Innovative Engineering Curricula and University Design ...

Copyright © 2011 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

Innovative Engineering Curricula and University Design

Competition Applications of Altair OptiStruct and HyperStudy Structural Optimization CAE Tools

Altair Inc

David Schmueser University Business Development Mgr, Altair Inc, Troy, MI USA Matthias Goelke Global University Business Director, Altair Inc, Boblingen, Germany


Presentation Topics Altair Inc Overview HyperWorks Optimization Technology

OptiStruct HyperStudy

University Design Competition Applications University of Michigan Solar Car Team Coventry University Shell Eco-Marathon Team

University Curriculum Applications Northwestern University

•Computational Methods in Engineering Design Michigan Technological University

•Enterprise Applications of Composite Material Design Altair Global EDU Optimization Instruction Modules

Copyright © 2011 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

Overview

Founded ... In 1985 as a product design consulting company Today ... A global software, services & technology leader with over 40 offices in 18 countries and 3,200+ customers worldwide

19 85

20 11

$212M

$100M


1,500 Employees worldwide 500 Project engineers, designers and technicians 220 Software support engineers and application specialists

400 HyperWorks developers

TEAM

Substantial Technical Human Resources

http://www.altair.com/


Altair: 28 Years of Innovation


HyperWorks for Academia

RADIOSS

Linear Non-Linear (Implicit)

Non-Linear (Explicit)

Thermal and CFD

Optimization – OptiStruct and HyperStudy

Multi-Body Dynamics

Partner Alliance Solutions

1-D Systems, Fatigue, Ergonomics, Industrial

Design, Injection Molding, Noise and Vbration (NVH),

Composite Materials, Electromagnetics

Pre-Post

RADIOSS - AcuSolve

RADIOSS - MotionSolve


Challenge Design a high performance race car powered by solar energy only

Solution Utilize OptiStruct to minimize the composites body and chassis weight

Design Impact • Reduce car weight by 90 kg from 2009 to 2012

design • Chassis met or exceeded strength requirements

“OptiStruct did a great job helping us to come up with an innovative lightweight design for our Quantum solar race car.”

Andrew Huang, Chief Mechanical Engineer, University of Michigan Solar Car Team

University of Michigan Solar Car Team


Topology Optimization: Preliminary Chassis Design

Tub-Style Chassis Design • Designed to Fit into An Outer Shell Surface

Determined from Aerodynamic Simulation • Suspension Hard Points Accurately Placed

HyperMesh Pre-Processing • Shell Elements • Lay-Up: Carbon, Core, Unidirectional

Carbon, Woven-Carbon Weave

OptiStruct Topological Optimizationted • Load-Path Regions Identified • Critical Areas for Unidirectioonal Carbon

Fiber Reinforcement Located



Composite Size Optimization: Final Vehicle Design

Manufacturing Constraints • Imposed for Regions of Complex Carbon-

Layer Shape • Applied at High-Load Chassis Locations

(Suspension Hard Points)

HyperMesh Modeling • Shell Elements for Uni-Directional Carbon

Plies • 3D Hexahedral Elements for Core Material

Optimized Vehicle Weight Savings: 90 kg • 20 kg in Lower Unibody Chassis Design • 20 kg in Upper Vehicle Surface Design • 50 kg in Battery Design



Coventry University Shell Eco-Marathon Team

Baseline Vehicle (2009) •Aluminum Tubular Chassis •Mass: 45 Kg •Poor Aero Performance

Composite Monocoque Concept (2010) •Feasibility Design •Aerodynamic Development Focus •Structural Development Needed

Fully Optimized Composite Monocoque (2011) •Fully Integrated Aero Design •Optimized Structure: 45 Kg •Designed for Manufacturability



Sandwich Structure Optimisation Process The reinforced sandwich structure approach started with the same 8 ply layup as pure carbon approach with the addition of 12mm honeycomb core in the floor and seatback sections.



