Using generative design tools in Fusion 360

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Hello everyone, I’m working on optimizing the weight/strength relationship for a bracket component in an aileron actuator. I’m using generative design tools in Autodesk Fusion 360. Can anyone guide me in setting up generative design studies?

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      I’ve been using this approach a lot lately, though in race car suspension, not aircraft! My strong advice is to start with clear objectives, the primary goal is weight, but recognize the secondary ones too. You clearly need a part that can perform and endure. I’d guess this type of part needs an extended service life. Prioritize constraints – if strength is critical, prioritize stiffness or minimize displacement.
               

      Your constraints are what defines the usefulness of the process, it’s easy to do a GIGO on this (garbage in, garbage out). Iterate to improve.

      Try to define some realistic load cases – aerodynamic forces from the aileron, actuator load, and moments from both. You might set these as point loads to start, keeping it simple. Later on, some might be better as pressure distributions.

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    • C

      You can evaluate the edge scenarios using boundary conditions. This simulates how the mounting and how your actuator interacts with the surrounding elements. You can impose fixed points at the areas where the actuator connects to other parts. These impose constraints on the design algorithm, so they get optimized for material usage.

      Also, set your manufacturability constraints early on. If you plan to use 3D printing, you can set up constraints that limit overhang angles to reduce supports. It’ll look different if you’re using CNC. Then you need to specify tool accessibility and allowable undercuts.

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        Christoph

        What about factors of safety?

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        Mary Williams

         Good question. There’s no direct FoS input in the setup, you do this through constraints or loading scenarios. Increase expected max loading by your FoS in setting up the study. 2 is an OK FoS in my work, but you’ll need more in flight-critical parts.

        Don’t forget to preserve geometry in any areas of the design that can’t be adjusted – literally ‘preserve geometry’ in Fusion 360. For this case, it’s likely the mounting and actuation points were connected to other elements. These will be fixed points.

        After generating some design options, the next step is refining the geometry.

        Use ‘edit form’ and ‘mesh to BRep’ tools to smooth out any rough surfaces or complex features that may pose challenges in manufacture. Simplify the geometry by deleting unnecessary details, particularly if you’re using CNC.

        Next do a manufacturability analysis for thin walls, sharp corners, or problem undercuts. For 3D printing, some post-processing tidy-ups like machining critical surfaces or adding filets are good.

        Finally, simulate to validate that the design performs criteria under the operational loads.

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        DrewK87

        How many iterations does it usually take to get a result you’re happy with?

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        Mary Williams

        Usually a couple does the job.

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Using generative design tools in Fusion 360
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