ANSYS TUTORIAL – Optimal Design of a Stiffened Beam

ANSYS Release 7.0

Dr. A.-V. Phan, University of South Alabama

1 Problem Description
Use ANSYS to perform the minimum weight design of a stiffened beam as shown. Structural steel of
circular and rectangular cross-sections will be selected for the bar and beam members, respectively.
The allowable stress in the elements is assumed to be 0.5 Sy . The tip displacement is constrained
to be no greater than 10−4 L. Let the yield strength and length of the beam be Sy = 250 MPa and
L = 3 m, respectively.

3
Y

Y






45 o









2 Z 





1 X 





 H
1 


L
W
500 kN
(a) (b)

Figure 1: A stiffened beam

2 Data Preparation
• Units to be used: Length (m), Force (N)

• Design variables: R (radius of the circular cross-section of the bar), W and H.

• Volume of the structure (the objective variable):

√
V = L(W H + 2πR2 )

• Allowable stress (state variable):

σa = 0.5 Sy = (0.5)(250 × 106 ) = 125 × 106 Pa

• Allowable tip displacement (state variable):

ua = 10−4 L = (10−4 )(3) = 3 × 10−4 m

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3 Problem Formulation
√
Minimize V (R, H, W ) = L(W H + 2πR2 ) [±0.01 m3 ]

Subject to 0 ≤ |σ|max ≤ 125 × 106 [±100 Pa]

0 ≤ u1 ≤ 3 × 10−4 [±0 m]

0.01 ≤ R ≤ 0.25 [±0.0025 m]

0.02 ≤ W ≤ 0.5 [±0.005 m]

0.02 ≤ H ≤ 0.5 [±0.005 m]

where |σ|max is the maximum absolute value of stress.

4 Analysis Preprocessing
1. Give the Job a Name
Utility Menu > File > Change Jobname ...
Enter a name in the ‘Change Jobname’ window, then click on OK.

2. Initialize the Design Variables

Utility Menu > Parameters > Scalar Parameters ...

• This brings up the ‘Scalar Parameters’ window. Enter ‘R=0.025’ in the ‘Selection’ field,
then click on Accept.
• Repeat the above step for ‘W=0.05’ and ‘H=0.05’. The ‘Scalar Parameters’ window
should look like this,

• Click on the Close button.

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3. Define Element Types

(a) Bar/Truss Element

Main Menu > Preprocessor > Element Type > Add/Edit/Delete
• This brings up the ‘Element Types’ window. Click on the Add... button.
• The ‘Library of Element Types’ window appears. Highlight ‘Link’ and ‘2D spar 1’.
After clicking on Apply you should see ‘Type 1 LINK1’ in the ‘Element Types’
window.
(b) Beam Element
• Highlight ‘Beam’ and ‘2D elastic 3’ in the ‘Library of Element Types’ window,
then click on OK.
• ‘Type 2 BEAM3’ should now be added to the ‘Element Types’ window. Click on
the Close button.

4. Define Real Constants

(a) Bar/Truss Element

Main Menu > Preprocessor > Real Constants > Add/Edit/Delete
• This brings up the ‘Real Constants’ window. Click on the Add... button.
• The ‘Element Type for Real Constants’ window appears. Highlight ‘Type 1 LINK1’,
then click on OK.
• In the ‘Real Constant Set Number 1, for LINK1’ window that opens, enter ‘3.1416*R*R’
for the ‘AREA’ field as shown,

• Click on OK. You should see ‘Set 1’ appears in the ‘Real Constants’ window.
(b) Beam Element

• In the ‘Real Constants’ window, click on Add ....

• This brings up the ‘Element Type for Real Constants’ window. Highlight ‘Type 2 BEAM3’
and click OK.
• In the ‘Real Constants for BEAM3’ window that appears, enter ‘W*H’, ‘W*H*H*H/12’
and ‘H’ for ‘AREA’, ‘IZZ’ and ‘HEIGHT’, respectively as shown. Click on OK.
• Click on the Close button in the ‘Real Constants’ window.

