Professional Documents
Culture Documents
Karen Silva
Treinamentos, WEBINARS e Parcerias Acadmicas
Training Objectives
Understand how to incorporate Inspire into traditional design processes to efficiently create
optimal designs
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Course Outline
1: Overview............................................................... 5 4: Analysis.. 48
Inspire Introduction FEA 101, Why Analysis?
Design Examples Analysis Tool Overview
Demonstration Loads and Supports
Exercise #1: Generating Your First Design Concept Load Cases
Overview of Parts/Material
2: Inspire Interface................................................... 19 Demonstration
Inspire GUI: Icons, Model Browser, Units, Navigation Exercise #4: Running A Simple Analysis
Measure, Configure, Translate/Rotate and View tools
Exercise #2: Rebuild Model 5: Simplify Tool and Optimizations..... 74
Simplify/Patch Tools
3: Sketching/Solid Edit 28
Overview of Sketching Tools, Push/Pull/Snap Overview of Optimization Functionality
DesignNon Design Space Shape Controls
Demonstration Demonstration
Exercise #3: Concept Design with Sketching and Solid
Edit Tools Exercise #5: Simplification Tools for Redesign
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Course Outline
6: Re-Analysis............................................................ 97
Analysis and Results Tools
Results Comparison Tool, Callouts
Demonstration
Exercise #6: Reanalysis
7: PolyNURBS.......................................................... 114
PolyNURBS Overview
Demonstration
Exercise #7: PolyNURBS
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Chapter 1: Overview
6
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Inspire Introduction
What is Inspire?
solidThinking Inspire enables design engineers, product designers, and architects to create and investigate structurally
efficient concepts quickly and easily. Traditional structural simulations allow engineers to check if a design will support the
required loads. Inspire enhances this process by generating a new material layout within a package space using the loads
as an input. The software is easy to learn and works with existing CAD tools to help design structural parts right the first
time, reducing costs, development time, material consumption, and product weight.
Why use Inspire?
Faster:
Produce efficient designs the first time
Eliminate several iterations of downstream redesign
Smarter:
Understand material, geometry and loading effects
Explore and study multiple design options
Lighter:
Efficient material distribution reduces weight
Material removal = reduced part costs
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Why Inspire?
Original Design *
Why Inspire?
Navigation Mouse
Left button Middle button Scroll wheel Right button
Goal:
In this exercise, you will learn how to import existing geometry and generate your first design
concept. Original Design
Inspire Results Final Design
20% mass
savings!
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1. Start Inspire.
2. Click the Open icon.
3. Browse and select C:\..\Exercise_1.stmod.
3
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1. Use the Topology Slider in the Shape Explorer window to explore the results.
Note: If the Shape Explorer window is not visible, double-click on the
optimized region of the part and the Shape Explorer window will reopen.
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1. Reposition the Topology Slider to the center mark. 4. You may also import the results by clicking
View Now in the Run Status window.
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Model Handling
Note: Objects can also be shown or hidden by clicking the icon next to them in the Model Browser.
Additional Show/Hide options are available in the View menu or by using keyboard shortcuts:
Press the H key to hide selected objects.
Press the I key to isolate selected objects.
Press the A key to toggle between showing and hiding all objects.
Press the R key to reverse the visibility of all parts in the model.
Objects that are hidden do not appear in the modeling window, but are still included in all calculations such as analysis,
optimizations, static weight calculations, mass computations, etc.
To exclude an object from these calculations, you must deactivate it with the Configure tool.
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Rotate to Closest Principal Axis Rotates the camera view normal to the closest global axis.
Clicking on the red, green, or blue (X,Y, or Z) axes automatically rotates the camera view
normal to the selected axis.
Clicking the circular enclosure rotates the model clockwise or counterclockwise in the
plane depending on which side of the circle you select.
Clicking the outer arrowheads rotates the model in the selected direction about the origin.
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Measure
3 1. Measure Length Measures the distance between any two points. A point is placed when
you left-click any location on the model.
