OptiStruct 2017 Tutorials and Examples

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OptiStruct Tutorials and Examples
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Table of Contents
Verification Problems...................................................................................................................................... 3
Accessing the Model Files ........................................................................................................................... 4
Raasch Challenge - curved strip hook .......................................................................................................... 5
NAFEMS Test Problem (LE3) - Radial Point Load on a Hemisphere ............................................................... 7
NAFEMS Frequency Benchmarks ................................................................................................................. 9
Pin-ended Double Cross (Test No. FV2).................................................................................................... 9
Cantilever with Off-Center Point Masses (Test No. FV4) ........................................................................ 12
Deep Simply-Supported Beam (Test No. FV5) ........................................................................................ 14
Clamped Thin Rhombic Plate (Test No. FV15) ........................................................................................ 18
Clamped Thick Rhombic Plate (Test No. FV22) ....................................................................................... 20
Simply-Supported Solid Square Plate (Test No. FV52) ............................................................................ 24
MacNeal-Harder Test Problems................................................................................................................. 27
Straight Cantilever Beam ....................................................................................................................... 27
Curved Cantilever Beam ........................................................................................................................ 30
Twisted Cantilever Beam ....................................................................................................................... 32
Scordelis-Lo Roof................................................................................................................................... 34
Tutorials and Examples ................................................................................................................................. 36
Accessing the Model Files...................................................................................................................... 36
Basic Small Displacement Finite Element Analysis.................................................................................. 40
Advanced Small Displacement Finite Element Analysis ........................................................................ 176
Large Displacement Finite Element Analysis ........................................................................................ 398
Fluid-Structure Interaction Analysis ..................................................................................................... 430
Multi-body Dynamics Analysis ............................................................................................................. 445
Topology Optimization ........................................................................................................................ 513
Topography Optimization .................................................................................................................... 632
Combination Optimization .................................................................................................................. 663
Size Optimization ................................................................................................................................ 740
Shape Optimization ............................................................................................................................. 846
1 OptiStruct 2017 Tutorials Altair Engineering
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Examples................................................................................................................................................. 947
Example Problems for Structural Analysis ............................................................................................ 948
Example Problems for Topology Optimization ..................................................................................... 967
Example Problems for Topology Optimization Using Minimum Member Size Control .......................... 982
Example Problems for Topography Optimization ................................................................................. 987
Example Problems for Topography Optimization Using Pattern Grouping .......................................... 1005
Example Problems for Size Optimization ........................................................................................... 1033
Example Problems for Shape Optimization ........................................................................................ 1038
Example Problems for Optimization with ESLM ................................................................................. 1046
Altair Engineering OptiStruct 2017 Tutorials 2

Verification Problems
File Location The verification problems use model files that are located in the demos/
directory of the software installation. In the verification problems, file
paths are referenced as <install_directory>/../. In order to locate
the model files needed, you will need to determine the path of the
installation directory <install_directory>. This path is dependent on
the installation that was performed at your site. To determine what this
path is, follow these instructions:
1. Launch the application.
2. From the Help menu, select Updates.
3. The HyperWorks Update Information dialog opens. The
installation directory path appears after Altair Home:.
The OptiStruct verification problem model files are located in
<install_directory>/demos/hwsolvers/optistruct.
The following verification problems using OptiStruct can be found in this section:
Raasch Challenge - curved strip hook
NAFEMS Test Problem (LE3) - Radial Point Load on a Hemisphere
NAFEMS Frequency Benchmarks
MacNeal-Harder Test Problems

Accessing the Model Files
Required model files for the models you build in the tutorials are available online.
1. To access model files, visit Altair Connect or the Altair Client Center.
A user ID and password are required to access the model files. Follow the instructions at the
website to obtain login credentials.
2. Select the required file package and download it onto your system.
Note that the files may require unzipping before proceeding with the tutorials. When
extracting zipped files, preserve any directory structure included in the file package.

Raasch Challenge - curved strip hook
Summary
Raasch challenge is a curved strip hook problem with a tip in-plane shear load, posed in 1990 by
Ingo Raasch of BMW in Germany. The problem poses a significant challenge to shell elements
because of the inherent coupling between three modes of deformation: bending, extension, and
twist. OptiStruct is benchmarked against the Raasch challenge to assure its shell elements
performance on linear static analysis.
Benchmark Model
Three types of elements are used for linear static analysis of the Raasch's hook. They are tria-
shell, quad-shell, and hexa-solid elements. For each type of element, five different mesh
densities (1x9, 3x17, 5x34, 10x68, and 20x136) are used to investigate the convergence of the
solution. Two elements are used in the thickness direction for solid elements, thus, the mesh
densities become 1x9x2, 3x17x2, 5x34x2, 10x68x2, and 20x136x2. The target is the z-
directional displacement at point A, the upper end corner of the hook. The target value is 4.9366
inches.
Linear Static Analysis Results
All results are normalized with the target value.
Element
Type
1x9 3 x 17 5 x 34 10 x 68 20 x 136
CTRIA3 0.9191 0.9977 0.9906 0.9991 1.0086
CQUAD4 0.9792 1.0078 0.9968 1.0039 1.0116
CHEXA 0.5407 0.8966 0.9695 0.9893 1.0015

File Location
<install_directory>/demos/hwsolvers/optistruct/Rhex.fem
<install_directory>/demos/hwsolvers/optistruct/Rquad.fem
<install_directory>/demos/hwsolvers/optistruct/Rtri.fem
Reference
Knight, Jr. N. F., Raasch Challenge for Shell Elements, AIAA Journal, Vol. 35, No. 2, February
1997.

NAFEMS Test Problem (LE3) - Radial Point Load on a
Hemisphere
Summary
This is the NAFEMS test problem LE3. The model is a hemispherical shell subjected to
concentrated radial loads at its free edges. It examines the performance of the three-dimensional
shell to model local bending behavior under conditions where the deformations are primarily due
to bending.
Benchmark Model
4-node, first order CQUAD4 elements are benchmarked in LE3. The hemisphere is 10m in radius
and 0.04m in radial thickness. Two pairs of identical loads, 4000N, are applied at the free edge of
the hemisphere, and are at right angles to each other. One pair of the loads is directed inwards
(toward the center) of the hemisphere, while the second pair is directed outward from the center,
producing deformation of compression in one direction and elongation in another. Since both the
geometry and loads are symmetrical, only a quarter of the hemisphere is modeled. Symmetric
boundary constraints are applied on edges AE and CE. The z-translation at point E is fixed, and
all displacements on edge AC are free. The test also requires the mesh of the hemisphere to have
equally spaced nodes on edges AC, CE, EA, BG, DG, and FG. The target is x-translation at point
A, with a target value of 0.185m. The material properties for the hemisphere are: E = 68.25 GPa
and  = 0.3.

All results are normalized with the target values of x translation at point A.
Element Type Mesh Configuration nac x nce x nea
CQUAD4 4x4x4 8x8x8 16 x 16 x 16 32 x 32 x 32 64 x 64 x 64
0.9865 1.0200 1.0076 1.0032 1.0016

File Location
<install_directory>/demos/hwsolvers/optistruct/LE3.fem
Reference
NAFEMS Ltd, The Standard NAFEMS BENCHMARKS TNSB Rev. 3, NAFEMS Ltd, Scottish Enterprise
Technology Park, Whitworth Building, East Kilbride, Glasgow, United Kingdom, 1990.

NAFEMS Frequency Benchmarks
Pin-ended Double Cross (Test No. FV2)
Summary
Test No. FV2 is a pin-ended double cross, in-plane vibration problem. OptiStruct is used to
investigate the coupling between flexural and extensional behavior, as well as the repeated and
closed eigenvalues of the double cross in normal modes analysis.
Benchmark Model
The 2-node simple beam elements are used to model the double cross. Each arm of the cross
consists of four elements. The x- and y-translation displacements are fixed at the end of all arms.
The material properties for the cross beams are:
E = 200x109 N/m2 and = 8000 kg/m3

Modal Analysis Results
The frequency of each targeted mode is normalized with the closed form solution.
f* = closed form solution
Mode 1 Modes 2 and 3 Modes 4, 5, 6, 7 and 8
f* 11.336 Hz f* 17.709 Hz f* 17.709 Hz

CBAR 0.9984 CBAR 0.9958 CBAR 0.9974
Mode 9 Modes 10 and 11 Modes 12, 13, 14, 15 and

16
f* 45.345 Hz f* 57.390 Hz f* 57.390 Hz

CBAR 1.0000 CBAR 0.9944 CBAR 0.9999
File Location
<install_directory>/demos/hwsolvers/optistruct/fv2.fem

Reference

Cantilever with Off-Center Point Masses (Test No. FV4)
Summary
Test No. FV4 is a cantilever beam with off-center point masses. The problem is set up to test the
behavior of coupling between torsional and flexural, off-center inertial axis, and close
eigenvalues. OptiStruct is used in this normal modes analysis.
Benchmark Model
The 2-node simple beam elements are used to model the problem. The cantilever beam consists
of five elements. Two rigid elements are used to connect mass 1, 10000 kg, and mass 2, 1000
kg, at the end of the cantilever beam. All degrees of freedom at end A are constrained. The
material properties for the cantilever beam are:
E = 200x109 N/m2 and = 8000 kg/m3


