Altair Hyperworks: A Platform For Innovation: Warren Dias

Altair HyperWorks: A Platform for Innovation
Warren Dias
Business Development Manager OptiStruct
ATCx Irvine
June 18, 2014
Copyright 2014 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Presentation Outline
OptiStruct: Modern Solver Technology for Innovative and Lightweight

Design
Analysis
Optimization
13.0 Preview
OptiStruct is
Industry-proven structural analysis solver for linear and nonlinear problems

Market leader for structural design optimization
Based on modern finite element and multi-body dynamics technology
Advanced analysis and optimization algorithms

Helps develop innovative,
lightweight and structurally efficient designs
Analyze and optimize strength,
durability and NVH performance
OptiStruct: Optimization Driven Design
Optimization
Stiffness,
Strength,
Stability
Noise and
Vibrations
Durability
Smart Multiphysics
Heat Transfer
Multi Body
Dynamics
Strength, Stiffness, Stability
Linear and Nonlinear Materials
Isotropic, Orthotropic, Anisotropic
Elasto-plastic with isotropic, kinematic and mixed hardening
Gasket material
Hyperelastic material
Small (NLSTAT) and Large (LGDISP) Deformation Formulation

Contact Definition
Gap elements
Contact elements (N2S and S2S)
Slide, Stick, Freeze, Friction

CLEARANCE, ADJUST
Contact-friendly elements
Heat transfer across contact
Strength, Stiffness, Stability
Thermal Effects
Temperature-dependant structural material properties
Gasket material supported
Preloading using Nonlinear Results
Buckling analysis
Frequency response analysis
Transient response analysis
Subcase Continuation
Changing loads and boundary conditions
Noise and Vibration
Fully Featured NVH Solver
Modal and Direct FR and Transient Analysis
CMS Super Elements
Powerflow Analysis
Automatic Fluid-Structure Coupling
Complex Eigenvalue Analysis
Random Response Analysis
Acoustic Analysis
Acoustic Source (ACSRCE)

Acoustic Impedance (Acoustic Dampers)
CHACAB, PACAB, CAABSF, PAABSF and MAT10 admittance
Modal, Panel, and Structural and Fluid Grid Participation in H3D
Interface to AMLS and FastFRS
Flex Body Generation
MotionSolve, AVL/EXCITE, ADAMS, SIMPACK, ROMAX and Vlab
Noise and Vibration
AMSES Eigenvalue Solver
Can calculate thousands of modes for millions of

degrees of freedom
Fast Large Scale Modal Solver (FASTFR)
Fast frequency response solution based on

thousands of modes with viscous and/or structural
damping
Radiated Acoustics
Equivalent Radiated Power
Intensity
Sound Pressure Level at Microphone Locations
Noise and Vibration
Automatic Result Filtering (PEAKOUT)

Peak Frequencies
Automatic One Step Transfer Path Analysis (PFPATH)
Transfer Function, Point Mobility, Grid Point Force and Path Participation with
Multiple Control Volumes
NVH Problem Diagnostics

Problem
Response
Which
Mode?
Which
Panel?
What
Energy?
Which
Paths?
Whats
Moving?
What
If?
What
Power
Flow?
What
DSA?
Powertrain Durability
1D and 3D Pretension Bolts
User-friendly definition
Flexible sequencing
Gasket Modeling
Highly nonlinear (nonlinear elastic +

plastic, hysteresis)
Elasto-plastic, elastic with damage, etc.
Leakage pressure
Temperature dependant
Plasticity
Kinematic and mixed hardening
Powertrain Durability
Contact solution for imperfect meshes
CLEARANCE and ADJUST options
Improved convergence of contact with friction
New friction model based on elastic slip distance
Non-symmetric solver
Specialized Expert System
PARAM,EXPERTNL,CNTSTB
Contact friendly elements
p2
KT
p1
ESL
Heat Transfer
Linear thermal solutions
Conduction, surface convection & heat

generation
Coupled thermal-structural analysis
Transient thermal, coupled transient thermalstructural
Heat transfer across CONTACTs
gap-dependent conductivity
pressure-dependent conductivity
k
Optimization for coupled thermal /
structural problems
Gap
Pressure
Topology
Free Size
Topography
Free Shape
Shape
Size
Design Fine
Tuning
Concept
Design
Optimization Disciplines
Overview of OptiStruct Functionality
Static with
Contact
Coupled thermomechanical
Topology
Normal Modes
Manufacturing
Constraints
Linear Buckling
Equivalent Static
Load Method
Frequency
Response
AMSES
AMLS Interface
Acoustic
Response
Direct & Iterative

