Shape Design Sensitivity Analysis and What-if Tool for 3-D Design Applications

Shape design parameters that govern the geometric shape of a structural component are the most effective way to improve design of 3-D elastic solid components. Four major characteristics, however, that are unique to the shape design problem make it more complicated than the traditional sizing problem; (1) it is difficult to retain the accuracy of finite element analysis results for a design model whose geometry changes during the design process, (2) it is difficult to handle the sophisticated shape design parameterization and update geometric shape, (3) efficient computation of shape design sensitivity information for a large scale problem is difficult to achieve, and (4) visualization of important design sensitivity information and automation of shape design processes to provide an effective design environment is not available.To support Concurrent Engineering activities, design parameters defined in the CAD model are the most important common data shared by various engineering disciplines. Design sensitivity analysis that computes structural responses with respect to design parameters defined in the CAD model is a critical step to support Concurrent Engineering activities.This paper presents a methodology to support structural shape design for 3-D elastic solid components, using the geometric modeler PATRAN [1]. The proposed methodology overcomes four major difficulties of shape design; accuracy, integration, efficiency, and effectiveness. A clevis and a turbine blade examples are given to demonstrate capabilities of the design tool.