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5. Define Material Properties
Main Menu > Preprocessor > Material Props > Material Models

• In the right side of the ‘Define Material Model Behavior’ window that opens, double
click on ‘Structural’, then ‘Linear’, then ‘Elastic’, then finally ‘Isotropic’.
• The ‘Linear Isotropic Material Properties for Material Number 1’ window comes up.
Enter in value for the Young’s modulus of 210 × 109 Pa (EX = 210E9), then click OK.
• Click on OK in the ‘Note’ window that appears. Then close the ‘Define Material Model
Behavior’ window.

6. Define Nodes
We are going to create 3 nodes given in the following table:

Node # X Y
1 0 0
2 3 0
3 3 3

Main Menu > Preprocessor > Modeling > Create > Nodes > In Active CS

• To create node #1, enter its node number, X and Y coordinates in the ‘Create Nodes
in Active Coordinate System’ window that comes up. Click on Apply.
• Repeat the above step for nodes #2 and #3. Note that you must click on OK instead
of Apply after entering data for the final node.

7. Define Elements

(a) Define Bar Element

Main Menu > Preprocessor > Modeling > Create > Elements > Elem Attributes
• This brings up the ‘Element Attributes’ window. Click on OK.

4
 (b) Create Bar Element
Main Menu > Preprocessor > Modeling > Create > Elements > Auto Numbered >
Thru Nodes
• The ‘Element from Nodes’ window opens. Select node 1, then node 3.
• Click on OK in the ‘Element from Nodes’ window.
(c) Define Beam Element
Main Menu > Preprocessor > Modeling > Create > Elements > Elem Attributes
• In the ‘Element Attributes’ window that opens, select ‘2 BEAM3’ for ‘Element type number’,
and ‘2’ for ‘Real constant set number’.
• Click on OK.
(d) Create Beam Element
Main Menu > Preprocessor > Modeling > Create > Elements > Auto Numbered >
Thru Nodes
• Select node 1, then node 2.
• Click on OK.
8. Mesh the Model
No need because we have defined the model using nodes and elements.
9. Apply Boundary Conditions
Main Menu > Preprocessor > Loads > Define Loads > Apply > Structural > Displacement >
On Nodes
• Pick nodes 2 and 3, then click OK in the picking window.
• In the ‘Apply U,ROT on Nodes’ window that comes up, select ‘All DOF’ for
‘DOFs to be constrained’, ‘Constant value’ for ‘Apply as’ and enter ‘0’ for
‘Displacement value’, then click OK.
10. Apply Loads
Main Menu > Preprocessor > Loads > Define Loads > Apply > Structural > Force/Moment >
On Nodes
• Pick node 1, then click OK in the picking window.
• In the ‘Apply F/M on Nodes’ window that opens, select ‘FY’ for ‘Direction of force/mom’,
‘Constant value’ for ‘Apply as’ and enter ‘-5E5’ for ‘Force/moment value’, (a force
of 500,000 N in the negative direction of the Y axis), then click on OK.

5 Analysis Processing (Solving)

Main Menu > Solution > Analysis Type > New Analysis
• Make sure that ‘Static’ is selected. Click OK.
Main Menu > Solution > Solve > Current LS
• Check your solution options listed in the ‘/STATUS Command’ window.
• Click the OK button in the ‘Solve Current Load Step’ window.
• You should see the message ‘Solution is done!’ in the ‘Note’ window that comes up. Close
the ‘Note’ and ‘/STATUS Command’ windows.

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6 Analysis Postprocessing
1. Parameterize the objective variable (Volume)
(a) Define the volume
Main Menu > General Postproc > Element Table > Define Table > Add ...
• This brings up the ‘Define Additional Element Table Items’ window. Select ‘Geometry’
and ‘Elem volume VOLU’ as shown,

• Click on OK, then click Close in the ‘Element Table Data’ window.
(b) Sum the element volumes to obtain the structure volume
Main Menu > General Postproc > Element Table > Sum of Each Item
• The ‘Tabular Sum of Each Element Table Item’ appears. Click on OK
• This opens the ‘SSUM Command’ window showing that the total volume is 0.0158304
m3 .
• Close the ‘SSUM Command’ window.
(c) Obtain the structure volume
Utility Menu > Parameters > Get Scalar Data ...
• In the ‘Get Scalar Data’ window that opens, select ‘Results data’ and
‘Elem table sums’ as shown,

• Clicking on OK will bring up the ‘Get Element Table Sum Results’ window. Com-
plete the window as shown,

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 • Click on OK.

