Posts Tagged "Tosca"

Previous few blog articles primarily addressed Abaqus 2020x enhancements. Let’s have a look at the extended products enhancements that include ISight, Tosca and FeSafe.

ISight Enhancements

  • Export of Approximations: Till 2019x release, the export of approximation models was limited to coefficient data or excel spreadsheet format. In 2020x release, the RBF and RSM approximation models can be exported to FMU as well.
  • New components: Functional Mock Up (FMU) and Computer Simulation Technology (CST) components are now available in ISight workflows.

Tosca Enhancements

  • Sensitivities support: Though not essentially an enhancement in 2020x, it is worth mentioning that all four modules of Tosca now accept Abaqus sensitivities for all types of non-linearities. However, supported analysis steps are Static and Frequency only. Inertia relief included.
  • New Response: Plastic strain PEMAG now supported for shape, size and bead optimization.
  • Algorithm stabilized: Higher volume fractions eventually lead to convergence and stability concerns. While convergence is an Abaqus issue, stability of optimization has been improved in topology module with large volume fractions.

Fe-Safe Enhancements in 3DX:

  • App enhancement: While the role is still a separate license called as durability engineer role, the mechanical and structural scenario have been enhanced to include the fatigue interface.

Simultaneous execution: Though it is well understood that any fe-safe analysis requires stress results from a stress analysis, user now has an option to simulate both structural and durability cases at the same time. The backend data management architecture takes care of sequencing and linking.

  • Material enhancement: The entire Fe-safe material database can now be imported in the 3DEXPERIENCE Platform. Surface finish factors supported as well.
  • Element nodal outputs: This is perhaps a KEY enhancement. The fatigue is a surface phenomenon so averaged stresses at the nodes on surface are most appropriate for fatigue analysis. In prior releases of 3DX, only integration point stresses were supported. Starting 2019x FD06, element nodal stresses are available for fatigue.
  • Loading enhancements: Loading blocks now include residual stresses as well as implicit dynamics step. All Fe-Safe algorithms with and without mean stress correction are now supported. Both SN curve as well as EN curve algorithms are now supported in 3DX.
  • Coming Soon!! Linux and COS execution on cloud.

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Additive manufacturing is not a new technology – it was introduced in the manufacturing industry in late 80s for very niche applications. Stereolithography, a variant of additive manufacturing, was introduced in 1986 for rapid prototyping applications; however, its true potential remained hidden for a long time. Additive manufacturing primarily refers to methods of creating a part or a tool using a layered approach. As a still-evolving technology, it now covers a family of processes such as material extrusion, material jetting, direct energy deposition, power bed fusion, and more.

Additive manufacturing expands design possibilities by eliminating many manufacturing constraints. Contrary to rapid prototyping and 3D printing, there has been a shift of focus to functional requirements in additive manufacturing; however, these functional requirements may deviate from what is expected due to many factors typical of an additive manufacturing process.

  • Change in material properties: Mechanical and thermal properties of a manufactured part differ from raw material properties. This happens due to material phase change which is typical to most additive manufacturing applications.
  • Cracking and failure: The process itself generates lots of heat that produces residual stresses due to thermal expansion. These stresses can cause cracks in material during manufacturing.
  • Distortion: Thermal stresses can lead to distortion that can make the part unusable.

The additive manufacturing process is not certifiable yet, which is a major barrier in widespread adoption of these processes commercially. The ASTM F42 committee is working on defining AM standards with respect to materials, machines, and process variables.

The role of Simulation in additive manufacturing

  • Functional design: The first objective is to generate a suitable design that meets functional requirements, then subsequently improve the design through optimization methodologies that work in parallel with simulation.
  • Generate a lattice structure: Many of the parts manufactured through AM have a lattice structure instead of a full continuum. One objective of simulation in AM is to generate a lattice structure and optimize it using sizing optimization.
  • Calibrate material: As mentioned before, the material properties of a final part can differ substantially from that of the raw material. The next objective is to capture the phase transformation process through multi-scale material modeling.
  • Optimize the AM process: Unwanted residual stresses and distortions can develop in the process. It is necessary to accurately capture these physical changes to minimize the gap between the as-designed and as-manufactured part specs.
  • In service performance: Evaluate how the manufactured part will perform under real life service loads with respect to stiffness, fatigue, etc.