Pure Carbon Optimisation Process The pure carbon fibre approach consisted of a complete covering of an 8 ply symmetrical layup. A three phase optimisation was utilized taking advantage of the automatic phase transitions.



Results - Mass Optimized Mass

•Pure Carbon 14.92kg

•Honeycomb Solution 13.73kg

The pure carbon fibre solution had smaller global displacements creating a stiffer overall structure. However the honeycomb panel solution provided a stiffer floor and seatback reducing the localized deformation primarily around the driver and seatbelt location points.


• OptiStruct is used within ME (Mechanical Engineering) and Segal Design Institute at Northwestern University:

• ME 341: Computational Methods for Engineering Design

• Senior undergraduate and entry level graduate

• ME 398: Engineering Design (Capstone Design) • Senior undergraduate

• ME 441: Engineering Optimization for Product Design and Manufacturing

• Entry level graduate • ME 495: Advanced Computational & Statistical

Methods for Engineering Design • Graduate level

Northwestern University Computational Design Courses


ME 341: Computational Methods for Engineering Design • Altair HyperWorks Tutorials

• In-class tutorial for topology optimization

• Outside-class tutorial for size optimization

• Selected Students’ Class Projects




ME 341 In-Class Tutorial for Topology Optimization



ME 341 Outside-Class Tutorial for Size Optimization



ME 341 Class Project 1

SRAM Omnium Crankset

First External Bearing Track Crank • Designed for track racing • Manufactured from

Aluminum 7050-T6 • Total assembly is 825g • Exceptional Stiffness

Project Goal: • To use Hyperworks and other available optimization techniques to reduce crank weight (without making considerations for the chain ring) without compromising product stiffness.


Topology Optimization • Blank used to perform a topology optimization with respect to the

following constraints:

• Mass - Maximum 300g

• Compliance

- Minimization

• Materials - Steel - Aluminum -6061, 7075






OptiStruct Contraints

Operation was performed with a 2000N load • Body allowed to rotate about spindle • Transverse movement of bolt holes prohibited



ME 341 Class Project 1 Topology Optimization Results- Aluminum 6061

Stresses: Displacement:




Results Summary

0 20 40 60 80

100 120

Aluminum 6061

Aluminum 7075

Steel

Perc

enta

ge

Material

Stresses

Percent of Yield

Percent of Ultimate

0 200 400 600 800

1000 1200 1400

Aluminum 6061 Aluminum 7075 Steel

Mas

s (g)

Material

Mass




Stamping Die Design Ford Motor Co. experiencing failure of a stamping die binder:

They have conducted a FE Analysis and created a new design, but they

would like to optimize the design:

Goal: Minimize the weight of the Binder. Subject to: Maximum Principle Stress is less than 40% binder material

yield stress.




Stamping Die Design Methodology: 2 Phase Analysis using HyperWorks:

Phase 1: Topology optimization Minimize compliance (max stiffness) subject to 25% maximum

volume fraction of material remaining. Phase 2: Size optimization

Minimize weight subject to a maximum principle stress level. Design Space created and loads and boundary conditions added:




Topology Optimization Results

• Results of the topology optimization with manufacturability constraints as shown:




Topology Optimization Summary The topology result was used to create a regular geometry: • Size Optimization conducted to minimize weight subject to

a stress constraint: Results in a near uniform 30 mm wall thickness

• 2 Stage method produced an acceptable, minimal weight design


Michigan Tech University: Board Sport Technologies Enterprise

Tutorial Development Related to Composite Wake Board Design

Three HyperWorks-Based Tutorials Were Completed: • Wakeboard Meshing Using HyperMesh

• Linear FE Analysis of the Wakeboard Subjected to Loads

Simulating the Rider Weight and Wakeboard Landing Resulting from Wave Jumping

• Wakeboard Optimization Using OptiStruct Shape Optimization Size Optimization Free-Size Optimization


• Done behind a boat at 20-25 mph

• Specific boats for big wakes (and big impact)