2. Parameterize the state variables

(a) Obtain the tip displacement

Utility Menu > Parameters > Get Scalar Data ...
• In the ‘Get Scalar Data’ window that appears, select ‘Results data’ and
‘Nodal results’. Click on OK.
• Complete the ‘Get Nodal Results Data’ window that opens as shown,

• Click on OK.
(b) Define the normal stresses in the elements
Main Menu > General Postproc > Element Table > Define Table
• Click on Add ... in the ‘Element Table Data’ window. In the ‘Define Additional
Element Table Items’ window that comes up, enter sequence number ‘LS, 1’.
• Click on Apply, then enter sequence number ‘NMISC, 1’.
• Repeat the previous step for the sequence numbers ‘NMISC, 2’, ‘NMISC, 3’ and
‘NMISC, 4’.
• Click on OK in the ‘Define Additional Element Table Items’ window.
• Click on Close in the ‘Element Table Data’.
(c) Determine the maximum normal stress in the elements
Main Menu > General Postproc > Element Table > Abs Value Option
To determine the maximum stress in terms of absolute value, check the box in the

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window that appears as shown, then click on OK

Main Menu > General Postproc > Element Table > Find Maximum
• To find the maximum of items ‘LS1’ and ‘NMISC1’, then assign the maximum as item
‘M1’, complete the window that opens as shown and click on Apply.

• Repeat the previous step to find ‘M2’ = max(M1, NMISC2), ‘M3’ = max(M2, NMISC3)
and ‘M4’ = max(M3, NMISC4).
• Click on OK.
Main Menu > General Postproc > List Results > Sorted Listing > Sort Elems
To find the maximum stress, complete the window that opens as shown and click OK.

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Utility Menu > Parameters > Get Scalar Data ...
• In the ‘Get Scalar Data’ window that appears, select ‘Results data’ and
‘Other operations’. Click on OK.
• Complete the ‘Get Data from Other POST1 Operations’ window that opens as
shown,

• Click on OK.
Utility Menu > Parameters > Scalar Parameters ...
• This function is used to view the values of the objective and state variables. The
‘Scalar Parameters’ window appears as shown,

• Click on Close

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(d) Write the Log File
Utility Menu > File > Write DB log file ...
This opens the ‘Write Database Log to’ window. Assign a name to this file (the default
extension is ‘lgw’). Click on OK. The log file should be similar to the following:
/BATCH
! /COM,ANSYS RELEASE 7.0 UP20021010 15:56:58 10/03/2004
/input,menust,tmp,’’,,,,,,,,,,,,,,,,1
! /GRA,POWER
! /GST,ON
! /PLO,INFO,3
! /GRO,CURL,ON
! /REPLOT,RESIZE
/FILNAME,OptDesign,0
*SET,R,0.025
*SET,W,0.05
*SET,H,0.05
/PREP7
!*
ET,1,LINK1
!*
ET,2,BEAM3
!*
!*
R,1,3.1416*R*R, ,
!*
R,2,W*H,W*H*H*H/12,H, , , ,
!*
!*
MPTEMP,,,,,,,,
MPTEMP,1,0
MPDATA,EX,1,,210E9
MPDATA,PRXY,1,,
N,1,0,0,,,,,
N,2,3,0,,,,,
N,3,3,3,,,,,
TYPE, 1
MAT, 1
REAL, 1
ESYS, 0
SECNUM,
TSHAP,LINE
!*
FLST,2,2,1
FITEM,2,1
FITEM,2,3
E,P51X
TYPE, 2