Mode 1 Mode 2 Mode 3
f* 1.723 Hz f* 1.727 Hz f* 7.413 Hz

CBAR 1.0054 CBAR 1.0048 CBAR 1.008
f* 9.972 Hz f* 18.155 Hz f* 26.957 Hz

CBAR 1.0055 CBAR 1.0067 CBAR 1.0068
File Location
Reference

Deep Simply-Supported Beam (Test No. FV5)
Summary
Test No. FV5 is a simply-supported beam problem. OptiStruct tests the repeated eigenvalues,
shear deformation, and rotary inertia. The possibility of missing extensional modes is also
investigated.
Benchmark Model
The 2-node beam elements are used to model the simply-supported beam which consists of five
elements. The displacements in x, y, and z direction, as well as the rotation in x direction are
fixed at the end A. In addition, the displacements in y and z direction are constrained at end B.
The material properties for the beam are:
E = 200x109 N/m2, = 0.3 and = 8000 kg/m3

Modes 1 and 2 Mode 3 Mode 4

Flexural Torsional Extensional
f* 42.649 Hz f* 77.542 Hz F* 125.00 Hz

CBEAM 1.0124 CBEAM 0.9157 CBEAM 1.0000
Modes 5 and 6 Mode 7 Modes 8 and 9

Flexural Torsional Flexural
f* 148.31 Hz f* 233.10 Hz f* 284.55 Hz

CBEAM 1.0409 CBEAM 0.8840 CBEAM 1.0725
File Location
Reference

Free Thin Square Plate (Test No. FV12)
Summary
Test No. FV12 is a thin square plate model, which contains three rigid body modes. OptiStruct
investigates the repeated eigenvalues and kinematically incomplete suppressions of the thin plate
in normal modes analysis.
Benchmark Model
The 4-node quad elements with 8x8 mesh configuration are used to model the plate. The x-
translation, y-translation displacements and z-rotational displacements are fixed for all nodes.
The material properties for the thin plate are:
E = 200x109 N/m2, = 0.3 and = 8000 kg/m3

The frequency of each targeted mode is normalized with the closed form solution. The closed
form solution is not available for mode 10, use target value for H.O.E. instead.

F* 1.622 Hz f* 2.360 Hz f* 2.922 Hz

CQUAD4 0.9964 CQUAD4 1.0145 CQUAD4 1.0231
Mode 7 and 8 Mode 9 Mode 10
F* 4.233 Hz f* 7.416 Hz F[HOE] 7.392 Hz

File Location
Reference

Clamped Thin Rhombic Plate (Test No. FV15)
Summary
Test No. FV15 is a thin rhombic plate problem. The behavior of distorted thin elements in normal
modes analysis is examined using OptiStruct.
Benchmark Model
The 4-node quad elements with 12x12 mesh configuration are used to model the thin rhombic
plate. The x-translation, y-translation displacements, and z-rotational displacements are fixed for
all of the nodes. In addition, the z-translation, x-rotational and y-rotational are fixed for the
nodes along the four edges. The material properties for the rhombic plate are:
E = 200x109 N/m2, = 0.3 and = 8000 kg/m3

The frequency of each targeted mode is normalized with the closed form solution. If a closed
form solution is not available, the target values for H.O.E. are used instead. All benchmarked
results are normalized with target values.
F* 7.938 Hz f* 12.835 Hz f* 17.941 Hz


F* 19.133 Hz f* 24.009 Hz f* 27.922 Hz

File Location
Reference

Clamped Thick Rhombic Plate (Test No. FV22)
Summary
Test No. FV22 is a thick rhombic plate problem. The behavior of distorted, thick elements in
normal modes analysis is examined using OptiStruct.
Benchmark Model
The 4-node quad elements with 10x10 mesh configuration are used to model the thick rhombic
plate. The x-translation, y-translation displacements, and z-rotational displacements are fixed for
all of the nodes. In addition, the z-translation, x-rotational and y-rotational are fixed for the
nodes along the four edges. The material properties for the thick plate are:
E = 200x109 N/m2, = 0.3 and = 8000 kg/m3

The frequency of each targeted mode is normalized with the closed form solution. The closed
form solution is not available for mode 6, the target value for H.O.E. should be used instead.
F* 133.95 Hz f* 201.41 Hz f* 265.81 Hz


F* 283.68 Hz f* 334.45 Hz F[HOE] 386.62 Hz

File Location
Reference

Cantilevered Tapered Membrane (Test No. FV32)
Summary
Test No. FV32 is a tapered membrane problem with irregular mesh. The geometry and mesh
symmetry are maintained along the x-direction. The shear behavior of membrane elements in the
normal modes analysis is examined using OptiStruct.
Benchmark Model
The 4-node quad elements with 16x8 mesh configuration are used in test FV32. The
displacements in z direction are fixed on all nodes and the x- and y-translation displacements are
fixed for the nodes along the y-axis. The material properties for the membrane are:
E = 200x109 N/m2, = 0.3 and = 8000 kg/m3

f* 44.623 Hz f* 130.03 Hz f* 162.70 Hz


f* 246.05 Hz f* 379.90 Hz f* 391.44 Hz

File Location
Reference

Simply-Supported Solid Square Plate (Test No. FV52)
Summary
Test No. FV52 is a well-established solid square plate, which contains three rigid modes with the
given boundary condition. The test examines the performance of OptiStruct normal modes
analysis on 3D solid elements.
Benchmark Model
The HEXA 8-node and HEXA 20-node solid elements are used in test FV52. An 8x8x3 mesh
configuration is used for HEXA 8-node elements, and a 4x4x1 mesh configuration is used with
HEXA 20-node elements. The z-directional displacement is constrained at Z = -5m plane along
the four edges of the plate. The material properties for the solid plate are:
E = 200x109 N/m2, = 0.3 and = 8000 kg/m3


Mode 4 Modes 5 and 6 Mode 7
f* 45.897 Hz f* 109.44 Hz f* 167.89 Hz

HEXA20 0.9760 HEXA20 1.0101 HEXA20 1.0072
HEXA8 0.9874 HEXA8 1.0413 HEXA8 1.0322
Mode 8 Modes 9 and 10
f* 193.59 Hz f* 206.19 Hz
HEXA20 1.0017 HEXA20 1.0022
HEXA8 1.0164 HEXA8 1.0164
File Location
<install_directory>/demos/hwsolvers/optistruct/fv52_HOE.fem
<install_directory>/demos/hwsolvers/optistruct/fv52_LOE.fem

Reference

MacNeal-Harder Test Problems
Straight Cantilever Beam
Length = 6.0; Height = 0.2; Depth = 0.1; E = 1.0E7: Poisson's ratio = 0.3.
Summary
This is a straight cantilever beam solved with solid and shell elements. Three models
(rectangular, parallelogram, trapezoidal) are made with each element's type to investigate the
effect of distorted elements with a high aspect ratio.
Benchmark Model
Six types of elements are used for this problem. They are tria-shell, quad-shell, and hexa-solid
elements, each with 1st and 2nd order. Four loading cases are used for each model; extension,
in-plane bending, transverse bending, and twist. For the extension and bending load cases, unit
loads are applied in a consistent fashion over all of the nodes at the tip of the beam. For the twist
load cases, a unit moment is applied at the tip.
Theoretical solutions for the deflections at the tip, computed by beam theory, are as follows.
Load Type Component Value
extension UX 0.00003
in-plane bending UZ 0.1081
transverse bending UY 0.4321
twist ROTX 0.03208

(a) Rectangular
in-plane in-plane Transverse Twist

extension bending bending
QUAD4 1.000 0.992 0.981 0.941
QUAD8 1.006 1.000 1.016 0.953
TRI3 1.000 0.032 0.973 1.072

TRI6 1.006 0.994 1.001 0.950
HEX8 0.988 0.978 0.973 0.892

HEX20 1.008 0.992 0.992 0.905
(b) Parallelogram

QUAD4 1.000 0.712 0.981 0.905
QUAD8 1.008 0.999 1.015 0.937
TRI3 1.000 0.012 0.955 0.931

TRI6 1.005 0.962 0.995 0.982
HEX8 1.012 0.624 0.529 0.820

HEX20 1.008 0.976 0.977 0.905
(c) Trapezoidal

QUAD4 1.000 0.173 0.964 0.869
QUAD8 1.005 0.981 1.015 0.950
TRI3 1.000 0.019 0.965 1.175

TRI6 1.006 0.972 0.999 0.947
HEX8 1.010 0.047 0.030 0.563

HEX20 1.008 0.902 0.950 0.905
File Location
<install_directory>/demos/hwsolvers/optistruct/CBhex.fem
<install_directory>/demos/hwsolvers/optistruct/CBpent1.fem
<install_directory>/demos/hwsolvers/optistruct/CBpen2.fem
<install_directory>/demos/hwsolvers/optistruct/CBquad.fem
<install_directory>/demos/hwsolvers/optistruct/cbquad2.fem

<install_directory>/demos/hwsolvers/optistruct/CBtri1.fem
Reference
MacNeal, R.H., and Harder, R.L., A Proposed Standard Set of Problems to Test Finite Element
Accuracy, Finite Elements in Analysis and Design, 1 (1985) 3-20.

