL 03 – MAX. DISPLACEMENTS

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	STOOL 03
	SW	nTop	Ansys	Swan	Inspire
Max. Disp. Topology [mm]	0.35	0.32	0.28	1.00	0.33
Max. Disp. Original [mm]	0.24	0.23	0.24	0.74	0.23
Topology/Original	1.47	1.41	1.18	1.35	1.42

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RESULTS - STOOL 02 – MAX. DISPLACEMENTS

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	STOOL 02
	SW	nTop	Ansys	Swan	Inspire
Max. Disp. Topology [mm]	0.50	0.45	0.39	1.40	0.47
Max. Disp. Original [mm]	0.24	0.23	0.24	0.74	0.23
Topology/Original	2.11	1.98	1.65	1.89	2.02

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RESULTS - STOOL 01 – MAX. DISPLACEMENTS

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	STOOL 01
	SW	nTop	Ansys	Swan	Inspire
Max. Disp. Topology [mm]	1.13	1.17	0.70	3.00	1.10
Max. Disp. Original [mm]	0.24	0.23	0.24	0.74	0.23
Topology/Original	4.76	5.15	2.95	4.05	4.73

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RESULTS - STOOL - TIME

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Posar per exemple que inspire no es de fiar (conclusions Finals )

A l’hora d’explicar “recapitular” i centrar a l’espectador

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CHAIR

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RESULTS - CHAIR – TOPOLOGIES - 03

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SolidWorks

nTop

Ansys

Swan

Fusion 360

Inspire

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RESULTS - CHAIR – TOPOLOGIES - 02

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SolidWorks

nTop

Ansys

Swan

Fusion 360

Inspire

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RESULTS - CHAIR – TOPOLOGIES - 01

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SolidWorks

nTop

Ansys

Swan

Fusion 360

Inspire

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RESULTS - CHAIR - VOLUME

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RESULTS - CHAIR 03 – MAX. DISPLACEMENTS

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	OPTIMAL CHAIR 03
	SW	nTop	Ansys	Swan	Inspire
Max. Disp. Topology [mm]	10.96	7.97	-	9.60	8.31
Max. Disp. Original [mm]	4.61	4.43	-	4.40	4.54
Topology/Original	2.38	1.80	-	2.18	1.83

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RESULTS - CHAIR 02 – MAX. DISPLACEMENTS

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	OPTIMAL CHAIR 02
	SW	nTop	Ansys	Swan	Inspire
Max. Disp. Topology [mm]	20.64	55.05	-	17.00	-
Max. Disp. Original [mm]	4.61	4.43	-	4.40	-
Topology/Original	4.48	12.42	-	3.86	-

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RESULTS - CHAIR 01 – MAX. DISPLACEMENTS

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	OPTIMAL CHAIR 01
	SW	nTop	Ansys	Swan	Inspire
Max. Disp. Topology [mm]	47.66	-	-	35.00	-
Max. Disp. Original [mm]	4.61	-	-	4.40	-
Topology/Original	10.35	-	-	7.95	-

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RESULTS - CHAIR - TIME

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Posar per exemple que inspire no es de fiar (conclusions Finals )

A l’hora d’explicar “recapitular” i centrar a l’espectador

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BICYCLE

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RESULTS - BICYCLE – TOPOLOGIES - 03

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SolidWorks

nTop

Ansys

Swan

Fusion 360

Inspire

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RESULTS - BICYCLE – TOPOLOGIES - 02

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SolidWorks

nTop

Ansys

Swan

Fusion 360

Inspire

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RESULTS - BICYCLE – TOPOLOGIES - 01

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SolidWorks

nTop

Ansys

Swan

Fusion 360

Inspire

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RESULTS - BICYCLE – TOPOLOGIES - 01

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RESULTS - BICYCLE – TOPOLOGIES - 01

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RESULTS - BICYCLE – TOPOLOGIES - 01

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From [3]

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RESULTS - BICYCLE - VOLUME

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RESULTS - BICYCLE 03 – MAX. DISPLACEMENTS

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	BICYCLE 03
	SW	nTop	Ansys	Swan	Inspire
Max. Disp. Topology [mm]	57.00	319.00	-	0.29	10200.00
Max. Disp. Original [mm]	28.34	25.47	-	0.01	27.69
Topology/Original	2.01	12.52	-	24.17	368.36

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RESULTS - BICYCLE 02 – MAX. DISPLACEMENTS

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	BICYCLE 02
	SW	nTop	Ansys	Swan	Inspire
Max. Disp. Topology [mm]	107.00	3429.00	-	1.40	45050.00
Max. Disp. Original [mm]	28.34	25.47	-	0.01	27.69
Topology/Original	3.78	134.63	-	116.67	1626.94

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RESULTS - BICYCLE 01 – MAX. DISPLACEMENTS

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	BICYCLE 01
	SW	nTop	Ansys	Swan	Inspire
Max. Disp. Topology [mm]	462	-	-	1.4	-
Max. Disp. Original [mm]	28.34	-	-	0.012	-
Topology/Original	16.30	-	-	116.67	-

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RESULTS - BICYCLE - TIME

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Posar per exemple que inspire no es de fiar (conclusions Finals )

A l’hora d’explicar “recapitular” i centrar a l’espectador

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CONCLUSIONS & FUTURES LINES OF RESEARCH

Do not trust the software
A lot of improvements (complex problems not supported)
Select one software considering all variables (results, time, post-analysis, personalization, interface…)

Modelling of the bicycle frame more detailed
Do test with printed models to test the reliability

FUTURES LINES OF RESEARCH

CONCLUSIONS

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