Wakeboarding


Wakeboard Geometry



Board Construction


• Foam core • Binding inserts • Wrapped in fiberglass with epoxy matrix • Top and bottom sheet for protection


Tutorial 1: Wakeboard Meshing Using HyperMesh


• Wakeboard Geometry Import

• Mesh ¼ of the Board

• Mesh Clean-Up & Reflection


Tutorial 2: Linear FE Analysis of the Wakeboard Subjected to Loads Simulating the Rider Weight and Wakeboard Wave

Jumping


• Rider Loads (200 lb Person)

• Wave Impact Loads

• Results-Inertial Relief Analysis (Von Mises Stress-Board Bottom)


Tutorial 3: Wakeboard Optimization Using OptiStruct


• Shape Optimization

• Size Optimization-Uniform Fiberglass Layer Thickness

• Free-Size Optimization-Variable Fiberglass

Layer Thickness


The HyperWorks Academic Blog www.altairuniversity.com

Repository of: E-Learning Videos Webinars Tutorials and Training Material Tricks & Tips HyperWorks & Altair News


http://www.altairuniversity.com/


The HyperWorks Starter Kit

www.altairuniversity.com/..... Download Path

A very basic introduction for HyperMesh beginners Summary of hints and recommendations Ideally to be read before the first HyperMesh class starts





HyperWorks StarterKit Videos

4 h of interactive training with audio

Basic introduction in: o GUI o Geometry o 2D Meshing o Analysis set-up o Debugging o Postprocessing

No installation required

Available on the Academic Blog



Capabilities •Desktop Framework

•HyperMesh •HyperView •HyperGraph •OptiStruct •Radioss bulk (b2b) •Collaboration Tools

•HyperView Player

HyperWorks 11.0 Student Edition

http://altair2010academic.files.wordpress.com/2011/06/student_edition.png


Limitations

•10,000 nodes

Models in HM can be larger (but not exported/saved)

Limitation applies during import *.h3d in HV/HG

•CAD formats: IGES, STEP, SolidWorks

•Import of HM, OS and Radioss bulk only

•Analysis and optimization may only be started within HM

•Platforms: Windows 32 (XP, Vista, 7)

•Database IS compatible with regular version

•May NOT be used for commercial purposes

HyperWorks 11.0 Student Edition


Free E-Book (2nd Edition) What is needed to run a FEA Strategic Planning Common Mistakes and Errors Consistent Units Geometry 1D-2D-3D Meshing Static Analysis NL Implicit Analysis Postprocessing

Available on the Academic Blog



Let us know your ideas and requests.

Thank You!



HyperWorks Simulation Technolgy

OptiStruct Optimization


Altair Optimization Driven Innovation

Your professor asks you the follwing:

„For the given stucture I need to have a new,

more innovative, and lighter solution.

Delivery date: Yesterday …“

What is your Strategy?


What if there are no similar or previous designs to reference?

What if the similar design doesn’t scale for the new configuration?

What if you don’t have experience with this type of design?

What if previous designs were never optimized for weight?

What if you have many load cases?

What if you have limited time to make design changes?

What if your engineering judgment leads you down the wrong path?

…

Challenges of the early design phase




... Innovative or „old“ and well known

solutions ???

In the concept phase the designer has maximum design freedom, but minimum design knowledge

Challenges of the early design phase – in a nutshell

80% of the product weight is determined at the concept design stage


CAE Driven Design Process

Topology optimization Method to find the optimum material distribution in a given design space

Topography optimization Method to evaluate the optimum stiffening pattern on a thin part


Size optimization Method to obtain optimum

dimensions of structural parts

Shape optimization

Find optimum shape of given part

CAE Driven Design Process


Bus Body Structure

• 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

• 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



CAD model with generic elements

Parametric Shape Vectors

Finite Element Modeling

Design Space and

Loads

Size and Shape Optimization

Topology Optimization

Final Design


System Level Requirements (loads analysis & packaging)


Altair Bus

December 2010

June 2010



Rotor Head Bell Crank



Design Problem » 6 Load Cases » Machined from one direction » Maintain pad-ups around attach points to interface

with existing structure » Reduce mass 10% while keeping stress limit on

previously optimized design

Optimisation Statement » Minimise Mass » Constraint on Stress (15ksi)

Methodology » Topology optimisation with Draw Direction

manufacturing constraints » Shape optimization to determine wall thickness'




Solid model meshed with Hex elements.

