How do I open HyperMesh in HyperWorks

HyperWorks introduction

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1 Innovation Intelligence HyperWorks Introduction Jan Grasmannsdorf Tuesday, September 18, 2012

2 Altair s Brands and Companies Technology Processes Know How Innovation Intelligence = Discover new ways in product development

3 got the knack? Click to play

4 got the knack? Dilbert 2010, United Feature Syndicate, Inc.

5 Global Presence Seattle, USA Montreal, Canada Lund, Sweden Moscow, Russia Beijing, China Mountain View, USA Toronto, Canada Gothenburg, Sweden Shanghai, China Los Angeles, USA Coventry, UK Delhi, India Austin, USA Manchester, UK Pune, India Tokyo, Japan Denver, USA Detroit, USA Böblingen, Germany Chennai, India Osaka, Japan Boston, USA Köln, Germany Hyderabad, India Nagoya, Japan Milwaukee, USA Hamburg, Germany Bangalore, India Mexico City, Mexico Charlotte, USA Hannover, Germany Seoul , Korea Huntsville, USA München, Germany KL, Malaysia Lyon, France Paris, France Sophia Antipolis, France Toulouse, France Melbourne, Australia Sao Paulo, Brazil Torino, Italy Madrid, Spain Over 40 offices across 16 countries

6 What's in HyperWorks? HyperMesh (Preprocessing) Radioss FEM MotionSolve MKS AcuSolve CFD OptiStruct / HyperStudy Optimization & Parameters HyperForm / HyperXtrude Manufacturing HyperView / Graph / Math (Postprocessing)

7 Development process without CAE Concept phase Construction & detailing Functional model & prototype Test phase & validation..n F Approval & production

8 Development process with CAE concept phase construction & detailing CAE / simulation functional model & prototype F test phase & validation approval & production

9 Development process with CAE and optimization concept phase optimization construction & detailing simulation / design opt. Functional model & prototype simulation test phase & validation simulation release & production

10 Upfront CAE at Volkswagen Genuine component 2.000g New component 1.550g mass minus 23% Development of aggregates, Volkswagen

11 Upfront CAE at Fortis Saxonia Source: Fortis Saxonia, TU Chemnitz

12 CAE Process Work Steps Geometry Import & Cleanup Which data is required for the simulation? CAD data cleaned up / repaired

13 Geometry import & cleanup Geometry import via interface to CAD software (Direkt, IGES, STEP) Task in the preprocessor: Repair of CAD geometry, cleanup with regard to network quality (e.g. element edge length> 3mm) 0.34 mm

14 CAE Process Work Steps Geometry Import & Cleanup Which data do you need for the simulation? CAD data cleans / repairs finite element model FEM mesh with physical properties e.g. Wall thickness, cross section, mass, stiffness

15 FEM meshing HyperMesh offers meshing algorithms and properties for 0 and 1D elements 2D shell elements 3D volume elements

16 FEM networking It is advisable to check the network quality in HyperMesh. Visual control Uniformity Element shape, size & evenness Gaps in the network? Unconnected geometries? Element normal Coherent mass / volume?

17 FEM networking Possible sources for criteria: Solver usually has preset quality criteria in HyperMesh that can be checked. Experience At critical points (notches, connections, etc.) the element quality should always be particularly good.

18 FEM network properties Caution: Pay attention to consistent units !!!

19 CAE Process Work Steps Geometry Import & Cleanup FEM Model Load Case Which data is required for the simulation? CAD data cleans / repairs FEM mesh with physical properties e.g. Wall thickness, cross-section, mass, stiffness, loads and boundary conditions, e.g. Power, temperature, speed

20 Example load case wind power plant How do you determine the correct loads for an FEM simulation? Dynamic multi-body simulation (MBS) The system is modeled with masses, centers of gravity, stiffness, dampers etc. Result: Forces acting on the structure during dynamic events Event emergency stop Courtesy of Nordic, Sweden

21 Example load case wind power plant The determined forces can be used directly in an FEM simulation: MKS emergency stop FEM simulation with determined load