Solvers
Random
Response
Design
Interpretation
Shape
Fatigue
Parallel
Processing
Topology Optimization
Determination of optimal
material distribution for a given
problem
Topology Optimization Density Method
Density = 1
Density = 0
E/E0
1
Finite element discretization of the design space
Function between density and elasticity using penalty factor p
/0
Weight reduced from 2kg to 1.5kg
500kg Weight Saving
Topology Manufacturing Constrains
Draw Direction
Extrusion
Symmetry
Pattern Repetition
Cyclic Repetition
No Hole Casting
Stamping
5 Repetitions
20 Repetitions
Without
Maximum
Size
WithMember
Pattern Repetition
Without
Pattern
Repetition
Without
Draw
Direction
Design
Space
No symmetry
XZ, YZ symmetry
Hollow section
No Symmetry
Min/Max Member Size
Material
Concentration
Eliminated
Without Extrusion
With Pattern Repetition
Without Pattern Repetition
YZ symmetry
XZ symmetry
WITH Maximum Member Size
With Draw Direction
Symmetry
Ribs
With Extrusion
10% material reduction for an

aluminium belt pulley
Geometry Recovery through OSSmooth
Iso-surface extraction and remeshing

PARASOLID, STEP, IGES, STL and H3D output formats
OSSmooth
Topography Optimization
Determination of optimal bead

patterns for shell structures
Topography Optimization on an Oil Pan
Initial Design
Altair OptiStruct
Design Problem:
Increase first mode from 60Hz to at
least 200Hz
Optimized Design
Door Inner Panel Design for Slamming Load
~ 19% Displacement Reduction
*Geo Metro Model from the NHTSA website
Stiffness improvement of the cover: +20%

Part consolidation and cost reduction: -30%
Free Size Optimization
Determination of
composite ply shape &
location
Design and Optimization of Composite Material

Composite Free-Size Optimization
What are the most efficient ply shapes?
Initial Design
Ply Slicing
Determines ply shapes
Final Design
Composite Shuffling
What is the exact stacking sequence to meet
manufacturing requirements?
Composite Size Optimization

How many plies of each ply shape to meet engineering targets?
Buckling factors improved by 10% & deflection improved

by more than 35% without increase in overall weight
Optimization of a Composite Sports Car Wing
Peak failure index reduced by 20%

Displacement constraint satisfied
Minimum reserve factor met
Shape Optimization
Determination of optimal shape of a

given design through user defined
shapes
Creating Shape Variables HyperMorph
Automatic mesh parameterization

Morphed shapes are used as design
variables in optimization
Mesh based, no CAD data needed
Easy creation of complex shapes
Seatbelt Retractor Bracket

-16%
-15%
-18%
-19%
Maximum
Stress:
Free Shape Optimization
Determination of optimal shape of a given

design through automatically generated
shapes
Free Shape Optimization NLSTAT
Analysis setup
interference fit
bolt pretension
contact with friction
bearing pressure load
Optimization setup
Design Constraints: Stresses
Objective: Minimize Volume
1-plane symm for DR1 and 2
Optimized Design
Weight : Unchanged
Stress Constraint Violation (~54%) : Eliminated
Improved Fatigue Life
Size Optimization
Determination of optimal
model parameters
Engine Mount Location Optimization
Optimization of 2 engine mount locations
Highly non-linear response
Use of super elements
Objective: Minimizing rough road shake at

drivers seat track
Best optimized acceleration response
Top four optimization results

This variation in results show the need for
a global search algorithm
OptiStruct 13.0 Highlights
Nonlinear Analysis
Large deformation for

solid assemblies
Hyperelastic material
laws
Contact
S2S
More results
Large strain plasticity for

