SIMULIA TOSCA_Structure Brochure 0114 Tosca Structure

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SIMULIA TOSCA STRUCTURE
THE STRUCTURAL OPTIMIZATION SYSTEM

TOSCA STRUCTURE
SIMULIA Tosca Structure is a flexible, modular software system for non-parametric structural optimization that provides topology,
KEY BENEFITS
sizing, shape and bead optimization optimization using industry standard finite element solvers (ANSYS, Abaqus, MSC Nastran).
The setup is simple – model parameterization is not necessary. Existing solver input files are used for the optimization. Tosca
Structure is based on market-leading technology and provides advanced capabilities for optimization with nonlinear analysis and
fatigue as well as a specific non-parametric morphing approach.

TOSCA STRUCTURE FEATURES
Innovative, lightweight design concepts

Improved designs for more durability and strength

Topology optimization
Conceptual design for lighter and stiffer structures. Create
lightweight, ready-to-manufacture product designs and
reduce time-to-market, physical tests, and prototype
builds.

Shape optimization
Improve existing designs for more reliable and durable
components. Minimize stress, strain, and damage – or any
combination of these – by automatic modification of the
surface geometry.

Efficient bead patterns for increased stiffness
and reduced noise

Best static and dynamic behavior through
optimized sheet thicknesses

Bead optimization
Improve the static and dynamic properties of shell
structures. Generate optimal bead layouts while
accounting for manufacturing constraints, complex
geometries, and realistic loads.

Sizing optimization
Obtain an optimal relation between weight, stiffness,
and dynamic behavior, to gain material savings and take
advantage of increased comfort.

TOSCA STRUCTURE ADVANCED CAPABILITIES
Full optimization potential with realistic simulation models
Nonlinear analysis—exploit the benefits of topology, sizing, shape and bead optimization in combination with contact,
material nonlinearity and large deformation. Avoid error-prone and time consuming model simplification.

Reduced weight and ensured reliability
Durability—augmenting shape optimization using fatigue simulation results, with standard or in-house fatigue solvers.
Save weight and ensure highest result quality for reliable components.

Faster design decisions by quickly changing mesh geometry
Morph—extending shape optimization to enable fast and easy creation of design variants. Make geometry changes
directly applied to the existing finite element mesh and avoid intermediate CAD modifications.

EXAMPLES OF INDUSTRIAL USE OF TOSCA STRUCTURE
Wind turbine mainframe
Optimization with Tosca Structure.topology
For larger wind turbines stiffness and strength requirements are
more difficult to meet. The redesign of the mainframe should
result in an economic design with optimal vibration behavior.
Topology optimization of the mainframe led to a lightweight
structure which met static and dynamic criteria. Manufacturing
constraints were considered during the optimization to
generate a producible design, e.g. to avoid under-cuts. Mass
reduction approaching 40%, a feasible final design, and a faster
development process were achieved.

Courtesy of Suzlon GmbH

The integration of Tosca Structure into the product
development process resulted in a shorter time-to-market
for the mainframe, and a lightweight cast structure with
40% mass reduction.

Rear wheel carrier
Optimization with Tosca Structure.shape
For the weight optimization of the chassis component multiple
criteria such as strength, fatigue, plasticity and stiffness had to
be considered.
Violated stiffness demands required a modified design for the
rear wheel carrier considering damage requirements for multiple
loads and maximum allowed strain for breaking loads. With
Tosca Structure a shape optimization was performed directly on
the existing model without error-prone model simplification or
time consuming parameterization. After 20 automated analysis
steps a redesign was derived with better performance and even a
reduced mass compared to the initial design.

Courtesy of BMW Group

Damage was reduced by 60% from the initial value. At the
same time formerly violated stiffness constraints were met.

Automotive muffler
Optimization with Tosca Structure.bead
Noise issues motivate engineers to find the optimal dynamic
behavior of the muffler. Key quality factors such as structural
stiffness and vibration behavior should be met.
In order to reduce noise and improve structural stiffness, bead
patterns are formed in sheet metal structures. In an automatic
loop with Tosca Structure.bead the optimal bead layout was
achieved after only three finite element analyses. Manufacturing
requirements were directly applied to achieve a faster
turnaround from analysis to the production process.

Courtesy of Tenneco

After only three FE analyses, a bead layout was created using
Tosca Structure. The 1st and 2nd eigenfrequencies were
increased significantly—from 280 to 520 Hz, and from 340
to 570 Hz, respectively. A corresponding reduction of noise
was achieved.

Body-in-White
Optimization with Tosca Structure.sizing
A higher eco-efficiency is one of the main targets in the
automotive industry. To realize a significant weight reduction
of a body-in-white, the optimum balance between weight,
stiffness, and dynamic behavior is required.
Targeting weight reductions, Tosca Structure.sizing optimizes
sheet thicknesses clustered together in groups or individually, up
to element level. This way the best static and dynamic behavior
for a body-in-white can be found. Through consideration of
multiple complex load scenarios, stiffness, and manufacturing
requirements, Tosca Structure.sizing helps to meet performance
and production goals for an overall increase in eco-efficiency.

The optimal combination of weight, stiffness, and dynamic behavior
using Tosca Structure.sizing resulted in a weight reduction of
15%—from initial 329 kg to 280 kg. While high stiffness
requirements contribute to an increase in comfort, all other
performance goals are met within a reduced development time.