4 2. Measure Box When active, creates a box that fully captures the selected parts volume with
2 dimensions.
1
3. Measure Angle Measures the angle between any three placed points on a part.
4. Measure Weight Measures the weight of any selected part(s). When active, several options
are available such as showing the CG or showing a bounding box about the assembly.
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Move
Move You can select objects either before or after you activate the Move tool, and then translate them by
clicking-and-dragging either the object or the tool itself. The table below shows which objects can be moved
directly with the Move tool.
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1. Start Inspire
2. Using the File Open icon, open the Exercise_2.stmod and practice rotating, zooming, panning, fitting,
hiding, and showing.
3. Rebuild the model using translation and snaps.
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1. Sketching Geometry
2. Push/Pull
3. Revolve
4. Mirror
5. Scale
6. Boolean operations
7. Design space
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Sketching Geometry
1
1. Create Point 1 1. Create Rectangle by Corners
3 2 2. Create Line 2. Create Rectangle by Center and Corner
2
3. Create Polyline 3 3. Create Rectangle by 3 Points
Sketching Geometry
1. New Part Allows you to create a new part before you start sketching. Any
existing sketch curves will be imprinted onto the current part before the new
one is created. Note: While sketching, you can
apply geometric relationships
2. Transfer Sketch Allows you to retroactively move your current sketch to a such as tangency and
new part. perpendicularity to lines, arcs,
3. Convert Lines Allows you to create sketch curves from reference and circles using sketch
geometry. constraints. As you sketch,
Inspire automatically applies
4. New Plane Allows you to create a new sketch plane by selecting a new many sketch constraints for
face. you. This behavior can be
disabled using the Preferences
5. Move Plane Allows you to move the sketch plane by opening window, which can be used to
the Move tool. modify the default angle
6. Options Allows you to modify your grid and snap settings. measurements for certain
constraints.
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Push/Pull
When Active, the Push/Pull tool can be used to modify faces, curves or radii.
To use the tool, click-and-drag a selected face/curve/radius in the direction
of the desired location. Or you can manually input displacement values.
Note: The push/pull tool can be activated by manually clicking the
Push/Pull Radius Push/Pull Face icon or by double-clicking on any feature in your model.
Note: To disable snaps while in push/pull mode, hold the alt key
during the operation.
Note: Use CTRL or Shift when dragging the face to create a new part.
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Revolve
The Revolve tool to revolve a planar face around an edge, a line, or a cylindrical hole using an axis of
revolution.
Note: Use CTRL or Shift when dragging the revolve to create a new part.
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Mirror
The Mirror tool reflects selected parts across a symmetry plane. You may keep or replace the original part, and can link the
mirrored part to the original as an instance.
Note: If you want to merge two mirrored faces that are coincident, box select them and then apply the
PolyNURBS Bridge tool.
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Scale
The Scale tool is used to resize selected parts. This tool is useful when working with an imported model that is associated
with a different default unit system. It allows you to select the objects to be scaled, position the scaling center, and define the
scaling factor.
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Boolean Operations
1 2 3
1. Combine creates the union of two objects or sets of objects by merging them with
one another, retaining all of the material in both
2. Subtract uses one object or set of objects as a tool to carve out a portion of
another object or set of objects
3. Intersect takes two objects or sets of objects and retains only those portions that
are common to both
Note: Intersect is often used to separate design and non design space regions.
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Boolean/Cut - additional
Combine - When combine is active, left-clicking any combination of parts in the assembly will combine
the selection.
Subtract - When subtract is active, the targets are defined as the objects you are wishing to modify. The
tools are defined as the modifiers to these targets. You have the option of keeping the tools in performing
this operation by selecting the Keep tools checkbox.
Intersect - Once in intersect mode, left-click one part or multiple parts as your targets, or the part(s) you
are wishing to modify. Next left-click the Tools button and select another intersecting part(s) as your tools,
or modifier(s). You have the option to keep either or both of the targets or tools when performing this
operation. With all Solid Edit tools, a preview of the operation will be shown; to proceed click the forward
arrow.