solids
Nonlinear heat transfer
Domain decomposition
Nonlinear Analysis
Large Deformation for Solid Assemblies
Hyperelastic Material Laws
General Polynomial Material Law
W=
Cij ( I1 3) ( I 2 3)
N
i + j =1
N=1, j=0
N=1
N=3, j=0
j=0
i =1
1
2i
( J el 3)
Di
Neo-Hookean
Mooney-Rivlin
Yeoh
Reduced polynomial
Nonlinear Analysis
Domain Decomposition
OptiStruct 13.0 Performance on HP Cluster with Ivy Bridge
8000
7273
6469
7000
2 MPI x 10 OMP / Node
Elapsed(s)
6000
4 MPI x 5 OMP / Node
4588 4290
5000
4000
3151
2535
3000
1947 1831
2000
1492 1626
1000
0
1
20
2
40
4
80
16
160
320
#Nodes
# cores
4 MPI x 5 OpenMP per node deliver better performance at low number of nodes
2 MPI x 10 OpenMP per node deliver best performance at 16 nodes
Maximum speedup of 4.75 versus 1 node and a x37 compared to single core!
Heat Transfer and Durability Analysis
Heat Transfer
Temperature-dependant material properties (conductivity)
Durability
Soderberg method for mean stress correction (SN method)
Dang Van factor of safety for multi-axial fatigue
Noise and Vibrations
Frequency Dependant Materials
Direct and modal FRF
Poro-elastic (BIOT) Materials

Rotor Dynamics Analysis
Modal frequency response and

complex eigenvalue analyses
Synchronous and asynchronous

analyses
Output data generation for the

Campbell diagram (critical speeds)
Optimization
New Response Types
ERP (Equivalent Radiated Power)
SPCFORCE
GPFORCE
Dang Van Factor of Safety for Multi-axial Fatigue
Optimization
OptiStruct MS Excel Integration

LOADLIB DRESP3
DRESP3
+
+
+
+
+
20
DRESP1
DESVAR
CELLIN
CELLIN
CELLOUT
ELIB
FUNC
5
1
B3
C10
E10
dresp3_excel.xlsx
ELIB
6
MYFUNC
7
THRU
B6
Optimization using RADIOSS Input Data
Optimization
Multi Model Optimization
Single Model Optimization
Multi-Model Optimization
Our vision is to radically change

the way organizations design
products and make decisions.
James R. Scapa, Chairman & CEO, Altair

Altair Hyperworks: A Platform For Innovation: Warren Dias

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Altair HyperWorks: A Platform for Innovation

OptiStruct: Modern Solver Technology for Innovative and Lightweight

Industry-proven structural analysis solver for linear and nonlinear problems

Advanced analysis and optimization algorithms

lightweight and structurally efficient designs

Analyze and optimize strength,

durability and NVH performance

OptiStruct: Optimization Driven Design

Strength, Stiffness, Stability

Linear and Nonlinear Materials

Isotropic, Orthotropic, Anisotropic

Elasto-plastic with isotropic, kinematic and mixed hardening

Small (NLSTAT) and Large (LGDISP) Deformation Formulation

Contact elements (N2S and S2S)

Slide, Stick, Freeze, Friction

Strength, Stiffness, Stability

Temperature-dependant structural material properties

Gasket material supported

Preloading using Nonlinear Results

Frequency response analysis

Transient response analysis

Changing loads and boundary conditions

Noise and Vibration

Fully Featured NVH Solver

Modal and Direct FR and Transient Analysis

CMS Super Elements

Automatic Fluid-Structure Coupling

Complex Eigenvalue Analysis

Random Response Analysis

Acoustic Source (ACSRCE)

Modal, Panel, and Structural and Fluid Grid Participation in H3D

Interface to AMLS and FastFRS

Flex Body Generation

MotionSolve, AVL/EXCITE, ADAMS, SIMPACK, ROMAX and Vlab

Noise and Vibration

AMSES Eigenvalue Solver

Can calculate thousands of modes for millions of

Fast Large Scale Modal Solver (FASTFR)

Fast frequency response solution based on

Equivalent Radiated Power

Sound Pressure Level at Microphone Locations

Noise and Vibration

Automatic Result Filtering (PEAKOUT)

Automatic One Step Transfer Path Analysis (PFPATH)

NVH Problem Diagnostics

1D and 3D Pretension Bolts

Highly nonlinear (nonlinear elastic +

Elasto-plastic, elastic with damage, etc.

Kinematic and mixed hardening

Contact solution for imperfect meshes

CLEARANCE and ADJUST options

Improved convergence of contact with friction

New friction model based on elastic slip distance

Specialized Expert System

Contact friendly elements

Linear thermal solutions

Conduction, surface convection & heat

Coupled thermal-structural analysis

Transient thermal, coupled transient thermalstructural

Heat transfer across CONTACTs

Overview of OptiStruct Functionality

Direct & Iterative