Error in Topology Optimization ABAQUS-TOSCA

[OkelloEng]

Hey All,

So basically I've completed my FEA model and ran it with success with topology optimization running also successfully.
Afterward, I wanted to change a few things in my FEA model and ran the analysis job successfully then I used similar Topology Optimization configurations but this time for the new FEA model and the below error pops up, it does not explain anything. Does anyone know why? I highly suspect it is a software/hardware thing rather than the analysis thing but I really appreciate your input if anyone had this error before. Interestingly, I fired up the old FEA model and then Topology Optimization, it worked successfully but happens only when I run the new FEA model.

I've referenced a similar case to me but nobody answered it and it was closed : thread1630-484138: Optimisation error

Kind regards,
OkelloEng

[16:33:37.559203|tosca_python] Solution failed!

[16:33:37.559203|tosca_python] Module abaqus failed

[16:33:37.576156|tosca_python] Tosca Structure failed to run the optimization task

Optimization process failed with an error.

 

[FEA way]

It’s hard to say what causes this error, it’s very general. Try to find some differences between the old model (which runs successfully) and the new one (which fails to run). Double-check the whole setup to make sure that there are no mistakes in the definition of the optimization task. Try removing features, simplifying the model until it starts working.

 

[OkelloEng]

Hey FEA way,

Thanks for the reply. Yeah i agree with you, it’s a very generic error which does not entail anything or what is actually wrong. I’m assuming it says Solution Failed as in TO is not able to initiate the converging equations and no solution were found. Just to note that this error starts right away after i submit the job, before any cycle.

This lead me to double-check everything again, also repeat the whole FE model process for the old first then the new. Using old FEA, TO worked fine. Using new FEA it didn’t work so this means and I’m assuming here, that the solution of FEA in the new is not making the TO to converge any of the responses for some reason which is leading to this error. To note, FEA model is successfully being completed without any errors.

Also did change the TO responses as in for example i used different volume reduction percentages. Created a new job deleted everything and started from scratch and yet the same thing.

From experience i know that Abaqus sometimes does lag for no reason and requires sometimes reinstalling or restarting the computer but not sure if this is case here.

I would appreciate any kind of feedback.

Thanks again for everyone’s support.

 

[FEA way]

If you are sure that the setup is correct and that there are no significant differences between the old and new model that could cause the problem then we can suspect that it might be a bug in the solver. Which version of Abaqus do you use ? Do you have all the available fix packs installed ?

 

[OkelloEng]

It's Abaqus/CAE 2020. Not sure if I have all the available fix packs installed, I believe no since it's been quite a while that I haven't checked or updated it.

What's confusing is if there is a bug in the solver, why would TO work for the old FEA model?


I'll retry everything again just for the sake of it.

Thanks again

 

[FEA way]

If you can, install the newest fix pack for this version of Abaqus (you can find it on the DS Download page) or, even better, upgrade to 2022 (available on the same page).

 

[OkelloEng]

Good news ! Turned out somehow the solver success check string file got corrupted in that specific CAE file.

Made a new CAE file and then redone everything and ran the optimization and now it’s running and so far so good.

Thanks for your inputs FEA way