Cut - When in cut mode, the targets are defined as the parts you are performing the cut on. The plane, or
cutting plane, can be defined by selecting a face or feature based on existing geometry and
translating/rotating accordingly with the move tools in the sub-icon.
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Non Design Space The region within the model in which material
will not be removed. This area is still included in the simulation, but not Note: In order to get an optimal solution,
modified. always try to give your model the absolute
maximum amount of design space possible.
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Goal: In this exercise, you will learn how to generate a basic design concept using the Solid
Edit tools to break up and simplify a model.
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Exercise 3: Concept Design with Sketching and Solid Edit Tools Step 1 of 7
1. Click File>Open> C:\..\Exercise_3.stmod. 4. Right-click any contour highlighted in red and select
2. Double-click on the side face of the bracket to enter Create Curves from All Reference Lines.
push/pull mode. Double-click again on the same face to
enter sketch mode on the selected surface.
4
Note: To exit any activated mode and return to the
default browser, press the Esc key.
2 3
Exercise 3: Concept Design with Sketching and Solid Edit Tools Step 2 of 7
1. Delete the curves as shown below by selecting the 2. Right-click once to exit Sketch mode and enter
curves individually or holding the left mouse button down Push/Pull mode.
and selecting multiple curves to delete with a box 3. Hold Left-click and drag the face seen below to the
selection. Once you select a curve, pressing Delete on opposite edge of the model. When the mouse hovers
the keyboard removes the selected curve.
over existing features in the model, the snap function
activates. The snap feature in Inspire will
automatically place the extruded geometry coincident
with the opposite existing edge labeled End in this
case.
Note: To ensure you are push/pulling the newly
1 created shape and not the existing geometry, it is
crucial you drag the face indicated below with the red
arrow in step 3.
Exercise 3: Concept Design with Sketching and Solid Edit Tools Step 3 of 7
4. Draw rectangle on surface.
1. Delete Existing Design folder from Model Browser. Tip: Use Rectangle by Center and Corner, placing the center
2. Double-Click on Hole Imprint and Push to remove material. at the midpoint of the vertical line shown below.
3. Orient your model as shown and create a sketch on the 4. Exit sketch mode and enter Push/Pull mode. Pull
indicated plane. Double-Click on a surface to enter each end of the rectangle you just created to exceed
Push/Pull and double-click again to enter in Sketch mode, the original geometry.
Create a new part. Note: You must
push/pull each
side of the
rectangle
separately to
achieve this
shape.
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Exercise 3: Concept Design with Sketching and Solid Edit Tools Step 4 of 7
2 3 4
1. The Targets tab is active by default. Select the larger part
labeled Design Space as the Target.
2. Select the Tools tab. Select the newly created intersecting
box part as your Tools. A preview of this operation should
be shown.
3. Select the Subtract tab. Right-click to exit out of Boolean.
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Exercise 3: Concept Design with Sketching and Solid Edit Tools Step 5 of 7
1. Select the Circle by Center and Point icon. Create a circle 3. Select the Boolean icon and select Intersect.
centered on the existing hole whose edge is coincident with
the existing geometry radius by using the snap feature. 4. Select your Targets as larger geometry.
5. Select your Tools as new cylinder.
1 6. Check the Keep Targets box.
7. Select the Intersect icon to perform the operation.
8. Right click to exit out of Boolean.
4 5 6
Exercise 3: Concept Design with Sketching and Solid Edit Tools Step 6 of 7
Note: Forces can be
1. Right-Click on the modified part to designate it as a rotated by either
Design Space. manually dragging
them along the
indicated rotate plane
or parametrically by
selecting the rotate
plane and entering a
value.
2. Click the Structure page. 5. Select the Draw Direction icon in the Shape
3. Select the Apply Forces icon in the Loads/Supports Controls group on the toolbar and select Extrusion.
group on the toolbar.