Curved Cantilever Beam
E = 1.0E7; Poisson's ratio = 0.25; Loading; unit force at tip.
Summary
This is a curved cantilever beam solved with solid and shell elements. A model is made with each
element's type to investigate the effect of distorted elements with a high aspect ratio.
Benchmark Model
elements, each with 1st and 2nd order. Two loading cases are used for each model; in-plane
bending, transverse bending. For both load cases, unit loads are applied in a consistent fashion
over all of the nodes at the tip of the beam.
in-plane bending UY 0.08734
transverse bending UZ 0.5022

In-plane Transverse Bending

Bending
QUAD4 0.952 0.955
QUAD8 1.015 0.984
TRI3 0.025 0.950
TRI6 1.005 0.961
HEX8 0.880 0.820
HEX20 1.009 0.946
File Location
Reference

Twisted Cantilever Beam
Length = 12.0; Width = 1.1; Depth = 0.32; E = 29.0E6; Poisson’s ratio = 0.22; Loading = unit forces at tip.
Summary
This is a twisted cantilever beam solved with solid and shell elements. A model is made with each
element's type to investigate the effect of distorted elements with a high aspect ratio.
Benchmark Model
elements, each with 1st and 2nd order. Two loading cases are used for each model; in-plane
bending, transverse bending. For both load cases, unit loads are applied in a consistent fashion
over all of the nodes at the tip of the beam.
in-plane bending UY 0.001754
transverse bending UZ 0.005424

In-plane Bending Transverse Bending
QUAD4 0.988 0.992
QUAD8 1.014 1.062
TRI3 0.839 0.984
TRI6 1.161 1.215
HEX8 0.986 1.005
HEX20 1.017 1.052
File Location
Reference

Scordelis-Lo Roof
R = 25.0; Length = 50.0, t = 0.25; E = 4.32E8; Poisson's ratio = 0.0; Ux = Uz = 0 on curved edge.
Summary
The Scordelis-Lo Roof is a classical benchmark problem for shell elements. Analytical and
experimental investigations were initially performed by Scordelis and Lo.
Benchmark Model
The roof structure is supported on both ends, and loaded by self weight of 90 pounds per square
foot, with only one quadrant modeled. Six types of elements are used for this problem. They are
tria-shell, quad-shell, and hexa-solid elements, each with 1st and 2nd order. Each element type
was benchmarked with different mesh density to check the convergence. As the original study
was related to concrete structure, Poisson's ratio is set to zero. The structure is curved and its
solution will exhibit membrane and bending behavior. Target solution for the vertical deflection at
the midpoint of the free edge is 0.3024.

Number of Nodes - space per sides
2 4 6 8 10
QUAD4 1.487 1.082 1.035 1.020 1.013
QUAD8 1.436 1.179 1.139 1.116 1.102
TRI3 1.169 0.753 0.829 0.886 0.920

TRI6 1.326 1.107 1.077 1.063 1.055
HEX8 0.142 0.550 0.868 0.951 1.000

HEX20 1.071 1.052 1.046 1.045 1.043
File Location
Reference

Tutorials and Examples
Accessing the Model Files

Required model files for the models you build in the tutorials are available online.
1. To access model files, visit Altair Connect or the Altair Client Center.
A user ID and password are required to access the model files. Follow the instructions at the
website to obtain login credentials.
2. Select the required file package and download it onto your system.
Note that the files may require unzipping before proceeding with the tutorials. When
extracting zipped files, preserve any directory structure included in the file package.

Introductory Tutorials
OS-0010: Running OptiStruct from HyperMesh

This tutorial demonstrates how to launch an OptiStruct job from within HyperMesh. A HyperMesh
database containing a fully defined OptiStruct finite element model is retrieved and an OptiStruct
job is launched from the OptiStruct panel in HyperMesh.
Exercise
Step 1: Load the User Profile

1. Launch HyperMesh. The User Profiles dialog appears upon start-up by default.
2. If the User Profiles dialog is not visible, select Preferences from the toolbar and choose User
Profiles.
3. Under Application:, select the OptiStruct radio button.
4. Click OK.
This loads the appropriate user profile. It includes the appropriate template, macro menu, and
import reader. It simplifies the menu systems to give access to only the functionality of
HyperMesh that is necessary.
Step 2: Retrieve the HyperMesh database

1. Click File > Open. An Open file browser window opens.
2. Select the plate.hm file you saved to your working directory from the optistruct.zip file.
Refer to Accessing the Model Files.
3. Click Open. The plate.hm database is loaded into the current HyperMesh session, replacing
any existing data.
Step 3: Launch the OptiStruct job

1. Choose the Analysis page and select the OptiStruct panel.
You can also choose OptiStruct from the Applications menu on the toolbar.
2. Click save as. A Save file browser window opens.
3. Select the directory where you would like to write the model file and enter the file name,
plate.fem, in the File name: field. For OptiStruct input decks .fem is the suggested
extension.
4. Click Save.
The name and location of the plate.fem file displays in the input file: field.
5. Set the memory toggle, located in the center of the panel, to memory default.
6. Set the run options toggle, located on the left side of the panel, to analysis.
7. Set the export options: toggle, underneath the run options switch, to all.

8. Click OptiStruct. This exports the input file and launches the job.
If the job is successful, new results files can be seen in the directory where the model file was
written. The plate.out file is a good place to look for error messages that will help to debug
the input deck if any errors are present.
The default files written to your directory are:
plate.html HTML report of the analysis, giving a summary of the problem

formulation and the analysis results.
plate.out ASCII output file containing specific information on the file set up, the
set up of your optimization problem, estimate for the amount of RAM
and disk space required for the run, information for each optimization
iteration, and compute time information. Review this file for warnings
and errors.
plate.res HyperMesh binary results file.
plate.stat Summary of analysis process, providing CPU information for each step
during analysis process.
plate.h3d HyperView binary result file.
Step 4: Post-process the OptiStruct job
While still in HyperMesh, launch HyperView after the job has finished from the OptiStruct panel
by clicking HyperView. HyperView opens and automatically loads the H3D file from the
OptiStruct job for post-processing.

OS-0020: Running OptiStruct at the Command Line
The tutorial Running OptiStruct from HyperMesh demonstrates how OptiStruct could be launched
from within HyperMesh. OptiStruct also can be run at the command line (UNIX or MSDOS). This
tutorial assumes you already have the running file, plate.fem, in either your UNIX or MSDOS
directory. This tutorial also assumes you know the location of the solver script.
In this tutorial, $HWSDIR describes the directory containing the OptiStruct executable. On UNIX
machines, the script is normally located in the HyperWorks installation directory under
<install_directory>/scripts/. On Windows, it is normally located in the HyperWorks
installation directory under <install_directory>/hwsolvers/scripts/.
Running OptiStruct from the Command Line (UNIX or MSDOS).
To run OptiStruct from the command prompt, enter:
$HWSDIR/<solver_name> plate.fem
To check the current version of OptiStruct at the command prompt, enter:

$HWSDIR/<solver_name> -version
To execute a check run to validate your input deck and determine how much RAM and
disk space is necessary for the run, at the command prompt, enter:
$HWSDIR/<solver_name> plate.fem -check
Information regarding memory requirements is written to the file plate.out.
See the Running OptiStruct section of the OptiStruct User's Guide for more detailed information.

Basic Small Displacement Finite Element Analysis
OS-1000: Linear Static Analysis of a Plate with a Hole

This tutorial demonstrates the creation of finite elements on a given CAD geometry of a plate
with a hole. Further, application of boundary conditions and a finite element analysis of the
problem are explained. Post-processing tools are used in HyperView to determine deformation
and stress characteristics of the loaded plate.
The following exercises are included:
 Setting up the problem in HyperMesh
 Applying Loads and Boundary Conditions
 Submitting the job
 Viewing the results
Exercise
Step 1: Launch HyperMesh and set the OptiStruct User Profile

1. Launch HyperMesh. The User Profiles dialog appears.
2. Select OptiStruct and click OK. This loads the user profile. It includes the appropriate
template, macro menu, and import reader, paring down the functionality of HyperMesh to
what is relevant for generating models for OptiStruct.
Step 2: Open the File plate_hole.hm

1. Click File > Open. An Open Model browser window opens.
Note: If HyperMesh Desktop was launched, use: File > Open >
Model.
2. Select the plate_hole.hm file you saved to your working directory from the optistruct.zip
file. Refer to Accessing the Model Files.
3. Click Open. The plate_hole.hm database is loaded into the current HyperMesh session,
replacing any existing data. The database only contains geometric data.
Set up the Problem in HyperMesh
When building models, it is encouraged to create the material and property collectors before
creating the component collectors. This is the most efficient way of setting up the file since
components need to reference materials and properties.
Step 3: Create the material

1. In the Model browser, right-click and select Create > Material. A default MAT1 material
displays in the Entity Editor.

