Shelled Generative CAD for Lightweight Crash Simulation Meshes
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Solution Overview
Problem
Current generative design methods for crash simulations result in heavy, stiff solid state designs that are computationally expensive and unwieldy, lacking an efficient mechanism for producing better-performing lightweight designs suitable for both additive manufacturing and CAE crash simulations.
Innovation Solution
A lightweight shelled generative design with an internal support structure is developed, allowing for efficient simulation and validation, utilizing a workflow that creates a representative CAD part and associative CAE crash simulation model, reducing simulation run time and mass while avoiding re-coater interference and powder trapping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a solid state generative design is used for crash simulations, then structural strength and stiffness are improved, but weight increases and computational cost becomes excessive
Solution Approach 1:
The patent applies shell-based generative design instead of solid state design, creating lightweight shell structures with optimized thickness distributions that maintain structural strength while dramatically reducing weight. The shell design allows for thin-walled structures that preserve crashworthiness without the excessive mass of solid components.
Solution Approach 2:
The patent changes the fundamental design parameter from solid volume to shell thickness, enabling weight reduction while maintaining structural integrity. By optimizing shell thickness distributions and using shell elements in simulations, the design achieves better weight-strength trade-offs compared to solid state designs.
2Reliability
If a solid state generative design is used for crash simulations, then structural integrity is improved, but simulation run time and computational resources increase significantly
Solution Approach 1:
Shell elements have fewer degrees of freedom compared to solid elements, resulting in smaller system matrices and faster solution times. The patent leverages this computational advantage by designing with shells, achieving both structural integrity and reduced simulation run time of up to 70% compared to solid state designs.
Solution Approach 2:
By changing from solid to shell formulation, the patent reduces the complexity of the simulation model while maintaining reliability. Shell elements require less computational resources and shorter solution times while preserving the essential structural behavior needed for crash simulation accuracy.
3Weight of moving object
If a shelled generative design with internal support structure is used, then weight is reduced and processing time decreases, but manufacturing complexity may increase
Solution Approach 1:
The patent applies local quality by varying shell thickness throughout the structure, concentrating material where needed for strength and using thinner sections where less support is required. This localized material distribution optimizes both weight and manufacturability, creating designs that are lightweight yet efficient to produce via additive manufacturing.
Solution Approach 2:
The patent incorporates internal support structures within the shelled design, creating nested geometries that provide structural reinforcement while maintaining overall lightweight characteristics. These internal features are integrated into the shell structure, optimizing both performance and manufacturability through additive manufacturing processes.
Data Source
AI summary
A method and system provide the ability to generate models. A generative shelled base is created as a hollow computer-aided design (CAD) design. A t-spline mid-surface shell is created from the generative shelled base, which is then used to create a shell mesh model. A t-spline solid body is created from the generative shelled base, which is used to create an internal support structure that is converted into a shell CAD geometry, which is used to create a support structure mid-surface shell. The support structure mid-surface shell is combined with the shell mesh model into a generative mid-surface mesh that is used in a computer-aided engineering (CAE) crash simulation. The generated shelled base is combined with the shell CAD geometry into a generative shelled solid that is utilized in an additive build simulation.