4. Create a -Z direction 14,500 N force inside BOTH of the 6. Select the design space. Select the Y-Z Plane as the
0.025 m holes. plane in which the extrusion manufacturing constraint
5. Using the Translate/Rotate tool in the Forces mini- will be applied identical to exercise 2.
toolbar, Rotate EACH force +45 degrees in the Y-Z plane.
Note: For steps 3 and 4, ensure you orient the force
5 FIRST in the -Z direction and SECOND in the +45
4
degree orientation in the Y-Z plane.
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Exercise 3: Concept Design with Sketching and Solid Edit Tools Step 7 of 7
1. Select the Run Optimization icon. 4. Use the Topology Slider in the Shape Explorer
window to explore the results.
2. Enter 0.030 m for the Minimum Thickness.
3. Click Run. 1
3
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Chapter 4: Analysis
49
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Introduction to Analysis
Analyze
The Analyze button is used to access the Finite Element Analysis (FEA) capabilities of Inspire. The primary applications are
to:
evaluate performance of existing designs to help in target setting.
evaluate new concepts developed from the Inspire results.
FEA is a numerical method that allows the designer to calculate the responses of a structure to combinations of applied loads
and supports. With this information the designer can determine if the proposed design meets the design requirements.
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Materials
Defined by using the Parts and Materials browser, the Property Editor, or by
right-clicking on a part. Note: In addition to materials, you may also apply
concentrated masses to your assembly for Analysis
Loads
Forces, torques and pressures
Supports
Fixed, sliding and pinned connections
Load Cases
Combinations of loads and supports to represent specific operating conditions
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Introduction to Analysis
1 1. Run Analysis Launches the run submission dialog where details of the run can
be defined.
4. Buckling Modes A Buckling mode analysis is used to predict when a part will
6 bend or collapse under load.
7
5. Speed/Accuracy Faster helps when testing a model to ensure that loads and
8 supports are correct. Once the results are good, More accurate is used to rerun
the analysis to achieve more precise stress and displacement results.
1
9
0
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Introduction to Analysis
1 6. Contacts - The Contacts option allows the behavior of parts that are contacting
to change.
2 7. Gravity Gravity can be added in a given direction for all load cases.
3 8. Load Cases If multiple load cases exist, active load cases for a run can be
4 selected.
5 9. Restore Recalls existing values from previous analysis runs.
7
8
1
9
0
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Introduction to Analysis
2
1. Show Analysis Results Used to show previously loaded analysis results.
1 3
2. Run History Contains a history of analysis and optimization results which
you can recall at any time.
3. Run Status - When Inspire is calculating the results, the run status dialog
will appear.
On completion, a green checkmark will show as will a green flag on the analysis
icon.
Factor of Safety Shows which areas of a model are in danger of yielding due to stress. A
factor of safety of 1.0 or lower means your part may fail. By default, areas that are approaching
a minimum safety factor of 1.0 are shown in red and indicate where the part is most likely to
fail.
Percent of Yield Shows which areas of a model are in danger of yielding due to stress. It is essentially the inverse of factor of safety and
is expressed as a percentage. A percent of yield of 100% means your part may fail. By default, areas that are approaching a percent of
yield of 100% are shown in red and indicate where the part is most likely to fail.
Tension and Compression shows which areas of the model are in tension and which are in compression. These results are derived
from the von Mises stress results.
Maximum Shear Stress One of three failure criteria Inspire displays, this predicts failure in shear.
von Mises Stress One of three failure criteria Inspire displays. The von Mises failure criterion is typically used to assess the structural
performance of ductile materials. A material is said to start yielding which in many instances is considered failure - when the von Mises
stress reaches the yield stress.
Major Principal Stress - One of three failure criteria Inspire displays. The major principal stress criterion is often used to predict the failure
of brittle materials.
Note: The appendix shows the explanation of these concepts in detail.