22 Load cases How do you determine the correct loads for an FEM simulation? Dynamic multi-body simulation (MBS) Measurements and empirical values ​​Consider: statics, dynamics (acceleration, braking, etc.), weight, environment, temperatures, shock loads, vibrations. Standards From the FE model, properties, material and load case results (for static load cases): F = K u load vector stiffness matrix = elements displacement vector

23 CAE Process Work Steps Geometry Import & Cleanup FEM Model Which data do you need for the simulation? CAD data cleans / repairs FEM mesh with physical properties e.g. Wall thickness, cross-section, mass, stiffness, loads and boundary conditions, e.g. Force, temperature, speed Load case solver Program for solving the set of equations, e.g. static, dynamic, linear, non-linear systems of equations

24 FE-Solver Radioss Linear Static & Dynamic

25 Altair FEM Solver Radioss Non Linear Static & Dynamic

26 Altair MKS Solver MotionSolve and CFD Solver AcuSolve MotionSolve MKS Simulation AcuSolve CFD Simulation Kinematics, dynamics, statics Understanding of systems, determining loads, coupling with flexible bodies FEM-based solver for stationary, unsteady, turbulent flows Fluid-structure coupling

27 CAE Process Work Steps Geometry Import & Cleanup FEM Model Load Case Which data is required for the simulation? CAD data cleans / repairs FEM mesh with physical properties e.g. Wall thickness, cross-section, mass, stiffness, loads and boundary conditions, e.g. Force, temperature, speed Program for solving the set of equations, e.g. Static, dynamic, linear, non-linear systems of equations Solver Evaluation of the calculated results, e.g. Deformation, strain, stress or optimization variable evaluation / analysis

28 Postprocessing of an FEM analysis Postprocessor: Comparison of the FE simulation with test results, standards, guidelines, empirical values, etc. Important: Are the results consistent (e.g. balance of forces)?

29 CAE process Work steps Geometry Import & Cleanup FEM model Load case Preprocessor HyperMesh FEM file Solver evaluation / analysis Solver Radioss, Motionsolve, Acusolve H3D file Postprocessor HyperView

30 Topology Optimization Concept finding The variable x in topology optimization is the stiffness & mass of each individual element in the installation space. Optimization goal f (x) is often the maximum possible stiffness with limited mass g

31 Topology Optimization Concept development Casting Direction Stiffness Measure F 1 F 2 M 1 Network Installation space, loads and boundary conditions Optimization task Iterative calculation Result & CAD implementation Start CAD design

32 Topology Optimization Concept Finding Solver Radioss + X 1 - X n; min f (x); g (x) = formulation of the optimization task: objective function (what is the objective of the optimization?) min f (x), max f (x) or min [max f (x)] design variables (what can I change?) X il X i X iu i = 1,2,3, N boundary function (which boundary conditions must I adhere to?) Gj (x) 0 j = 1, 2, 3 ,, M OptiStruct optimization

33 OPTIMIZATION DISCIPLINES

34 Concept Design with Solid Thinking & Inspired Easy to use industrial concept design

35 Altair Optimization Driven Innovation Fan Bracket - Example

36 Topology Optimization Application examples Holder insufficiently dimensioned (return) Component should be redesigned Goal: Reduce stresses Courtesy TECOSIM GmbH, Ruesselsheim

37 Topology Optimization Application examples Topology Optimization Result Courtesy TECOSIM GmbH, Ruesselsheim

38 Topology Optimization Application examples CAD feedback with OSSmooth: Courtesy TECOSIM GmbH, Ruesselsheim

39 Topology Optimization Application examples Original component Optimized component Max. Mises Stress Max. Displ. Mass Courtesy TECOSIM GmbH, Ruesselsheim

40 Topology optimization application examples chainring installation space optimization process Thanks to the Elbflorace Racing Team e.v. Optimized component

41 Topology Optimization Application examples Chainring manufactured Comparison mass, (diameter%) Thanks to the Elbflorace Racing Team e.v.

