An Integrated Approach for Shape Optimization with Mesh-Morphing

Although the CAD parameters allow to update easily the geometrical model, the numerical models updating into Finite Elements (FE) software with different mesh result to be often heavy, due to the necessity both to create new mesh and to make usually time consuming and complex CAE calculations for updating the loading conditions. The aim of the present research is to devise a reliable methodology and at the same time to reduce computational burden in the shape optimization studies of mechanical components. In particular, an integrated Multibody (MB) and Mesh-Morphing (MM) approach was developed to perform shape optimization, in order to reduce maximum tensions. Using the RBF Morph ACT Extension plugin implemented in the commercial solver FEM ANSYS® Mechanical vers. 18.2 along with the commercial MB software MSC ADAMS® vers. 2017, shape optimizations can be obtained in a very short time, by acting directly at the mesh so updating node positions and mesh elements geometry without bringing different geometrical models of the component into the FE environment. To validate the methodology, a crankshaft for a high performance Internal Combustion Engine (I.C.E.) was chosen, as case study, to optimize the fillet zones between web and pin.