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Comparison Tool
Compare the results of multiple analysis or optimization runs. The Compare Results button is located at the bottom of
the Analysis Explorer.
For analysis:
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.
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1. a cylindrical hole
1 2. a face
3. an edge
4. a point
Mini-toolbar options:
Loads/Supports - Supports
1. Apply Supports Used to hold a part so it doesn't displace when loads are applied to it. A support can be applied
at a single point on the model, to an edge, a face, or at the center of a hole. You can apply any number of supports
to a model.
1 Note: Supports can also be applied at a distance. This will be discussed in advanced topics.
Loads/Supports - Supports
1. Apply Supports You can edit individual supports to allow translation in one or more directions.
Free in 1 direction
Free in 2 directions
Free in 3 directions
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Loads/Supports - Loads
3 4
2. Apply Pressures Applies a distributed force that acts perpendicular to every point along the face. Pressures typically
arise from gases or liquids pressing on a face, and can act in either the inward or outward direction on a solid.
3. Apply Torques Applies a torque, or a twisting force. Torques can be applied either to a face or to the center of a hole,
in which case it acts on the interior face of the hole.
Note: Torques and Forces can also be applied at a distance. This will be discussed in advanced topics.
4. Apply Forces Applies a force, push, or a pull in a particular direction on the model. Forces can be concentrated at a
single point or distributed evenly across an edge or a face. A force can also be applied at the center of a hole, in which
case it is applied as a distributed force on the hole's inner face.
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Load Cases
Load Case a set of loads and displacements that act on a model at one time. A model can experience different load cases
at different times; for example, consider a building that is subjected to gusts of wind. At one moment the wind pressure on the
side of a building may come from the east, and the next moment it may change and come from the west. If you want to create
a building that will resist wind blowing from either east or west, you would create two different load cases: the first containing a
pressure from the east direction, and the second with a pressure from the west direction. This allows you to generate one
shape that is optimized to handle any number of different load cases.
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Load Cases
Fasteners
Fasteners are used to connect parts together using bolts and screws.
Inspire will automatically find the holes within a default size range calculated based on the geometry.
Joints
Joints are used to connect parts together using pins or sliding pins.
Inspire will automatically find the holes within a default size range calculated based on the geometry.
Contacts
The Contacts tool finds neighboring parts and designates whether they should be bonded, contacting, or have no contact.
The Contacts Tool shows the areas in contact. Bonded contacts are in red, areas
where parts are contacting are shown in green. The contacts can be automatically
assigned or selected in the guide bar.
An Auto Search Distance can be entered when finding contacts. This is the distance at which parts will be considered in
contact, which by default is set automatically. Deselect Auto Search Distance and enter a value in the text field to change the
search tolerance.
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3. Apply an 2435N Force on each upper pivot boss, and rotate -45 degrees off the positive Y-Axis.
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1. Select the Fasteners icon. On the guide bar, left click the drop-down menu
which says Aligned Holes and select Single Holes. Left click the two holes
at the bottom of the fork to add a nut and bolt fastener to each.
2. Select the Joints icon. Left click on the two holes of the rocker which have no
forces acting on them to add pin connections.
3. Select the Contacts icon. Left click on the red surfaces near the pins where
the rocker meets the seat tube and the fork. Select Contacting to redefine
the contact types.
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1. Select the Supports icon. Apply supports to the two nut and bolt connections on the fork. Apply another support to the
one cylindrical hole through the seat tube. Apply one final support to the surface at the end of the seat tube.
Tip: Right-Click each individual Force/Support in the model browser to Include/Exclude it from particular Load Case.
The supports should go in both load cases and the 45 degree loads should go in Load Case 2.
4. Assign Titanium (Ti-17) to the two pins, and Aluminum (7075) to all other parts.
Tip: Right-click on each part to assign materials
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3
Note: Its a best practice to run a pre-run
checklist:
Materials assigned
Model correctly supported
Realistic loadings
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Simplify
Imprints Used to find and remove imprints such as scratches and trimmed points. When active, the number of
imprints found in your assembly is displayed above the icon. You can use the arrow keys to scroll through the imprints
found in detail. To reset the search, press the back icon. To remove all found imprints, press the remove icon.