Now let’s discuss each of these objectives in more detail, with respect to SIMULIA. […]

In the years to come, fuel efficiency and reduced emissions will be key factors in determining success within the transportation & mobility industry. Fuel economy is often directly associated with the overall weight of the vehicle. Composite materials have been widely used in the aerospace industry for many years to achieve the objectives of light weight and better performance at the same time.

The transportation & mobility industry has been following the same trends, and it is not uncommon to see the application of composites in this industry sector nowadays; however, unlike the aerospace industry, wide application of composites instead of metals is not feasible in the automotive industry. Hence, apart from material replacement, other novice methods to design and manufacture lightweight structures without compromise in performance will find greater utilization in this segment. In this blog post, I will discuss the application of TOSCA, a finite element based optimization technology.

The lightweight design optimization using virtual product development approach is a two-step process: concept design followed by improved design.

Design concept: The product development costs are mainly determined in the early concept phase. The automatic generation of optimized design proposals will reduce the number of product development cycles and the number of physical prototypes; quality is increased and development costs are significantly reduced. All you need is the definition of the maximum allowed design space – Tosca helps you to find the lightest design that fits and considers all system requirements. The technology associated with the concept design phase is called topology optimization that considers all design variables and functional constraints in optimization cycle while chasing the minimum weight objective function. The technique is iterative that often converges to a best optimal design.


The user starts with an initial design by defining design space, design responses, and objective function. Design space is the region from where material removal is allowed in incremental steps and objective function is often the overall weight of the component that has to be optimized. With each incremental removal of material, the performance of the component changes. Hence each increment of Tosca is followed by a finite element analysis to check existing performance against target performance. If target performance criteria is satisfied, the updated design increment is acceptable and TOSCA proceeds to the next increment. This process of incremental material removal is continued until the objective function is satisfied or no further design improvement is feasible. The image below depicts a complete CAD to CAD process flow in Tosca. The intermediate processes include TOSCA pre-processing, TOSCA and a finite element code based co-simulation and TOSCA post processing.

Tosca workflow

During the material removal process, TOSCA may be asked to perform the optimization that provides a feasible solution not only from a design perspective but from a manufacturing perspective as well. For example, TOSCA may be asked to recommend only those design variations that can be manufactured using casting and stamping processes. This is possible by defining one or more of manufacturing constraints available in TOSCA constraints library.

manufacturing constraints

While the topology optimization is applicable only on solid structures, it does not mean TOSCA cannot perform optimization on sheet metal parts. The sizing optimization module of TOSCA allows users to define thickness of sheet metal parts as design variables with a lower bound and an upper bound. […]

Our SIMULIA user community has been using the conventional analysis and portfolio tokens for a while now. These tokens are primarily used to access the Abaqus CAE pre-processor, Abaqus solver, and the Abaqus viewer. The analysis configuration offers Abaqus solver licenses in the form of tokens, and Abaqus CAE as well as Abaqus viewer as interactive seats. The portfolio configuration offers all three components of Abaqus, i.e. the solver itself, Abaqus CAE as well as Abaqus viewer as tokens.

                                                                                                                                                      IS SIMULIA = only ABAQUS!

The new equation has been EXTENDED

                                                                                                                                   SIMULIA = ABAQUS + ISIGHT + TOSCA + FESAFE

The overall simulation offerings from Dassault Systèmes go way beyond Abaqus finite element simulations. The functionalities now include process automation, parametric optimizations, topology optimization, fatigue estimation, and many more. And starting from Abaqus release 6.13-2, all these additional capabilities are included in a single licensing scheme called extended tokens. Here is an overview of these additional SIMULIA products.extended-products


ISight is an open desktop solution for creating flexible simulation process flows, consisting of a variety of applications, to automate the exploration of design alternatives, identify optimal performance parameters, and integrate added-value systems. The simulation process flows created from ISight can include multiple third party simulation components such as Ansys, LS-DYNA, Nastran, Mathcad as well as general purpose components such as Matlab, excel, calculator, and many more. It offers advanced parametric optimization, Design of experiments and Six Sigma techniques. Moreover, the vast amount of Simulation output data generated by such techniques can be managed effectively using the post processing runtime gateways of ISight. It’s rightly called a Simulation Robot.




Tosca is a general purpose optimization solution for designing high performance light weighted structures. As fuel economy continues to be the most important design factor in the transportation and aviation industries, designing lightweighted components and assemblies will remain a top priority, and Tosca can really help to achieve those objectives. […]

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