A FEA OPTIMIZATION PROCEDURE FOR IMPROVING STRUCTURAL PERFORMANCES

C. Del Vecchio
Arcetri Astrophysical Observatory
Florence, Italy

http://medusa.as.arizona.edu/lbtwww/tech/fea.htm

Proceedings of the ESO conference on Progress in Telescope and Instrumentation Technologies, held in Garching, Germany, ed. M-H. Ulrich, p. 83 (1992.)

Abstract

1. Introduction

2. Description of the Method

3. An Application to a Large Telescope

References

Abstract

A simple iterative procedure for improving static and dynamic performances of complex mechanical structures is described. This method uses the results of the stress analysis of a frame built with only tension and compression elements to modify the cross sections of each element in order to better achieve the complex goal. An example relative to the Columbus Telescope is presented.

1. Introduction

More and more strict requests are coming from the astronomers regarding structural stiffness of astronomical instrumentation. In particular, the dynamic specifications for a telescope are severe, in order to guarantee that the telescope is stiff enough for the astronomical use (see [2]). The Finite Element Analysis (FEA) -- the most versatile analysis technique in engineering -- allows us to achieve very accurate results when evaluating structural stresses and/or the dynamic behavior of a structure.

We present here a method called dynamic optimization, that can be used to adjust the characteristics of the finite elements of a model in order to increase the eigenfrequency values, while, if possible, preventing the increase of the structural mass. The main restriction of the method concerns the element type we can work with, because only tension and compression elements, such as trusses and/or membranes, are suitable for this procedure.

The method is presented after a very brief discussion of its basic assumptions. The example reported in the last section demonstrates an application of this algorithm.

2. Description of the Method

2.1 The Basic Assumptions

An obvious way to maximize the resonant frequencies of a complex structure is to increase the stiffness of its elements. This is trivially what one needs in a one--degree--of--freedom oscillating system, with the pulsation of the mass m equal to k/m, where k is the elastic constant of the spring. In the FEA of a multidegree system, both springs kj and masses mj of the j-th element are assumed to be proportional to the element cross section. The whole idea is therefore that of finding a criterion selecting, in a given mode, elements acting mainly as a spring and elements acting mainly as a dead mass. The criterion we adopted is that of the element modal strain, i.e. the strain of the element when the structure is deformed according to the considered modal shape.

In general, FEA codes do not produce strains as output. Nevertheless, they always compute the element stresses. Within the linear theory -- the one usually adopted in the dynamic analysis -- the strain is proportional to the stress. When the elements are simple, e.g. in truss and in membrane cases, the strain is inversely proportional to the cross section, so that the information about the stress/strain can be directly related to the cross area for trusses and the thickness for membranes.

2.2 The Core Algorithm

Let us consider a model consisting of n finite elements, and perform a modal analysis computing m eigenfrequencies and m eigenvectors of displacements. If these displacements are applied to the same model in a static run, we can define a modal stress matrix S whose elements ik are the modal stress of the i-th element at the k-th mode of frequency fk. If f k* is the desired value for the frequency of the k-th mode, we define a matrix S' as

S'=[(ik / kmax) * ( fk* / f k) ] (i=1,.......... ,n k=1, ........,m) [1]

where kmax is the maximum value of the k-th column of S. The matrix S' defined by Eq.[1] identifies the normalized stresses
_
at frequency f k*. If *imax is the maximum value of each row of S', and * is the mean value of the n stresses *kmax,
we can define a vector M of n components defining the correction factor of the cross section or thickness of each finite element:

_
M=[ *imax / *] (i=1, ........ ,n). [2]

The weights (f k* / f k) are somewhat arbitrary, and the optimization has a higher probability of producing improved frequencies for the lowest frequency modes if one allows a reduction of the frequency for the highest considered modes.

2.3 The Iterative Process

Actually, this procedure has to be regarded as a step of an iteration. A strict application of the results given by Eq.[2] can produce non realistic values of cross sections. For example, too small sections may be not appropriate for manufacturing reasons or because buckling may occur. Furthermore, the structural mass distribution may result somewhat different from the original one. For these reasons, the values produced by Eq.[2] are to be modified in order to avoid unrealistic corrections -- an appropriate module in the software could perform this task automatically, according to the imposed specifications.

Because the iterative process is not necessarily convergent, and needs to be continuously monitored by the FE analyst, it terminates as soon as satisfactory results are achieved. The procedure can be summarized as follows:

3. An Application to a Large Telescope

When applying the above procedure to a telescope FE model, some further complications may occur. As a telescope rotates, it must be analyzed at several angular positions -- the restraint locations vary with respect to the structure. Furthermore, the dynamic response may be heavily affected by moving loads -- a modern telescope is a very versatile instrument, accommodating a number of focal stations, with some components changing their positions on the structure.

For these reasons, the astronomical application of the method requires that the matrix S in Eq.[1] contains all the geometrical configurations and all the load cases, and that the small variations deriving from Eq.[2] are used as input of a further modal analysis in order to iterate the process.

What follows is an example using only the core algorithm in a single iteration, and takes into account the first three modes of vibration at four zenith angles of an alt-az instrument -- the Columbus Telescope. The FE model is a simplified version of the one described in [1], and is shown in Fig. [1].

Figure 1:The FE model to be optimized.

The purpose is to increase the stiffness -- possibly decreasing the structural weight -- for some zenith angles--say 0 °, 30 °,
60 °, and 90 °. For this reason, the matrix S, and consequently S' defined in Eq. [1], is here defined by pasting the stress matrices coming from the analyses performed at the various zenith angles:

S=[ S 0 | S30 | S 60 | S 90 ] .

Similarly, also the frequencies f k of Eq.[1] are defined by the mode number and the zenith angle.

Eqs [1] and [2] were obtained by means of a Matlab [4] script file in two different ways, in order to show the arbitrary choice of the weights defined in Sec. 2.2. In the first run, = 2 was used in Eq. [1], in the second one, = 1. In both cases, the optimization was performed with a goal of 12 Hz for all modes and positions of the telescope, i.e. it was imposed f k*=12 for each k in Eq.[1].

Fig. 2 shows the results of the optimization program using = 1 in the top half plot and = 2 in the bottom half plot. The original first three frequencies (before the optimization) are plotted as dotted lines, while the optimized ones are plotted as solid lines.

Figure 2: Results of the Optimization.

Even if this example has no real practical implication -- it employs only the core algorithm -- it shows that the goal is achieved with a certain margin, and that the optimized curves are smoother than the original ones -- the variation in frequency is much reduced. The amplitude of the variation depends on the selected weighting criterion. The linear law gives good results at low zenith angles, but it does not work equally well near the horizon. The quadratic law shows a smoother behavior of the frequencies with respect to the zenith angle. It is to be noticed that the structural mass, which was originally equal to
209.5 * 10 3 Kg, drops to 188.5 * 103 Kg in the quadratic case, and to 190 * 10 3 Kg when the linear criterion is applied.

References

  1. C. Del Vecchio, ``Finite Element Analysis
    of the Columbus Telescope Project Elevation Structure'', Proceedings of this Conference.

  2. J. M. Hill, ``Optical Design, Error
    Budget and Specifications for the Columbus Project Telescope'',
    Proc. SPIE, 1236, pp. 86-107, 1990.

  3. G. J. De Salvo, R. W. Gorman. ANSYS -- Engineering
    Analysis System -- Users's Manual for Version 4.4.
    Swanson Analysis System, Houston, 1989.

  4. J. Little, C. Moler et al. Pro-Matlab -- User's Guide. The MathWorks, Inc., South Natick, 1990.