Rounds Finds and removes any rounds (concave) or fillets (convex) in your assembly. While the arrow, reset, find
and remove icons are similar to the other Simplify/Patch icons, Simplify has a Find Options menu (left icon) where you
can find all that are larger, smaller, or similar (+ or - 5%) in size. You can also filter your results to find rounds only,
fillets only, or all.
Note: It is recommended to remove small fillets first,
then larger fillets, then rounds.
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Simplify
Holes Used to find and remove holes and pockets. It will also find raised areas, such as lettering. The
operations are similar to the Rounds tool in that you can find smaller, larger or similar holes with the Find
Options menu.
Plug Finds holes and pockets in your assembly and plugs them by filling the area with a new part. The Plug
feature operates identically to the Holes feature except the Plug tool creates a new part to fill the hole or
pocket, while the Holes tool absorbs it into the surrounding part.
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Patch
Patch Used to fill in missing surfaces in order to create a solid. It also allows you to remove and remake bad
or problematic surfaces. Click on a selected red edge to attempt a patch. If the patch is successful, the new
patched surface is shown in red.
Shape Controls
2
1. 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
1 can be applied to a design space, and four types of draw directions are available: single draw,
split draw, stamping, and extrusion.
2. Symmetry You can generate symmetric shapes, even under asymmetric conditions, by defining
symmetry planes in the design space. You don't always get a perfectly symmetric shape, but you
do get a result that is very nearly symmetric.
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Single Draw Used when the parting plane between the halves of the mold lies outside the design space.
Only one half of the mold is pulled away from the design space in the direction of the arrows leaving a
shape without any negative draft angles in the specified direction.
Split Draw Used when the parting plane between the halves of the mold lies inside the design space.
Both halves of the mold are pulled away from the design space in two different directions. When defining a
split draw direction on a design space, the optimizer determines the best location of the parting plane
along the draw direction.
Extrusion - Similar to a single draw, but the profile of the resulting shape maintains a constant cross-
section along the draw direction. The No Hole option is not available with extrusion. You cannot use the
Extrusion draw direction with any symmetry constraint.
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Symmetric You can apply up to three symmetry planes to a design space. The planes are
always orthogonal to one another, and can be rotated as a group in any orientation relative to the
design space.
Note: Symmetry planes are valid for optimization but not analysis.
Cyclic Cyclic repetition with asymmetric sectors. The red shaded area is a single sector.
Cyclic Symmetric Cyclic repetition with symmetry creates self-symmetric sectors that are
symmetric about the red radial planes. The red shaded area is a single sector
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Displacement Constraints
Apply Displacement Constraints When active, can be applied to a model to limit deflections in desired
locations and directions. These constraints should only be applied to non-design spaces, and while they can
be used as the sole constraint for an optimization, we recommend using them alongside a stress constraint.
You can choose to limit displacement in one direction or in all directions, as shown in the images below. A
displacement constraint in one direction can have an upper bound, a lower bound, or both.
Enforced Displacement
Apply Enforced Displacements- Applied when you don't know the magnitude of a force applied to a part,
but you do know how much the part displaces as a result of that force
Enforced displacements essentially act as a force, and can be applied to a point, edge, or face. When applied
to a hole, they are applied to the hole center rather than the face. They are represented as blue arrows and
can be included in one or more load cases.
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Optimize
1. Name of Run Enables the user to uniquely name each optimization run.
1
2. Optimization Objective Can be toggled to either Maximize Stiffness or Minimize
2 Mass. Maximize Stiffness produces a result that will resist deflection, essentially giving
you load paths for a particular analysis. On the other hand, Minimize Mass produces
3 the lightest resulting shape.
3. 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
4
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.