42 Case study Bracket Redesign Engine Mount Bracket - Material saving Design Space Design Proposal (1997) 7 Loadcases Objective: Minimize the Mass Stiffness should be the same Initial Design Mass: 950g Annual Cost Savings Weight reduction per part = 0.22 kg Annual Production Volume = 200,000 pcs Total Mass Reduction = 44,000 kg Nominal Material Cost = $ 0.80 / kg (1997) Total cost Savings in Material = $ 35,200 / yr Design Mass: -20%

43 Altair Optimization Driven Innovation Bus Body Structure Design Problem Develop an alternative body structure for a new 30 bus (compared to a conventional 40 bus) from concept through detail Optimization Problem statement: Minimize Weight With Constraints on Torsional and Bending frequencies Stiffness (Static Displacements) Final Design Method s Used: Design package space created based on overall bus dimensions and sub-system packaging constraints. Loads Determined analytically OptiStruct topology optimization used to create the initial concept design Concept Design interpreted to render it manufacturable OptiStruct Shape / Size optimization used for tuning the concept design

44 Altair Optimization Driven Innovation System Level Requirements (loads analysis & packaging) Design Space and Loads Topology Optimization CAD model with generic elements Final Design Parametric Shape Vectors Finite Element Modeling Size and Shape Optimization

45 Altair Optimization Driven Innovation Altair Bus June 2010 December 2010

46 Free Size Optimization Example: Bike Frame Design a Training Bike from a Clean Sheet Should be as light as possible, while maintaining stiffness, safety and comfort regulations Use composite materials

47 Free Size Optimization Example: Bike Frame Design Space = Maximum Thickness for all Fiber Layers (0, 45, -45, 90) Design Variable: Thickness of all Elements Objective: Minimize Mass, Constraint: Stiffness according to regulations

48 Free Size Optimization Example: Bike Frame Thickness Results for all Composite Fiber Layers The Layer at 0 needs the most material

49 Free Size Optimization Example: Bike Frame Design Interpretation and further optimization leads to 12 Composite Patches All regulations were met with this lightweight frame Patch 1 Patch 2

50 Shape Optimization Example: Plate The original design shows below. There are several circle holes in the support structure. Pressure P = 10 N / mm² applies on the top end The bottom end is fixed in x, y and z-direction Pressure P = 10N / mm2 Fixation FE model of original design Load & Fixation

51 Shape Optimization Example: Plate Analysis Result: Von Mises stress The peak stress of the original model is 212MPa> 125MPa. Stress exceeds allowed limit almost by factor 2!

52 Shape Optimization Example: Plate Design variable: 1 free shape dv for each hole, totally 8 dvs Constraints: stress <125 Mpa Objective: Minimize total volume 8 DVs

53 Shape Optimization Example: Plate After 17 iterations, the optimization run converged. Following is the shape change animation and stress of new design. -42% + 4% peak stress volume

54 HyperWorks 11.0 Student Edition Altair Online Store: Registration with UNIVERSITY MAIL ADDRESS! Then order the Student Edition (please follow the instructions on the website). Finally, enter the code FREE_Edu_FS for a free version

55 What are the next steps? The HyperWorks Academic Blog

56 What are the next steps? The HyperWorks Starter Kit Videos Introduction for HyperWorks Beginners Contains important hints and tips for using the software. Interactive videos guide you through the program. It is best to read and practice before the first HyperWorks course begins

57 Training Center Free Learning Training Center or summary Altair tutorials and study projects in one central location Practice projects for different topics and levels, e.g. also composite optimization, tube frame optimization, etc. Integration of theoretical and practical aspects of the FEM simulation model database for your own projects

58 New Altair eBook Practical Aspects of Finite Element Simulation - A Student Guide Personalized PDF file that can be ordered free of charge from Altair Contents Basic introduction to FEM simulation for beginners From modeling to linear static simulation Model planning 1D, 2D, 3D meshing Linear-static simulation and evaluation

59 What are the next steps? October HyperWorks for students workshop TU Freiberg October 19/20 HyperWorks for students workshop Cologne University of Applied Sciences October HyperWorks online seminars, in English Further dates in BB, Munich, Graz, Cologne, Hanover Register at

60 What are the next steps? Workshop September 21, 2012: Installation of HyperWorks and AcuSolve package + updates Installation of license file ftp.altair.de/outgoing/altair_134/altair_workshop_2012.zip Save in the installation /security/altair_lic.dat Control panel Environment variable Altair_License_Path = / altair_lic .dat Thanks to Skyline Motorsport ev