2. For Name, enter steel. Similarly, enter the material values next to the corresponding fields,
as shown in Figure 1.
Figure 1: Material property values for steel
If a material property does not display a value next to it, it is turned off. To edit these
material properties, click in the blank Value fields next to them and enter the required
values.
A new material, steel, has been created. The material uses OptiStruct's linear isotropic
material model, MAT1. For E (Young's Modulus), enter 2E+05 and for NU (Poisson's Ratio),
enter 0.3. It is not necessary to define a density value since only a static analysis is
performed. Density values may be required, however, for other solution sequences.
At any time, the card image for this collector can be modified by clicking on steel in the
Model browser or by using the Card Editor .
Step 4: Create the Properties and update the Component Collector

1. In the Model browser, right-click and select Create > Property. A default PSHELL property
2. For Name, enter plate_hole.
3. For Material, click Unspecified > Material.
4. In the Select Material dialog, select steel and click OK.

Figure 2: Selecting the material steel for the property plate_hole
5. For T (thickness of the plate), enter 10.0, as shown in Figure 3.
Figure 3: Property values for plate_hole
If a property field does not display a value next to it, it is turned off. To edit these properties,
click on the blank Value fields next to them and enter the required values.
A new property, plate_hole, has been created as a 2D PSHELL. Material information is also
linked to this property.
6. In the Model browser, click on the component plate_hole. The component fields are
displayed in the Entity Editor below.
7. For Property, click Unspecified > Property.

8. In the Select Property dialog, select the plate_hole property and click OK.
The component plate_hole has been updated with a property of the same name and is
currently the “Current Component” (see the box in the lower right for plate_hole). This
component uses the plate_hole property definition with a thickness value of 10.0. The
material steel is referenced by this component.
At any time, the card image for this collector can be modified by clicking on plate_hole in the
Model browser or by using the Card Editor and the material referenced by this component
collector can be changed using the update option in the Collectors panel.
Figure 4: Selecting the property plate_hole for the component plate_hole
Apply Loads and Boundary Conditions to the Model
In the following steps, the model is constrained so that two opposing edges of the four external
edges cannot move. The other two edges remain unconstrained. A total load of 1000N is applied
at the edge of the hole in the positive z-direction.
Step 5: Create load collectors (spcs and forces)

1. In the Model browser, right-click and select Create > Load Collector. A default load collector
2. For Name, enter spcs.
3. Click on the default Color and select a color from the color palette.

Figure 5: Creating the spcs Load Collector
4. A new load collector, spcs is created, as shown in Figure 6.
Figure 6: New load collector "spcs" is created in the Model browser
5. Create another load collector named forces using steps 5.1 to 5.3.

Step 6: Create constraints
1. From the Model browser, expand Load Collector, right-click on spcs and click Make
Current to set spcs as the current load collector.
Figure 7: Setting spcs as the current load collector
2. Click BCs > Create > Constraints to open the Constraints panel, as shown in Figure 8.
Figure 8: Accessing the Constraints panel

3. Make sure nodes is selected from the entity selection switch.
Figure 9: Menu after clicking on the entity selection switch
4. Use Shift + Left Click + Hold to select the nodes, as shown in Figure 10.
Figure 10: Nodes to be selected for the constraints
5. Constrain dof1, dof2, dof3, dof4, dof5, and dof6 and set all of them to a value of 0.0, as
shown in Figure 11.
Dofs with a check are constrained, while dofs without a check are free.
Dofs 1, 2, and 3 are x, y, and z translation degrees of freedom.
Dofs 4, 5, and 6 are x, y, and z rotational degrees of freedom.

Figure 11: Constraining all Degrees of Freedom of the selected nodes.
6. Click create. This applies the constraints to the selected nodes.

7. Click return to go to the main menu.
Step 7: Create forces on the nodes around the hole

1. In the Model browser, set your current load collector to forces, following Step 6.1 above.
2. Click BCs > Create > Forces to open the Forces panel.
3. Use SHIFT + Left Click + Hold and release the mouse button at the same location to get a
small window with options to select the shape of the selection window. Select Circle Interior
as shown in Figure 12.
Figure 12: Choosing a circular (Inside of Circle) selection window.
4. Use SHIFT + Left Click + Hold to select the nodes shown in Figure 13 using the circular
selection window.

Figure 13: Nodes selected for the application of loads around the hole
5. Set the coordinate system toggle to global system, as shown in Figure 14.
6. Click the vector definition switch and select constant vector.
7. Click magnitude = and enter 21.277 (that is 1000 divided by the number of nodes 47).
8. Click the direction definition switch below magnitude =, and select z-axis from the pop-
up menu.
Figure 14: Assigning direction and magnitude to the forces.

9. Click create. This creates a number of point forces, with the given magnitude in the z-
direction, to be applied to the nodes about the hole.
Step 8: Create an OptiStruct subcase (also referred to as a loadstep)

1. In the Model browser, right-click and select Create > Load Step. A default load step displays
in the Entity Editor.
2. For Name, enter lateral forces.
3. Click on the drop-down menu in the Value field next to Analysis type in the Entity Editor
and select Linear Static.
4. For SPC, click Unspecified > Loadcol.
5. In the Select Loadcol dialog, select spcs and click OK.
Figure 15: Selecting the Load Step spcs
6. For LOAD, click Unspecified > Loadcol.

7. In the Select Loadcol dialog, select forces and click OK. An OptiStruct subcase has been
created which references the constraints in the load collector spcs and the forces in the load
collector forces.

Figure 16: Creating the lateral forces loadstep
Step 9: Submitting the job

1. From the Analysis page, enter the OptiStruct panel.
Figure 17: Accessing the OptiStruct panel
2. Click save as following the input file: field. A Save file browser window opens.
3. Select the directory where you would like to write the OptiStruct model file and enter the
name for the model, plate_hole.fem, in the File name: field. For OptiStruct input decks
.fem is the recommended extension.
4. Click Save.
The name and location of the plate_hole.fem file displays in the input file: field.
5. Set the export options: toggle to all.

6. Set the run options: toggle to analysis.
7. Set the memory options: toggle to memory default.
Figure 18: Fields in the OptiStruct panel
8. Click OptiStruct. This launches the OptiStruct job.

If the job is successful, the new results files should be in the directory from which
plate_hole.fem was selected. The plate_hole.out file is a good place to look for error
messages that could help debug the input deck if any errors are present.
The default files written to the directory are:
plate_hole.html HTML report of the analysis, providing a summary of the problem

plate_hole.out OptiStruct output file containing specific information on the file setup,
the setup of your optimization problem, estimates for the amount of
RAM and disk space required for the run, information for each of the
optimization iterations, and compute time information. Review this file
for warnings and errors.
plate_hole.h3d HyperView binary results file.
plate_hole.res HyperMesh binary results file.
plate_hole.stat Summary, providing CPU information for each step during analysis
process.
Viewing the Results
Displacement and Stress results for linear static analyses are output from OptiStruct by default.
The following steps describe how to view those results in HyperView.
HyperView is a complete post-processing and visualization environment for finite element
analysis (FEA), multi-body system simulation, video and engineering data.
Step 10: View a contour plot of stresses

1. When the message 'ANALYSIS COMPLETED' is received in the HyperWorks Solver View
window, click Results. HyperView is launched and the results are loaded.

Figure 19: The HyperWorks Solver View window
2. Click the Contour toolbar icon .

3. Select the first pull-down menu below Result type: and select Element Stresses (2D &
3D) (t).
4. Select the second pull-down menu below Result type: and select vonMises.
5. Select None in the field below Averaging method:.
Figure 20: The Contour panel

6. Verify that the fields in the Contour panel match those in Figure 21 and click Apply.
A contoured image representing von Mises stresses should be visible. Each element in the
model is assigned a legend color, indicating the von Mises stress value for that element,
resulting from the applied loads and boundary conditions.
7. Click the XY Top Plane View icon in the View Controls toolbar at the top center to view the
model, as shown in Figure 21.
Figure 21: The vonMises Stress plot for the given subcase
At this stage, you can try to answer the following questions to test the understanding of the
current problem.
 What is the maximum von Mises stress value?
 At what location does the model have its maximum stress?
 Does this make sense based on the boundary conditions applied to the model?
Step 11: View a contour plot of displacements

1. Select the first pull-down menu below Result type: and select Displacement (v).
2. Select the second pull-down menu below Result type: and select Mag.
3. Click Apply.
The resulting contours represent the displacement field resulting from the applied loads and
boundary conditions. Answer the following questions:
 What is the maximum Displacement value?
 At what location does the model have its maximum displacement?