5 4. Frequency Constraints Allows the user to control the frequency at which an
optimized part vibrates. You may choose to either maximize frequencies or set a
6 specific minimum frequency.
7
8 5. Thickness Constraints You can control wall thicknesses and the diameters of
9 beam-like members in a shape by specifying a minimum and/or maximum thickness.
1
The default maximum thickness is 2 times the value entered for minimum thickness.
0 11 This value directly correlates to run times.
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Optimize
Use the Topology slider on the Shape Explorer to analyze the quality of your results. If the topology of your shape
doesnt change much when you move the slider, this means youve 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:
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.
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Solution: Since regions are shown that have structure beginning All structures are complete while the topology slider is
to form while the topology slide is near the middle, Inspire needs near the middle. When moving the topology slider to the
more design space to work with to complete the particular load right only thickens the created structures, you know you
path. Increasing the Mass Target by 5-10% should resolve have arrived at a good solution.
this issue.
Minimize Mass
Good Design With Minimize Mass, a good design is one in which all
structures are connected, regardless of what position the
topology slider is in.
Note: 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.
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Comparison Tool
Compare the results of multiple analysis or optimization runs. The Compare Results button is located at the bottom of
the Shape Explorer.
For optimization:
Compare across runs only
The width of the color bands indicate the magnitude of the result
Additional columns can be added to show any of the parameters from the Run Optimization window
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2
1
4
5 6
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3. Double click the X-Y plane used for the Extrusion and
select Split Draw.
7
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Chapter 6: Re-Analysis
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Fit/Analyze
Once a concept has been generated, the user has the ability to do the following with the results:
Export results as an STL Saving your result as an STL gives the user a raw, unsmoothed result file that can then be
viewed in typical CAD software. To save the result as an STL, simply click File>Save As> and select the STL file type
Fit Surfaces Over the Optimized Shape Fits a smooth surface over the generated shape. The resulting surface model can
then be exported to most CAD systems. To perform this operation, the user can either select the Fit icon in the shape
explorer or right click the optimized shape and select Fit Surfaces to Optimized Shapes.
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.
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Displacement results are created for both linear static and normal mode analyses. It is
important to check displacements for general analysis and also when understanding baseline
design pre concept generation with Inspire.
For static analysis it is important to check the following for each load case being considered:
Correct Order of Magnitude: Are the displacements of the correct size? If a component
100 mm long has a displacement of 1000 mm this will indicate incorrect load magnitudes or
inappropriate supports. It can also indicate incorrect material properties.
Shape of Deformation: By animating the model for each load it is possible to ensure the
structure is deflecting in a logical way. Unusual behaviour is usually found to be the result
of incorrectly applied loads and/or supports.
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The Factor of Safety is calculated by looking at the stress in each part and comparing it with the
yield stress (as defined in the material properties) for that part.
Factor of safety = yield stress / calculated stress
F.S. < 1.0 (or near 1.0) will show as RED indicating likely regions of failure.
The larger the F.S. the less likely a part is to fail.
An accurate F.S. depends on accurate loadings and accurate material and analysis models.
There is no definitive factor of safety that is suitable for all applications.
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Tension and Compression shows the user which areas of the model are in tension, and which areas
are in compression. These results are derived from the von Mises Stress results.
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The von Mises failure criterion is typically used to assess the structural performance of ductile
materials.
A material is said to start yielding which in many instances is considered failure when the von
Mises stress reaches the yield stress.
The equation can be represented in the 2D case by the ellipse shown below.
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The Major Principal Stress also known as the normal stress, Coulomb, or Rankine criterion is
often used to predict the failure of brittle materials.
The Major Principal Stress states that failure occurs when the maximum (normal) principal stress
reaches either the uniaxial tension strength st, or the uniaxial compression strength sc,
Compared with the von Mises criterion, the Major Principal Stress criterion can be seen as a non
conservative approach if applied to ductile materials.