10
MAT, 1
REAL, 2
ESYS, 0
SECNUM,
TSHAP,LINE
!*
FLST,2,2,1
FITEM,2,1
FITEM,2,2
E,P51X
FLST,2,2,1,ORDE,2
FITEM,2,2
FITEM,2,-3
!*
/GO
D,P51X, ,0, , , ,ALL, , , , ,
FLST,2,1,1,ORDE,1
FITEM,2,1
!*
/GO
F,P51X,FY,-5E5
FINISH
/SOL
!*
ANTYPE,0
! /STATUS,SOLU
SOLVE
FINISH
/POST1
AVPRIN,0,0,
ETABLE, ,VOLU,
!*
SSUM
!*
*GET,Volume,SSUM, ,ITEM,VOLU
!*
*GET,U1,NODE,1,U,SUM
!*
AVPRIN,0,0,
ETABLE, ,LS, 1
!*
AVPRIN,0,0,
ETABLE, ,NMISC, 1
!*
AVPRIN,0,0,
ETABLE, ,NMISC, 2
!*
AVPRIN,0,0,

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 ETABLE, ,NMISC, 3
!*
AVPRIN,0,0,
ETABLE, ,NMISC, 4
!*
SABS,1
SMAX,M1,LS1,NMIS1,1,1,
SMAX,M2,NMIS1,NMIS2,1,1,
SMAX,M3,NMIS2,NMIS3,1,1,
SMAX,M4,NMIS3,NMIS4,1,1,
ESORT,ETAB,M4,0,0, ,
!*
*GET,SMax,SORT,,MAX
! LGWRITE,OptDesign,lgw,C:\DOCUME~1\DR8BDD~1.PHA\,COMMENT

7 Optimization Preprocessing
1. Assign the Log File
Main Menu > Design Opt > Analysis File > Assign
In the ‘Assign Analysis File’ windows that pops up, specify the log file by typing its name or
browsing for its location. Click OK

2. Define the Design Variables

Main Menu > Design Opt > Design Variables > Add...

• Complete the window that opens as shown for the design variable H using the limits and
tolerance specified in the problem formulation. Click on Apply.

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 • Repeat the previous step for the design variables R and W. Click on OK instead of Apply
after entering data for W.
3. Define the State Variables
Main Menu > Design Opt > State Variables > Add...
• Complete the pop-up window as shown for the state variable SMAX using the limits and
tolerance specified in the problem formulation. Click on Apply.

• Repeat the previous step for the state variables U1, then click on OK instead of Apply.
4. Define the Objective Variable
Main Menu > Design Opt > Objective
Specify VOLUME as the objective variable and enter the convergence tolerance defined in the
problem formulation as shown,

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8 Optimization Processing
1. Specify the Optimization Method
Main Menu > Design Opt > Method/Tool

• In the ‘Specify Optimization Method’ window that shows up, select First-Order. Click
on OK.
• Complete the following window that opens as shown, then click on OK.

2. Execute the Optimization Process

Main Menu > Design Opt > Run

• Click on OK in the ‘Begin Execution of Run’ window to start the optimization.

• The process converges after 11 iterations. Click on OK to close the ‘Note’ window.

9 Optimization Postprocessing
1. View the Final Results
Utility Menu > Parameters > Scalar Parameters ...
This opens the ‘Scalar Parameters’ window where the following final results are found:

R = 0.17972667 m

W = 0.279317374 m

H = 0.281996234 m

|σ|max = 9, 143, 336.07 Pa

u1 = 3.015004667 × 10−4 m

V = 0.279317374 m3

Note that displacement constraints at the tip is violated. However, the final result for u 1 falls
within the default tolerance set by ANSYS.

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2. Plot the Optimization Histories
Main Menu > Design Opt > Design Sets > Graphs/Tables

• History of the Design Variables

To obtain a history graph of the design variables, in the following window that pops up se-
lect ‘Set number’ as ‘X-variable parameter’, and ‘H’, ‘R’ and ‘W’ as ‘Y-variable parameter’,

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 Click on ‘OK’ and your ANSYS screen should look like this,

• History of the State Variables

The following history graphs of the state and objective variables can be obtained in a
similar manner:

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• History of the Objective Variable

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