» Design region specified (green)

» Non-Design region (blue) separated




» 25% reduction of component weight

» Principal stress below limit of 15 ksi

Optimisation Results Optimized Design Baseline Design





Composites Design Optimization


Unique Composite Design Methodology

Design Synthesis (Concept Design) Technologies • Isotropic Solid Topology • Isotropic Shell Topology • Isotropic Free-Size • Composite Free-Size

Design Tuning Technologies • Isotropic Size/Shape Optimization • Composite Size/Shape Optimization • Composite Shuffling Optimization

Unique Composite Design Synthesis Methodology 1. Topology – What is the Shape of the Part? 2. Composite Free-Size – What are Shapes of the Plies that make up the Part? 3. Composite Size/Shape – How many Plies required to meet Engineering Targets? 4. Composite Shuffling – What is a Probable Stacking Sequence to meet Mfg Considerations?

Complimentary Technologies


Composite Free-Size Optimization

Isotropic Free-Size vs. Composite Free-Size

Captures Coupling Between Total Thickness and Ratio of Ply Orientations (%0 %45 %90) by Updating Individual Ply Thickness

Stacking Sequence Effects Captured by SMEAR Technology • A = Stacking Sequence Independent • B = 0 • D = At2/12 – Stacking Sequence Independent

Unique Composite Design Synthesis – “Growing of Plies”

T = Lower T = Upper PSHELL

T = Ply3 (opti) 90

T = Ply2 (opti) -45 T = Ply4 (nom) 45

PCOMP

sym

T = Lower T = Upper

T = Ply3 (nom) 90

T = Ply2 (nom) -45

T = Ply1 (nom) 0

T = Ply4 (opti) 45

PCOMP

sym

T = Ply1 (opti) 0 T_0

T_Total

After Optimization

Continuous Thickness between T_Lower and T_Upper


Composite Size Optimization – How Many Plies? Stack Synthesized Ply Shapes

Define Manufacturing Constraints • Min/Max Ply Angle Percentages • Balanced Laminates

Define Optimization Targets • Stress/Strain Targets • Deformation/Buckling Targets • Minimize Mass

Perform Size Optimization to Determine Number of Plies Required to Meet Engineering Targets

90 Deg (2 Plys)

45 Deg (2 Plys)

-45 Deg (2 Plys)

0 Deg (2 Plys)

90 Deg (2 Plys)

45 Deg (2 Plys)

-45 Deg (2 Plys)

0 Deg (2 Plys)

90 Deg (2 Plys)

45 Deg (2 Plys)

-45 Deg (2 Plys)

0 Deg (2 Plys)

After Optimization

90 Deg (2 Plys)

45 Deg (2 Plys)

-45 Deg (2 Plys)

0 Deg (2 Plys)

Free-Size Results

Size Results


Composite Shuffling – What is a Probable Stacking?

Shuffling • Defines “Probable” Stacking Sequence • Obeys Manufacturing Constraints

Manufacturing Constraints • Min/Max Total Laminate Thickness • Min/Max Ply Thickness • Min/Max Ply Angle Percentage • Balanced Ply Angles • Constant Ply Thickness

After Optimization

Size Results Shuffle Results



Challenge Design a high performance race car powered by solar energy only

Solution Utilize OptiStruct to minimize the composites body and chassis weight

Business Impact • Reduce car weight by 90 kg from 2009 to 2012

design • Chassis met or exceeded strength requirements

“OptiStruct did a great job helping us to come up with an innovative lightweight design for our Quantum solar race car.”

