Mesh Morphing for CAD Shape Optimization
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Solution Overview
Problem
Shape optimization in computer-aided engineering (CAE) systems using mesh parameterization is time-consuming and often fails to meet design constraints, as it requires significant effort and cost to reconstruct CAD models, and may result in geometric inconsistencies between the mesh and the CAD model.
Innovation Solution
A system and method that integrates CAD-based design, mesh morphing/generation, and finite element analysis (FEA) to generate a morphed mesh by displacing boundary nodes and interpolating interior node displacements, ensuring the updated mesh meets specified model characteristics and constraints, thereby optimizing the CAD model without reconstructing it.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If mesh parameterization is used for shape optimization, then the finite element analysis can be performed, but significant time and effort are required to reconstruct the CAD model
Solution Approach 1:
The patent uses the existing CAD model as a template and creates a morphed mesh by displacing nodes rather than reconstructing the entire CAD model. The morphed mesh serves as a copy that captures the optimized shape while preserving the original CAD model's parametric structure, eliminating the need for time-consuming reconstruction
Solution Approach 2:
The patent segments the shape optimization process into two independent parts: (1) morphing the finite element mesh by displacing nodes to achieve optimized geometry, and (2) updating the CAD model parameters separately. This segmentation allows the mesh to be optimized without requiring full CAD reconstruction, significantly reducing time and effort
2Manufacturing precision
If mesh parameterization is used for shape optimization, then the optimization can be performed, but geometric inconsistencies may occur between the mesh and the CAD model
Solution Approach 1:
The patent implements a feedback mechanism where the morphed mesh geometry is used to update the CAD model parameters, ensuring that the CAD model remains consistent with the optimized mesh. The system continuously checks and adjusts the parametric representation to maintain geometric consistency between the CAD model and the finite element mesh throughout the optimization process
Solution Approach 2:
The patent changes the parameters of the existing CAD model to reflect the optimized shape from the morphed mesh, rather than creating a new CAD model. By adjusting the parametric variables of the original CAD model to match the morphed mesh geometry, the system maintains geometric consistency while achieving shape optimization
3Shape
If the CAD model is reconstructed from the optimized mesh, then the optimized shape is obtained, but the process is costly and time-consuming
Solution Approach 1:
The patent performs preliminary action by maintaining the CAD model's parametric structure and updating it with optimized parameters before finalizing the design. By preparing the CAD model in advance with the ability to accept updated parameters from the morphed mesh, the system avoids costly and time-consuming reconstruction processes while still achieving the optimized shape
Data Source
AI summary
A system and method for shape optimization that includes receiving information regarding a model that represents one or more physical objects to be manufactured, the information comprises a finite element mesh, geometric parameters, geometric constraints, and manufacturing constraints of the model and generating a morphed mesh that results in an updated finite element mesh in order to meet specified model characteristics. The method further includes generating the morphed mesh by displacing nodes located at the boundary regions of the model and determining a displacement of interior nodes of the finite element mesh using an interpolation of boundary node displacement.