Generative shell design for simulations
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.
1 . A computer-implemented method for generating models, comprising:
generatively creating, until convergence is reached via a generative design process within a generative design software application, a generative design, wherein the generative design comprises a hollow computer-aided design (CAD) design;
exporting the generative design as a generative shelled base;
creating, from the generative shelled base, a shelled solid body and a mid-surface shell;
creating, from the shelled solid body, a CAD geometry for an internal support structure;
converting the CAD geometry into one or more CAD faces and one or more CAD solid bodies;
creating, from the mid-surface shell, a shell mesh model;
combining the one or more CAD faces and one or more CAD solid bodies with the shell mesh model into a generative mid-surface mesh;
providing the generative-mid-surface mesh to a computer-aided engineering (CAE) crash simulation application for validation of the generative mid-surface mesh;
combining the generative shelled base with the CAD geometry into a generative shelled solid; and
providing the generative shelled solid to an additive build simulation application.
2 . The computer-implemented method of claim 1 , wherein the creating the generative design comprises:
creating obstacles and applying boundary conditions with constraints;
generating one or more outcomes based on the generative design, wherein the one or more outcomes:
comprise a historical recipe for creating the generative design; and
are based on stress forces that are applied to the generative design;
analyzing the one or more outcomes and the generative design, wherein the analyzing comprises adding a t-spline to the historical recipe;
calculating a safety factor for the generative design based on the historical recipe; and
iterating the creating the generative design by adjusting the safety factor until an optimized generative design acquired.
3 . The computer-implemented method of claim 2 , wherein the creating the generative design is performed by a solver that generates a t-spline of the generative shelled base in a uniform thickness.
4 . The computer-implemented method of claim 1 , wherein the internal support structure does not trap powder and is shaped to provide inertia against bending.
5 . The computer-implemented method of claim 1 , wherein the shelled solid body is created by:
creating, from the generative shelled base, a t-spline body, wherein the creating the t-spline solid body comprises:
acquiring an outer t-spline face from the generative shelled base; and
offsetting the outer t-spline face by a defined thickness to create an inner surface resulting in the t-spline solid body.
6 . The computer-implemented method of claim 1 , wherein the creating the mid-surface shell comprises:
creating, from the generative shelled base, a t-spline mid-surface shell, wherein the creating of the t-spline mid-surface shell comprises:
acquiring an outer t-spline face from the generative shelled base; and
offsetting the outer t-spline face by a defined thickness to create an inner surface resulting in the t-spline mid-surface shell.
7 . The computer-implemented method of claim 1 , wherein the combining the one or more CAD faces and the one or more CAD solid bodies with the shell mesh model comprises a Boolean operation.
8 . The computer-implemented method of claim 1 , wherein the combining the generated shelled base with the CAD geometry comprises a Boolean operation.
9 . The computer-implemented method of claim 1 , wherein the combining the one or more CAD faces and the one or more CAD solid bodies with the shell mesh model further comprises:
intersecting the internal support structure with the one or more CAD faces; and
deleting a portion of the internal support structure that extends beyond the one or more CAD faces.
10 . A computer-implemented system for generating models, comprising:
(a) a computer having a memory;
(b) an application executing on the computer, wherein the application is configured to:
(i) generatively create, until convergence is reached via a generative design process within a generative design software application, a generative design, wherein the generative design comprises a hollow computer-aided design (CAD) design;
(ii) export the generative design as a generative shelled base;
(iii) create, from the generative shelled base, a shelled solid body and a mid-surface shell;
(iv) create, from the shelled solid body, a CAD geometry for an internal support structure;
(v) convert the CAD geometry into one or more CAD faces and one or more CAD solid bodies;
(vi) create, from the mid-surface shell, a shell mesh model;
(vii) combine the one or more CAD faces and one or more CAD solid bodies with the shell mesh model into a generative mid-surface mesh;
(viii) provide the generative-mid-surface mesh to a computer-aided engineering (CAE) crash simulation application for validation of the generative mid-surface mesh;
(ix) combine the generative shelled base with the CAD geometry into a generative shelled solid; and
(x) provide the generative shelled solid to an additive build simulation application.
11 . The computer-implemented system of claim 10 , wherein the application creates the generative design by:
creating obstacles and applying boundary conditions with constraints;
generating one or more outcomes based on the generative design, wherein the one or more outcomes:
comprise a historical recipe for creating the generative design; and
are based on stress forces that are applied to the generative design;
analyzing the one or more outcomes and the generative design, wherein the analyzing comprises adding a t-spline to the historical recipe;
calculating a safety factor for the generative design based on the historical recipe; and
iterating the creating the generative design by adjusting the safety factor until an optimized generative design acquired.
12 . The computer-implemented system of claim 11 , wherein the application creating the generative design comprises a solver that generates a t-spline of the generative shelled base in a uniform thickness.
13 . The computer-implemented system of claim 10 , wherein the internal support structure does not trap powder and is shaped to provide inertia against bending.
14 . The computer-implemented system of claim 10 , wherein the application creates the shelled solid body by:
creating, from the generative shelled base, a t-spline body, wherein the creating the t-spline solid body comprises:
acquiring an outer t-spline face from the generative shelled base; and
offsetting the outer t-spline face by a defined thickness to create an inner surface resulting in the t-spline solid body.
15 . The computer-implemented system of claim 10 , wherein the application creates the mid-surface shell by:
creating, from the generative shelled base, a t-spline mid-surface shell, wherein the creating of the t-spline mid-surface shell comprises:
acquiring an outer t-spline face from the generative shelled base; and
offsetting the outer t-spline face by a defined thickness to create an inner surface resulting in the t-spline mid-surface shell.
16 . The computer-implemented system of claim 10 , wherein the application combines the one or more CAD faces and the one or more CAD solid bodies with the shell mesh model via a Boolean operation.
17 . The computer-implemented system of claim 10 , wherein the application combines the generated shelled base with the CAD geometry via a Boolean operation.
18 . The computer-implemented system of claim 10 , wherein the application combines the one or more CAD faces and the one or more CAD solid bodies with the shell mesh model by:
intersecting the internal support structure with the one or more CAD faces; and
deleting a portion of the internal support structure that extends beyond the one or more CAD faces.