CAD/CAE Lecture – Midterm

The midterm consisted of creating a modified Dragon spacecraft support bracket using parametric design and optimize the structure against a predefined load and mass requirement.

Actual support brackets attached to Dragon can be seen in black.

Actual support brackets attached to Dragon can be seen in black.

Prompt:

The attached drawing file contains all necessary dimensions, parameters, and instructions for the optimization of a simplified and modified Dragon support bracket. Model the part using correct design intent, add the necessary parameters to the correct references, run a static analysis, and optimize the part for minimum mass given a max VM stress design limit. The parameter values given in the drawing should be used as initial starting points for the static analysis and any sensitivity or optimization studies you run. Consider running a sensitivity study to help narrow the variable window and starting values for the optimization.

This is an individual assignment. You may NOT discuss your method, details, or answers with other students.

The optimization takes between 15 minutes to several hours in solve time depending on how the part is constructed, the mesh density, allocated resources, and parameter limits.

Modified Dragon support bracket students are to create.

Modified Dragon support bracket students are to create.

First pass to show stress distribution and other areas of interest.

First pass to show stress distribution and other areas of interest.

Solution

My solution was created in ProE WF 5.0 and analyzed in ProMechanica. In addition, I recreated the part in ANSYS Design Modeler and optimized the part using a static structural module linked to a parameter and optimization module.

ProjectSchematic

Original model

Original model

Original model with mesh

Original model with mesh

Original model - VM Stress

Original model – VM Stress

Original model - deformation

Original model – deformation

DXOptimizationEvaluateContainerTradeoff

Trade off between Mass and Max VM Stress

DXOptimizationEvaluateContainerHistory33

Optimization history – Max VM Stress

DXOptimizationEvaluateContainerHistory22

Optimization history – Step width

DXOptimizationEvaluateContainerHistory11

Optimization history – Small rib

DXOptimizationEvaluateContainerHistory

Optimization history – Depth of cut

Response chart

Response chart