Step 12: View the deformed shape
1. Click the Isometric View icon in the view controls toolbar (Top center) to display the
isometric view of the model.
2. Click the Deformed toolbar icon .
3. Set Result type: to Displacement(v), Scale: to Scale factor; and Type: to Uniform.
4. In the field next to Value, enter 500. This means that the displacement results of the analysis
is multiplied by 500.
5. For Show:, select Wireframe.
6. Click Apply. A deformed plot of the model with the displacement contour should be visible,
overlaid on the original undeformed mesh in isometric view (see Figure 22).
Figure 22: Isometric view of the deformed plot overlaid on the undeformed mesh (model units is set to 500)

OS-1010: Thermal Stress Analysis of a Coffee Pot Lid
In this tutorial, an existing finite element model of a plastic coffee pot lid demonstrates how to
apply constraints and perform an OptiStruct finite element analysis. HyperView post-processing
tools are used to determine deformation and stress characteristics of the lid.
 Retrieve the HyperMesh database file
 Set up the problem in HyperMesh
 Apply loads and boundary conditions to the model
 Submit the job
 View the results in HyperView
Retrieve the HyperMesh Database File

2. Select OptiStruct and click OK. This loads the user profile. These profiles include the
appropriate template, macro menu, and import reader, paring down the functionality of
HyperMesh to what is relevant for generating models for OptiStruct.
The User Profiles dialog can also be accessed from the Preferences menu on the toolbar.
Step 2: Open the File coffee_lid.hm

Model.
2. Select the coffee_lid.hm file you saved to your working directory from the optistruct.zip
3. Click Open.
The coffee_lid.hm database is loaded into the current HyperMesh session, replacing any
existing data. The database only contains geometric data.
Set up the Problem in HyperMesh
When building models, it is encouraged to create the material and property collectors before
creating the component collectors. This is the most efficient way of setting up the file since
components need to reference properties and materials.

Step 3: Create the material
The imported model has two component collectors with no materials. A material collector needs
to be created and assigned to the component collectors.
1. Click the Model tab.
2. Within the Model browser, right-click and select Create > Material. A default MAT1 material
template displays in the Entity Editor below the Model browser.
3. For Name, enter plastic.
4. Similarly, input the material values next to the corresponding fields as shown in Figure 1.
Click ENTER after inputting the values. A new material, plastic, has been created.
material properties, click on the blank Value fields next to them and enter the required
values.
The material uses OptiStruct linear isotropic material model, MAT1. For E (Young's Modulus),
enter 1137; for NU, (Poisson's Ratio), enter 0.26; and for A (coefficient of linear thermal
expansion), enter 81x10-6. It is not necessary to define a density value since only a static
analysis is performed. Density values may be required, however, for other solution
sequences.
At any time, the card image for this collector can be modified by clicking on plastic in the
Figure 1: Material property values for “plastic”

Step 4: Edit the properties and update the component collector
1. Expand the Property folder in the Model browser and click on PSHELL. The PSHELL property
entry is displayed in the Entity Editor.
2. Verify that the thickness value, T, is set to 2.5.
3. Notice that the Value field next to Material is set to <Unspecified>. This indicates that no
material properties are being referenced by this property.
Figure 2: Selecting the Material plastic for the property PSHELL

5. In the Select Material dialog, select plastic and click OK. The material, plastic is now
assigned to the property PSHELL.
Figure 3: The PSHELL property entry fields in the Entity Editor
6. Repeat steps 4.1 to 4.5 to update the property PSHELL1 and assign the material plastic to
it.
The property collectors and component collectors, PSHELL and PSHELL1, now reference the
material plastic. The component collectors that reference the corresponding properties are
automatically updated with the specified material. If you access the Entity Editor and edit
either of these property or component collectors, notice that the Material fields are now all set
to plastic(1).
Apply Loads and Boundary Conditions to the Model
Thermal loading has already been applied to the model. In the following steps, constraints will be
applied to the model.
Step 5: Create a load collector

template displays in the Entity Editor.
2. For Name, enter constraints.
3. Click on the default Color and select a color from the color palette. A new load collector,
constraints is created.

Figure 4: Creating the constraints Load Collector
Step 6: Create constraints at the corners of the spout cut-out

1. Click BCs > Create > Constraints to open the Constraints panel.
2. Click the entity selection switch and select nodes from the menu.
3. Select the two nodes, shown in the following figure, at the corners of the spout cut-out, by
clicking on them in the graphics area.
Figure 5: Selecting nodes for constraints at corners of spout cut-out
4. Constrain only dof3.

 DOFs with a check will be constrained while dofs without a check will be free.
 DOFs 1, 2, and 3 are x, y, and z translation degrees of freedom.
 DOFs 4, 5, and 6 are x, y, and z rotational degrees of freedom.
5. Select create. Two constraints are created. Constraint symbols (triangles) appear in the
graphics area at the selected nodes. The number 3 is written beside the constraint symbol,
indicating the dof constrained.

6. In the size field, enter 1.0. Note how the size of the constraint symbols in the graphics area
changes.
Step 7: Create constraints opposite the spout cut-out to simulate two

hinges
1. Click Geometry > Create > Nodes > XYZ to open the Nodes: XYZ panel.
2. For x =, enter the value 0.0.
3. For y =, enter the value -10.0.
4. For z =, enter the value 0.0.
5. Click create. A node is created with the coordinates (0, -10, 0). This indicates the
centerline of the coffee lid.
8. Select the nodes in the following figure, by clicking on them in the graphics area.
Figure 6: Creating constraints opposite the spout cut-out to model hinges.
9. Constrain only dof1, dof2, and dof3.

10. Click create. This creates four more constraints. Again, this is verified by the appearance of
constraint symbols in the graphics area.
12. From the Geom page, select the temp nodes panel.
13. Click clear all. This removes the temporary node that was created at (0, -10, 0).
14. Click return.

Step 8: Create an OptiStruct subcase (also referred to as a loadstep)
1. In the Model browser, right-click and select Create > Load Step. A default load step
template is now displayed in the Entity Editor.
2. For Name, enter brew cycle.
3. Expand Analysis type and select Linear Static.
Figure 7: Selecting the constraints
5. In the Select Loadcol dialog, select constraints and click OK.

6. For TEMP, click Unspecified > Loadcol.
7. In the Select Loadcol dialog, select THERMAL_LOADING and click OK.
An OptiStruct subcase has been created which references the constraints in the load collector
constraints and the forces in the load collector THERMAL_LOADING.

Figure 8: Creating the brew cycle loadstep
Submit the Job
Step 9: Run the Analysis

2. Click save as. A Save As browser window opens.
name for the model, lid_complete.fem, in the File name: field. The .fem filename extension
is the suggested extension for OptiStruct input decks.
4. Click Save.
The name and location of the lid_complete.fem file displays in the input file: field.
If the job is successful, new results files can be seen in the directory where the OptiStruct
model file was written. The lid_complete.out file is a good place to look for error messages
that will help to debug the input deck if any errors are present.

lid_complete.html HTML report of the analysis, giving a summary of the problem

lid_complete.out OptiStruct output file containing specific information on the file set
up, the set up of your optimization problem, estimates for the
amount of RAM and disk space required for the run, and compute
time information. Review this file for warnings and errors.
lid_complete.h3d HyperView binary results file.
lid_complete.res HyperMesh binary results file.
lid_complete.stat Summary of analysis process, providing CPU information for each

step during analysis process.
View the Results
Displacement and Stress results are output from OptiStruct for linear static analyses by default.
The following steps describe how to view those results in HyperView.
Step 10: View the deformed shape

2. Click the Wireframe Elements icon on the toolbar.
3. Set the Animation Mode to Linear .
4. Select the Deformed panel toolbar icon .

5. Set Result type: to Displacement (v).
6. Set Scale: to Model units and enter a value of 2.
This means that the maximum displacement will be two model units and all other
displacements will be proportional.
7. Set the toggle under Undeformed Shape to Wireframe, and select Color as the
Component.
8. Click Apply. A deformed plot of the model should be visible, overlaid on the original
undeformed mesh. Refer to the following figure to see what the plot should look like in
isometric view.
Does the deformed shape look correct for the boundary conditions applied to the mesh?

Figure 9: Isometric view of deformed plot overlaid on original undeformed mesh with model units set to 2.
Step 11: View a contour plot of stresses and displacements

1. Select the Contour panel toolbar icon .
2. For Result type:, select Displacement (v).
3. For data type, select Mag which represents the magnitude of the displacements.
4. Click Apply. A contoured image of your model should be visible. The contours represent the
displacement field resulting from the applied loads and boundary conditions.
 What is the maximum displacement value?
 At what location does the model have its maximum displacement?
5. For Result type:, select Element Stresses (2D & 3D).
6. For data type, select vonMises.
7. Click Apply. Each element in the model is assigned a legend color, indicating the von Mises
stress value for that element, resulting from the applied loads and boundary conditions.
 What is the maximum von Mises stress value?
 At what location does the model have its maximum stress?
8. Click File > Exit to leave HyperView.

Step 12: Review the following points
Representation of the hinge opposite of the spout cut-out:
In this analysis, the region around the hinges may be a concern. There are relatively high stress
values that must be resolved. For instance, if testing shows that the coffee pot lid wears out
around the hinge area over time, these thermal stresses could possibly cause that fatigue.