POWERFUL OPTIMIZATION AUTHORING INTERFACES
Tosca Structure, as an open optimization solution, offers a wide range of graphical user interfaces. Choose from a selection of
fully featured user interfaces to seamlessly fit into your individual CAE environment. Use an intuitive graphical user interface for
easy setup and execution of optimization tasks and workflows.
Optimization module in Abaqus/CAE
•	 Define optimization tasks interactively on 3D Abaqus Standard models
•	 Author, run and post-process directly in familiar Abaqus/CAE
environment
•	 Automatic consistency checks
•	 Integrated graphical user interface for optimization and FEA jobs

Tosca ANSA environment (TAe)

Tosca Extension for ANSYS Workbench

•	 Define optimization tasks interactively on predefined 3D
models supporting Abaqus, ANSYS, MSC Nastran

•	 Define topology optimization tasks interactively on 3D
ANSYS Workbench models

•	 Author (based on ANSA preprocessing technology), run
and post-process – no FE model modifications

•	 Author, run and post-process your optimization task within
familiar ANSYS Workbench environment

•	 Automatic consistency checks

•	 Automatic consistency checks

•	 Fully automated validation runs

•	 Semi-automatic validation runs

•	 Tosca Structure.view integrated to visualize results

ANSA

Tosca Structue.gui

•	 Define optimization tasks interactively on 3D models
supporting Abaqus, ANSYS, MSC Nastran

•	 Define optimization tasks using existing properties and
group definitions of FE models

•	 Author (as integrated part of ANSA), run and post-process—
additional to FE preprocessing

•	 Form-based optimization authoring

•	 Automatic consistency checks

•	 Easy and fast wizards for standard tasks

•	 Fully automated validation runs
•	 Tosca Structure.view integrated to visualize results

•	 Author and run optimization tasks
•	 Tosca Structure.view to visualize results
•	 Supports Abaqus, ANSYS, MSC Nastran FE models

KEY BENEFITS FOR OPTIMIZATION SOLUTIONS WITH TOSCA STRUCTURE
Tosca Structure features best-in-class optimization technology
for high quality simulation results. Take full advantage of your
optimization potential while leveraging advanced simulation
capabilities such as material and geometrical nonlinearity
(large deformation and contact).

Tosca Structure creates optimized design concepts with
significant potential for savings of material and weight.
Optimization in an early phase speeds up the product
development and hence results in a shorter time-to-market.
Gain and maintain a better competitive position in the
marketplace with innovative, state-of-the-art designs.

ECONOMIC ADVANTAGES

TECHNICAL HIGHLIGHTS

• Economic use of existing IT investments

• Seamless integration with leading FEA &
durability solvers

• Faster turnaround from analysis to design or manufacturing

• Direct use of existing knowledge and models

• More durable and lightweight designs

• Full design flexibility without time-consuming
parameterization

• Optimized products drive innovations in your market

• Fast and easy creation of design variants avoiding
intermediate CAD modifications using shape
morphing capabilities
• High fidelity optimization for nonlinear analysis and
durability
• Simultaneous optimization to meet static, dynamic,
and thermo-mechanical requirements
• Handling of complex manufacturing conditions
• Automatic validation analysis runs and direct
data transfer to CAD systems

INDUSTRIAL APPLICATION EXAMPLES OF SIMULIA TOSCA STRUCTURE
TRANSPORTATION & MOBILITY

MARINE & OFFSHORE

AEROSPACE & DEFENSE

Brake,
Wheel Carrier,
Wishbone,
Exhaust Muffler,
Turbocharger Housing

Drive-Shaft,
Crankshaft,
Crankcase

Engine and Gearing
Components

ENERGY, PROCESS & UTILITIES

LIFE SCIENCE

Drive-Shaft,
Hub,
Machine Slide,
Rotary Blades

Medical Devices,
Measuring Technique,
Hearing Aids

INDUSTRIAL EQUIPMENT
Telehandler Axle, Tractor Lever,
Machine Slide, Machine
Housing Cylinder Head,
Oil Pan, Turbocharger
Housing

CONSUMER GOODS &
CONSUMER PACKAGED GOODS

FIND MORE APPLICATIONS ON
OUR WEBSITE

Beverage Bottles,
Packaging,
Household Appliance

www.3ds.com/tosca

ENOVIA

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SIMULIA

Our 3DEXPERIENCE Platform powers our brand applications, serving 12 industries,
and provides a rich portfolio of industry solution experiences.
Dassault Systèmes, the 3DEXPERIENCE Company, provides business and people with virtual universes to imagine sustainable innovations.
Its world-leading solutions transform the way products are designed, produced, and supported. Dassault Systèmes’ collaborative solutions
foster social innovation, expanding possibilities for the virtual world to improve the real world. The group brings value to over 170,000
customers of all sizes in all industries in more than 140 countries. For more information, visit www.3ds.com.

Europe/Middle East/Africa
Dassault Systèmes
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CS 40501
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France

Asia-Pacific
Dassault Systèmes
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Tokyo 108-002
Japan

Americas
Dassault Systèmes
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Waltham, Massachusetts
02451-1223
USA

© Dassault Systèmes 2013, all rights reserved. CATIA, SolidWorks, ENOVIA, SIMULIA, DELMIA, 3DVIA, 3DSwYm, EXALEAD, and Netvibes are registered trademarks of Dassault Systèmes or its subsidiaries in the US and/or other countries.

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