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For modal analysis it is important to check the if the natural frequencies are reasonable. The natural
frequencies for each normal mode is displayed under result type.
For a free vibration analysis (no supports) all parts of the model will be in motion and coherent no
parts will move independently of other parts.
If supports are used then those areas should move as per their constraints (fixed, slide, etc.)
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Callouts
Callouts show analysis results at a point of interest on the model. Callouts are created using the icon in the Analysis Explorer.
Callout Tools:
Create, Show, and Hide Callouts - Click the icon, then select a point of interest on your model to create a callout.
Click the icon again to toggle callouts off and on.
List Callouts - Click the icon to display a table showing all of the callouts that have been created, with values for
several result types. Each callout is specific to the selected run and load case.
Min/Max Callouts - Click the icon to automatically create a callout showing where the maximum value occurs for the
selected result type. When factor of safety is selected, the minimum is shown.
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Chapter 7: PolyNURBS
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Introduction to PolyNURBS
PolyNURBS allow you to quickly create free-form solid geometry that is smooth and continuous.
Clicking the PolyNURBS icon opens a secondary ribbon with several tools:
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Why PolyNURBS?
PolyNURBS is a new modeling method that allows you to trace over optimized results with precision, ease, and efficiency
STL geometry is represented as triangulated polymeshes, which are great for concept design and 3D printing, but not directly
compatible with subsequent CAD tools or manufacturing. NURBS are preferred in these use cases because they more
accurately and efficiently represent curved geometry.
This new modeling method allows you to easily trace over optimized results to create a smoother, watertight NURBS version
of the STL geometry. The resulting model can be exported to other CAD systems and is readily usable for manufacturing.
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PolyNURBS Tools
Add/Edit PolyNURBS - The main PolyNURBS tool and can be accessed from the Geometry tab on the ribbon. It allows you
to edit the shape of a PolyNURBS object either directly or by using graphical manipulators.
Create - Create a single PolyNURBS cage, either around a selected object or as the starting point for a new
model. This is the tool you should start with if you want to build PolyNURBS geometry without wrapping.
Wrap - Quickly generates PolyNURBS geometry by clicking along your existing shape. You can
create multiple cages, and bridge the face of one cage to another.
+/- - Adds a block to the face of an existing PolyNURBS cage. You can also hold down the Shift key
to remove blocks. This allows you to quickly build the basic shape of a PolyNURBS object.
Loop - Draws an edge loop around a cage, subdividing the PolyNURBS object. Creating subdivisions
gives you more control when editing the cage.
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PolyNURBS Tools
Bridge - Creates a bridge or a tunnel between two faces. The faces can belong to either the same cage or different cages.
Bridge - Use the Bridge tool to create a bridge or a tunnel between two faces. The faces can belong
to either the same cage or different cages.
Demonstration
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Goal: In this exercise, you will learn how to use PolyNURBS to create geometry for export
from optimized part geometry.
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1. Open Exercise_7_start.stmod. The model contains a The optimized geometry should appear as below.
design space with a constrained end and a 1,000N force
on the opposite end.
2. Run the optimization to Maximize Stiffness for a 30%
Mass target.
3. When finished activate the Shape Explorer and move the
slider as shown in the image.
1. Activate the PolyNURBS tool. 4. Click approximately in the area shown below to set
the end face.
2. In the secondary menu activate the Wrap tool.
1. Click on the part as shown in the image to set the first end of
the PolyNURB entity.
Note: The goal is to create as many faces as 6. Repeat the process to create the wraps as
needed to approximately follow the geometry necessary. The resulting geometry is shown in the
from the optimization. next page.
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1. In the secondary menu activate the Bridge tool. The results appear as shown below
1. Create a bridge on the top of the model as shown: 4. Activate the Bridge tool.
1. With no tool selected in the secondary toolbar, click the top 3. Use the same process to change the lower end.
face near the non-design space.
4. Use the drag process to drag the faces and the edges
to reshape the opposite end as shown.
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