OS-1020: Normal Modes Analysis of a Splash Shield
In this tutorial, an existing finite element model of an automotive splash shield is used to
demonstrate how to set up and perform a normal modes analysis. HyperMesh post-processing
tools are used to determine mode shapes of the model.
 Retrieving the OptiStruct input file
 Setting up the model in HyperMesh
 Applying Loads and Boundary Conditions to the Model
The sshield.fem file is needed to perform this tutorial.
Exercise

Step 2: Import a Finite Element Model File in HyperMesh

1. Click File > Import > Solver Deck. An Import tab is added to your tab menu.
2. For the File type:, select OptiStruct.
3. Select the Files icon . A Select OptiStruct file browser opens.

4. Select the sshield.fem file you saved to your working directory from the optistruct.zip
5. Click Open.
6. Click Import, then click Close to close the Import tab.
Step 3: Review Rigid Elements

Notice there are two rigid "spiders" in the model. To be able to distinguish the spiders clearly in
the model, click the Shaded Elements and Mesh Lines icon . They are placed at locations
where the shield is bolted down. This is a simplified representation of the interaction between the
bolts and the shield. It is assumed that the bolts are significantly more rigid in comparison to the
shield.
The dependent nodes of the rigid elements have all six degrees of freedom constrained.
Therefore, each "spider" connects nodes of the shell mesh together in such a way that they do
not move with respect to one another. Revert to the Wireframe Elements Skin Only mode by
clicking on the icon.

The following steps show how to review the properties of the rigid elements.
1. Click Mesh > Edit > 1D Elements > Rigids to open the Rigids panel.
2. Click review.
3. Select one of the rigid elements in the graphics region.
In the graphics area, HyperMesh displays the IDs of the rigid element and the two end nodes
and indicates the independent node with an 'I' and the dependent node with a 'D'. HyperMesh
also indicates the constrained degrees of freedom for the selected element, through the dof
check boxes in the Rigids panel. All rigid elements in this model should have all dofs
constrained.
Step 4: Setting up the Material and Geometric Properties

The imported model has four component collectors with no materials. A material collector needs
to be created and assigned to the shell component collectors. The rigid elements do not need to
be assigned a material. Shell thickness values also need to be corrected.
2. For Name, enter steel.
3. Similarly, input the material values next to the corresponding fields as shown in Figure 1.
Click ENTER after inputting the values. A new material, steel, has been created.
The material uses OptiStruct linear isotropic material model, MAT1. For E (Young's Modulus),
enter 2E+05; for NU (Poisson's Ratio), enter 0.3 and for RHO (material density), enter 7.85E-
09. A material density is required for the normal modes solution sequence.
material properties, click on the blank Value fields next to them and enter the required
values.
At any time, the card image for this collector can be modified by clicking on steel in the

Figure 1: Material property values for steel
4. In the Model browser, click on the property design to display the property entry in the Entity
Editor. Change the thickness value (T) from 0.3 to 0.25 as shown in Figure 2.
5. Click on the field next to the Material field and then click on the Material selector.
6. In the Select Material dialog, select the newly created steel material and click OK. This
changes the material from gn to steel on the property design.
7. Similarly, on the property nondesign, update the thickness value (T) from 0.3 to 0.25 and
change the material from gn to steel.
Figure 2: Updating the thickness value for design and nondesign property entries

Applying Loads and Boundary Conditions to the Model (Steps 5 - 7)
The model is to be constrained using SPCs at the bolt locations, as shown in the following figure.
The constraints are organized into the load collector 'constraints'.
To perform a normal modes analysis, a real eigenvalue extraction (EIGRL) card needs to be
referenced in the subcase. The real eigenvalue extraction card is defined in HyperMesh as a load
collector with an EIGRL card image. This load collector should not contain any other loads.
Step 5: Create EIGRL card (to request the number of modes)

In the following steps, the model is constrained so that two opposing edges of the four external
edges cannot move. The other two edges remain unconstrained. A total load of 1000N is applied
at the edge of the hole in the positive z-direction.
2. For Name, enter EIGRL.
3. For Card Image, select EIGRL.
Figure 3: Selecting the card image
4. Click Color and select a new color from the color palette.
5. For V2, enter the value 200.000.
6. For ND, enter the value 6.

Figure 4: A new load collector "EIGRL" is created in the Model browser
Step 6: Create Constraints at Bolt Locations

1. Create another load collector, named constraints.
Figure 5: Selecting nodes for constraining the bolt locations

3. Select the two nodes, shown in the figure above, at the center of the rigid spiders, by clicking
on them in the graphics area.
4. Constrain all dofs with a value of 0.0.
5. Click load types= and select SPC.
6. Click create. Two constraints are created. Constraint symbols (triangles) appear in the
graphics area at the selected nodes. The number 123456 is written beside the constraint
symbol, if the label constraints is checked ‘ON’, indicating that all dofs are constrained.
7. Click return.
Step 7: Create a Load Step to perform Normal Modes Analysis

template is now displayed in the Entity Editor.
2. For Name, enter bolted.
3. Click on the drop-down menu for Analysis type and select Normal modes.
5. In the Select Loadcol dialog, select constraints and click OK.
6. For METHOD(STRUCT), click Unspecified > Loadcol.
7. In the Select Loadcol dialog, select EIGRL and click OK. An OptiStruct subcase has been
created which references the constraints in the load collector constraints and the real
eigenvalue extraction data in the load collector EIGRL.

Figure 6: Loadstep is created
Submitting the Job
Step 8: Save the database

1. Click File > Save As to open the Save Model As browser window.
Note: In HyperMesh Desktop, click File > Save As > Model to

save the .hm file.
2. Use the browser to select set the directory in which you want to save the file.
3. For the File name:, enter sshield_complete.hm.
4. Click Save.
Step 9: Running Normal Modes Analysis

1. From the Analysis page, click OptiStruct.

3. Select the directory where you would like to write the file and, in File name:, enter
sshield_complete.fem.
4. Click Save.
The name and location of the sshield_complete.fem file displays in the input file: field.
If the job was successful, new results files can be seen in the directory where the OptiStruct
model file was written. The sshield_complete.out file is a good place to look for error
messages that will help to debug the input deck if any errors are present.
sshield_complete.html HTML report of the analysis, giving a summary of the

problem formulation and the analysis results.
sshield_complete.out OptiStruct output file containing specific information on the

file set up, the set up of your optimization problem,
estimates for the amount of RAM and disk space required
for the run, information for each of the optimization
iterations, and compute time information. Review this file
sshield_complete.h3d Hyper 3D binary results file.
sshield_complete.stat Summary of analysis process, providing CPU information for

each step during analysis process.
Review the Results using HyperView
Eigenvector results are output by default, from OptiStruct for a normal modes analysis. This
section describes how to view the results in HyperView.
Step 10: Load the Model and Result Files into the Animation Window
In this step, you will load a file into the HyperView animation window.
2. Click Close to exit the Message Log menu if it appears.

Step 11: View Eigen Vectors
It is helpful to view the deformed shape of a model to determine if the boundary conditions have
been defined correctly and also to check if the model is deforming as expected. In this section,
use the Deformed panel to review the deformed shape for last Mode.
1. Click the animation selector switch in the lower toolbar and select Set Modal
Animation Mode .
2. Select the Deformed toolbar icon .

3. Leave Result type: set to Eigen mode (v).
4. Set Scale: to Model units.
5. Set Type: to Uniform and enter in a scale factor of 10 for Value:.
 This means that the maximum displacement will be 10 modal units and all other
 Use a scale factor higher than 1.0 to amplify the deformations while a scale factor smaller
than 1.0 would reduce them. In this case, displacements are accentuated in all directions.
Figure 7: Deformed shape panel
6. Click Apply.
7. Under Undeformed shape:, set Show: to Wireframe. A deformed plot of the model
overlaid on the original undeformed mesh is displayed in the graphics area.
8. In the Results browser pull-down menu, you can change the view between various subcases
using the Load Case and Simulation Selection drop-down menus, as shown below:
9. Select Mode 6 - F=1.496557E+02 from the list to view Mode 6.

10. To animate the mode shape, click Start/Pause Animation in the animation toolbar.
11. To control the animation speed, use the Animation Controls on the animation toolbar, as
shown below:
12. Review the other mode shapes.
Step 12: A few points to be noted

In this analysis, it was assumed that the bolts were significantly stiffer than the shield. If the
bolts needed to be made of aluminum and the shield was still made of steel, would the model
need to be modified, and the analysis run again?
It is necessary to push the natural frequencies of the splash shield above 50 Hz. With the current
model, there should be one mode that violates this constraint: Mode 1. Design specifications
allow the inner disjointed circular rib to be modified such that no significant mass is added to the
part. Is there a configuration for this rib within the above stated constraints that will push the
first mode above 50 Hz? See tutorial OS-2020 to optimize rib locations for this part.