Andrew Huang, Chief Mechanical Engineer, University of Michigan Solar Car Team


Goal: • Determine the laminate lay-up & composite patch

positions

Optimization Objective: • Minimize the Mass

Subject to: • Multiple target wing displacement fields • (Twisting – Bending)

Solution using Free Element Sizing optimization: • Determine whether displacement fields are achievable • Determine minimum required mass

Due to the complexity of the structure and the number of load cases, without this technology, a ‘trial and error’ process would not be commercially realistic.

• Note: • The 45 & -45 layer thicknesses are

linked (new OptiStruct feature) • Only symmetric laminates are

considered for all studies. • Use smearing option to simulate

uniformly distributed ply stack.

Marc Funnell (Airbus UK) Altair Paper: Targeting Composite Wing Performance – Optimum Location of Laminate Boundaries

Case Study

Copyright © 2011 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Pl

y An

gle

= 0

Bending Only Twist and Bending: 9.6% increase in mass

Ply

Angl

e =

90

Ply

Angl

e =

45/-4

5

-5.6%

Change in mass

134.7%

Change in mass

17.3%

Change in mass

Free Size Optimization (FSO) - Results


The optimization took approx 6 minutes on a laptop & converged in about 10 iterations

The optimization quickly & easily shows: • Plies can be tailored to meet specific displacement & twist angle targets • Where patches of each orientation are required • Optimized Mass prediction • Ply lay-up has a direct effect upon the bending & torsional stiffness • Patch positions are dependent upon loading AND design constraints

Free Size Optimization (FSO) - Summary

Total thickness contour Bending Target Only

Total thickness contour Twist & Bending Target



HyperStudy Multi-Physics Analysis


HyperWorks for Academia – Optimization

HyperStudy - Solver Neutral Design of Experiment, Multi-Disciplinary

Optimization and Stochastic Simulation Engine

•Automates processes for parametric study, optimization and robustness assessment

• Integrated with HyperWorks thru HyperMesh, MotionView and direct solver interfaces


HyperStudy: Multi-disciplinary Design Studies

CFD

Safety

Multi Body

Dynamics

NVH

General

• RADIOSS • LS-DYNA • ANSYS • Abaqus • NASTRAN • ……

• RADIOSS • MADYMO • LS-DYNA • ……

• MotionSolve • ADAMS • ……

• RADIOSS • NASTRAN • ……

• MS EXCEL • EXT READERS

• FLUENT • CFD++ • STARCD • ……

Strength

CFD

Safety

Multi Body

Dynamics

NVH

General

Strength Before Optimization

After Optimization

Fine Tuning System Design Sub-System

Design Component

Design Manufacturing Concept


Astrium Aurora Mars Module

Challenge Layout airbag landing system of Aurora Mars Lander

Ensure safe and reliable landing

Virtual process: only limited testing possible

Solution HyperStudy to optimize airbag parameter to ensure soft

landing

Minimize risk of landing failure through Monte Carlo

study

Results 93% less payload acceleration in “dive through” landing

scenario

44% reduction in airbag stresses


Case Study CAE Driven Design of Airbag Systems at TAKATA

“By applying HyperStudy’s automatic shape optimization to the airbag design process, we were able to cut development time dramatically, with transparent and objective results.”

Axel Heym CAE Manager, TAKATA-PETRI AG, Germany

Challenge • Geometric layout of the airbag required numerous CAD-CAE iterations • Needed to reduce development time

Solution

• Upfront optimization using HyperWorks’ morphing technology • Morphing to parameterize the airbag without CAD data

Results

• Automatic process: no expertise in airbag design needed • Elimination of CAD-CAE iterations • Over 30% reduction in development time

Before:

After Optimization:

Innovative Engineering Curricula and University Design ...

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