OS-1030: 3D Inertia Relief Analysis using OptiStruct
An existing finite element model is used in this tutorial to demonstrate how HyperMesh may be
used to set-up an inertia relief analysis. The analysis is then performed using OptiStruct and
post-processed in HyperView. The figure below illustrates the structural model used for this
tutorial.
Figure 1: Structural model with static loads and support constraints applied

Exercise
Step 1: Launch HyperMesh, set the OptiStruct User Profile and retrieve
the model file

Model.
4. Select the ie_carm.hm file you saved to your working directory from the optistruct.zip file.
5. Click Open. The ie_carm.hm database is loaded into the current HyperMesh session,
replacing any existing data.
Step 2: Create load collectors used to conduct the inertia relief analysis
In this step you create two collectors: one for static loads and the other for constraints.
1. In the Model browser, right-click and select Create > Load Collector. A default load
collector template displays in the Entity Editor.
2. For Name, enter static_loads.
3. Click Color and select another color from the color palette. A new load collector named
static_loads is created.
Figure 2: Creating the load collector
4. Create another load collector named SPCs using steps 2.1 to 2.3.
Figure 3: Load collectors are shown in the Model browser

Step 3: Create the SUPORT1 required in the analysis
2. Verify the yellow entity selector is set to nodes. If not, click the switch to the left and select
nodes.
3. Select the node that sits in the middle of the multi-node rigid on the foremost attachment
point of the control arm to the chassis. This can be seen in the following figure as 1st
constraint.
4. Deselect the degrees of freedom dof4 through dof6 by clicking to uncheck the box beside
each.
5. Click load types = and select SUPORT1 from the pop-up menu. The load type is modified to
perform inertia relief analysis.
6. Click create.
7. Select the node and the rearward attachment point of the control arm of the chassis that can
be seen in the figure as 2nd constraint applied.
8. Remove the dof1 and verify the nodes button remains active.
9. Click create.
Figure 4: Nodes to select for constraint boundary conditions.

10. Create the third constraint by deselecting the dof2 and choosing the top node in the rigid
which would fasten the bottom of the shock assembly to the control arm. This can be seen in
the figure below. (Switch to the Wireframe Elements Skin Only mode by clicking on the
icon to view the rigid).
11. Click create.
Figure 5: Final constraint applied to control arm model
12. Click return to exit the panel.
Step 4: Create the static forces for the analysis

1. Right-click the static_loads collector and click Make Current to set it as the current load
collector.
3. Verify the yellow entity selector is set to nodes. If not, click the switch and select nodes.
4. Select the node on the top of the rigid at the end of the control arm, as shown in the figure
below.
5. Set magnitude= to -1e+05.
6. Click the switch beside the direction selector and select x-axis.
7. Click create.
8. Select the same node. (After verifying the yellow entity selector is set to nodes and is
activated).
9. Set magnitude = to 3e+05.
10. Change the force orientation to the z-axis.
11. Click create. The forces can be seen in the figure below.

12. Click return and to exit the panel.
Figure 6: Application of static forces
Step 5: Create the OptiStruct subcase

template is now displayed in the Entity Editor below the Model browser.
2. For Name, enter linear.
3. Click on the drop-down menu for Analysis type and select Linear Static.
5. In the Select Loadcol dialog, select static_loads and click OK.
6. For SUPORT1, click Unspecified > Loadcol.
7. In the Select Loadcol dialog, select SPCs and click OK. An OptiStruct loadstep has been
created, which references the inertia relief support points in the load collector SPCs and the
forces in the load collector static_loads.

Step 6: Create the control cards necessary to conduct the inertia relief
analysis
1. Click Setup > Create > Control Cards to open the Control Cards panel.
Note: Use Next and Prev to browse through the different control
card pages.
2. Click TITLE and enter a title for this inertia relief analysis and click return.
3. Click PARAM and turn on INREL.
4. Under INREL_V1, toggle the selection to be -1. This requests that an inertia relief analysis
be performed.
5. Click return twice to go to the main menu.

Submitting the Job
Step 7: Run the inertia relief analysis

The OptiStruct panel accomplishes two things: it saves the current model with its settings to
create the input file OptiStruct uses, and allows you to select the type of analysis.
2. Verify ie_carm.fem is in the input file: field. If not, click save as and enter ie_carm.fem.
The file extension .fem is necessary for OptiStruct to recognize it as an input file.
4. Leave the toggle for memory options: set to memory default.
5. Click OptiStruct. (You must have saved the file in Step 2 to proceed further). This launches
the OptiStruct job.
If the job is successful, you should see new results files in the directory where HyperMesh was
invoked. The ie_carm.out file is a good place to look for error messages that will help you
debug your input deck, if any errors are present.
The default files that are written to your directory are:
ie_carm.html Web-based file which gives a summary of the input deck and
simulation conducted.
ie_carm.h3d Results file which contains everything from displacement to

stress results that can be viewed in HyperView.
ie_carm.res HyperMesh binary results file.
ie_carm.out ASCII based output file of the model check run before the
simulation begins and gives some basic information on the
results of the run.
ie_carm.stat Detailed breakdown on the CPU time used for each significant
stage in the analysis.
Viewing the Results
OptiStruct provides contour information for all of the loadsteps that were run. The following steps
describe the process for viewing those results in HyperView.
Step 8: View a deformed shape

2. Verify that the Animate Mode is set to Linear Animation Mode .
3. Click the Deformed panel toolbar icon .

4. Set Result Type: to Displacement(v).
5. Set Scale: to Model units and enter a value of 10.
This means that the maximum displacement will be 10 model units and all other
6. Click Apply.
7. Set the toggle under Undeformed shape: to Wireframe: and select Color as the
Component. A deformed plot of the model should be visible, overlaid on the original
undeformed mesh.
Step 9: View a deformed animation of the loading displacement

1. Verify that the Animate Mode is set to Linear Animation Mode .
2. Click the Start/Pause Animation icon to start the animation.
3. Both the play speed and starting point of the animation can be controlled using the Animation
Controls.
4. With the animation running, use the lower slider bar in the Animation Controls panel to adjust
the speed of the animation.
5. Click the Start/Pause Animation icon, again, to stop the animation.
Step 10: View a von Mises stress contour of the static loadcase
1. Click the Contour icon on the toolbar.
2. Select Element Stresses (2D & 3D) as the Result type:.
3. The stress type should be set to vonMises.
4. Click Apply and notice the graphical display of stresses.
5. Once you are finished viewing, select File from the menu and select Exit to exit HyperView.
Note: Beginning with 8.0, there is a parameter PARAM, INREL, -2 that

can activate inertia relief analysis without the need for a
SUPORT/SUPORT1 entry. You can activate that parameter by
clicking on the PARAM field on the Control Cards panel. In this
tutorial, our intention was to show the steps in creating SUPORT1
cards; therefore the parameter was not used.
As an additional exercise, you could run this tutorial using the

above mentioned parameter. In that case, you would not create
SUPORT1 cards or choose that load collector in the subcase.

OS-1040: 3D Buckling Analysis using OptiStruct
All of the files referenced in the OptiStruct tutorials are available from the website. Refer to
Accessing the Model Files.
Overview
In this tutorial the steps required to perform a buckling analysis using OptiStruct are covered.
The figure below illustrates the structural model used for this tutorial.
Structural model with static loads and constraints applied.
This tutorial uses the following exercises to set up the structural model for a buckling analysis:
 Create boundary conditions for buckling analysis
 Post-process results

Exercise
the file
3. Click File > Open > Model. An Open Model browser window opens.
Model.
4. Select the buckling.hm file you saved to your working directory from the optistruct.zip
5. Click Open.
The structural model has already been set up to contain the necessary elements, parts,
property, and material data.
Step 2: Create load collectors

Create three load collectors (SPC, Static load and Buckling load) and assign each a color of your
choice. Follow these steps for each load collector.
1. In the Model browser, right-click and select Create > Load Collector. A default load
collector template displays in the Entity Editor.
2. For Name, enter SPC.
3. Click Color and select a color from the color palette. A new load collector, SPC, is created, as
shown below.

4. Create another load collector named Static load using steps 2.1 to 2.3.
5. Create another load collector named Buckling load.
6. For Card Image, select EIGRL from the drop-down menu.
8. For ND, enter the value 2. This tells OptiStruct that you would like to extract the first two
buckling modes.
Step 3: Create loads and boundary conditions for the model

For the nodes in the following figure that show where constraints have to be created, creating
these constraints and assigning them to the spc load collector is outlined in the following steps.
1. In the Model browser, expand the Load Collector folder and right-click SPC > Make
Current.

3. Select all of the nodes on the bottom face of the beam, as shown in the figure (Use the
nodes: on Plane option by clicking nodes >> on plane. Now, make sure that the N1N2N3B
selection entities are displayed and N1 is active. Click on any three nodes on the plane shown
in the figure below and click select entities. This selects all the nodes on the plane).
4. Deselect the degrees of freedom dof4 through dof6.

5. Click create to create the necessary boundary constraints.
6. Click return.
7. From the Model browser, right-click Static-load > Make Current.
9. Select all of the nodes on the top face of the beam, as indicated in the figure below (Use the
procedure outlined in Step 3.3).
Nodes selected for application of static forces.
10. Set magnitude= to -10000.

11. Set the direction selector to z-axis.
12. Click create. The forces display in the graphics area.
13. Click return.
Step 4: Create an OptiStruct Loadstep (also sometimes called subcase)

The last step in establishing boundary conditions is the creation of a subcase.
2. For Name, enter Linear.
3. Click on the drop-down menu for Analysis type and select Linear Static.
5. In the Select Loadcol dialog, select SPC and click OK.
7. In the Select Loadcol dialog, select Static load and click OK.
8. Create another load step named Buckling.

9. Click on the drop-down menu for Analysis type and select Linear buckling.
11. In the Select Loadcol dialog, select Buckling load and click OK.
12. For STATSUB(BUCKLING), click Unspecified > Loadcol.
13. In the Select Loadcol dialog, select Linear and click OK.
Note: A STATSUB card allows for the selection of a linear static subcase for buckling analysis.

Step 5: Run both linear and buckling analysis
3. Select the directory where you would like to write the OptiStruct model file and name your
input file (buckling.fem, for example) and click Save.
7. Click OptiStruct to launch your job. This launches the OptiStruct job.
invoked. The buckling.out file is a good place to look for error messages that will help you
debug your input deck if any errors are present.

buckling.h3d HyperView binary results file.
buckling.res Results file which contains everything from displacement to stress

results that can be viewed in the Post page within HyperMesh.
buckling.out ASCII based output file of the model check run before the simulation
begins and gives some basic information on the results of the run.
buckling.stat Detailed breakdown on the CPU time used for each significant stage in
the analysis.
Post process the results in HyperView
OptiStruct gives you contour information for all of the loadsteps that were run. This section
describes the process for viewing those results in HyperView.
Step 6: View results of Linear Loadstep: Von Mises contour stress

1. From the OptiStruct panel, click the HyperView icon. HyperView launches with the
buckling.h3d file which contains the model and the results.
2. Use the drop-down Subcase selector to change the analysis that you are reviewing in the
current window.
3. Select Subcase 1 – Linear, in the Results browser.

4. Click the Contour icon .
5. Select Element Stresses (2D and 3D) as the Result type and set the sub type to von
Mises.
6. Click Apply. This should show the contour of von Mises stress.
Step 7: View results of Buckling Loadstep: Deformed shape and

Animating Results
1. Click Clear Contour from the Result display control panel.
2. Activate Subcase 2 – Buckling in the Results browser and make sure the simulation is for
Mode 1.
3. Click the Deformed panel toolbar .
4. Under Deformed shape:, enter a Value of 10.

5. Under Undeformed shape:, for Show:, select Wireframe from the drop-down list.
6. Click the Start/Pause Animation icon to view the animation.

Similarly, check the results for the 2nd mode.

OS-1050: Connection of Dissimilar Meshes using CWELD
Elements
In this tutorial, an existing finite element model of a simple cantilever beam is used to
demonstrate how to connect dissimilar meshes using CWELD elements.
Figure 1: Cantilever beam with dissimilar meshes.

 Comparing results with a control example

Exercise

Model.
4. Select the dissimilar.hm file you saved to your working directory from the optistruct.zip
5. Click Open. The dissimilar.hm database is loaded into the current HyperMesh session,
Step 2: Create membrane elements

The database contains two unconnected components: solid_fine and solid_coarse. These
unconnected components are to be connected by CWELD elements using the "grid to element"
option. In order to achieve this, membrane elements need to be created on the matching faces of
the solid_coarse and solid_fine components.
2. For Name, enter membrane_coarse.
3. For Card Image, select PSHELL from the drop-down menu.
6. Check the box next to MID2_opts. An option list appears beneath MID2_opts.
7. Click the switch next to USER and select BLANK from the pop-up menu. Notice the MID2
field disappears from the card image.

8. Check the box next to MID3_opts. An option list appears beneath MID3_opts.
9. Click the switch next to USER and select BLANK from the pop-up menu. Notice the MID3
field disappears from the card-image.
10. For T (thickness), enter 1E-6.

12. For Name, enter membrane_fine.
13. Input the corresponding values for membrane_fine exactly the same as for membrane_coarse.
14. In the Model browser, right-click and select Create > Component.
15. For Name, enter membrane_coarse.
17. In the Select Propety dialog, select membrane_coarse and click OK.
18. From the Tool page, click faces.

19. Click comps, select the solid_coarse component, click select > find faces. Membrane
elements are created on the faces of solid_coarse component and they appear on the graphic
window.
20. In the Model browser, right-click the component ^faces and click Isolate. This displays only
^faces component.
21. From the Tool page, click organize.
22. Select only the elements that lie on the matching face.
(Rotate the model so you can see the matching face, then, after making sure elems is
selected, click on any one of the elements on the matching face. Then, click elems >> by
face. This selects all the elements on the matching face).

Figure 4: Selecting elements on matching face for solid_coarse component
23. Click dest component = and select membrane_coarse from the list of components.
24. Click move. The elements are now part of the membrane_coarse component.
25. Click return.
26. On the Tool page, select faces.
27. Click delete faces.
30. For Name, enter membrane_fine.
32. In the Select Property dialog, select membrane_fine and click OK.
33. On the Tool page, select faces.
34. Click comps, select the solid_fine component, and click select > find faces. Membrane
elements are created on the faces of solid_fine component and they appear on the graphics
window.
35. Click return.
36. Right-click ^faces component and click Isolate. This displays only ^faces component in the
graphics window.
37. From the Tool page, select the organize panel.
38. Select only the elements that lie on the matching face as shown below. (Use a method similar
to the one mentioned in Step 2.22 of this section).

Figure 5: Selecting elements on matching face for solid fine component.
39. Click dest component= and select membrane_fine from the list of components.
40. Click move. The elements are now part of the membrane_fine component.
41. Click return.
42. From the Tool page, select the faces panel.
43. Click delete faces and click return to return to the main menu.
44. In the Model browser, right-click and select Components > Hide.
45. Click the icon highlighted in red below to keep only the membrane elements in display.
Figure 6: Displaying only membrane elements
Step 3: Create CWELD elements

A PWELD property must be created for the CWELD elements.
2. For Name, enter welds.
3. For Card Image, select PWELD from the drop-down menu and click Yes to confirm.

6. For D (weld diameter), enter 0.1. This creates a new property definition named welds.
8. For Name, enter welds.
9. Click Color and select a color. This creates the new component named welds.
10. From the 1D page, click spotweld.
11. Make sure the using elems subpanel is selected.
12. Click elems >> displayed.
13. Click the switch under element config: and select rod from the pop-up menu.
14. Click property = and select welds from the list of properties.
15. Click search tolerance = and enter 0.1.
16. Click nodes >> by collector and select the membrane_fine collector.
17. Click create. A weld element is created at each node on the fine-mesh matching face. A
number of plot elements are created too, these are helpful to find the elements attached
when looking for the welds.
18. Click return to return to the main menu.
Submitting the Job

1. Click File > Save As.
2. In the File name field, enter dissimilar.hm.
3. Click Save.
Step 5: Running OptiStruct

You can also get to the OptiStruct panel from the Applications menu on the toolbar.
2. Click save as and select the directory where you would like to write the OptiStruct model file,
enter the file name dissimilar.fem, and click Save.
model file was written. The dissimilar.out file is a good place to look for error messages

dissimilar.html HTML report of the analysis, giving a summary of the problem

dissimilar.out OptiStruct output file containing specific information on the file

setup, the setup of your optimization problem, estimates for the
amount of RAM and disk space required for the run, information
for each of the optimization iterations, and compute time
information. Review this file for warnings and errors.
dissimilar.h3d HyperView binary results file.
dissimilar.stat Summary of analysis process, providing CPU information for each

Post Processing Analysis Results using HyperView
Step 6: View displacement contour

1. When the message Process completed successfully is received in the command window,
close the window.
2. In the OptiStruct panel, click HyperView. This loads the results for the current run into
HyperView.
3. Set the animation type to Linear .

6. Click Apply. The resulting colors represent the displacement field resulting from the applied
loads and boundary conditions.
7. Click the Page Layout icon on the toolbar.
8. Choose the second layout in the first row of the pop-up window. This changes the graphic
area in two separate windows. The left window will have the previously loaded model and the
right window will be blank. Load the control example in the right side window to compare the
results.
9. Click the right-hand pane in the display area. A blue line appears around the window to show
that it is selected.
10. Click the Load Result icon in the toolbar.
11. Click Load Model and select the file control.h3d you saved to your working directory
from the optistruct.zip file as both the model and results file.
12. Click Apply.

13. Right-click on the left pane and activate menu over Apply Style To > Current Page > All
Selected. This option applies results from the current window to the new window.
You can now visually compare the displacement results from the dissimilar mesh model with a
uniform mesh model.
Step 7: View von Mises Stress results

1. Select the left-hand panel in the display area.
2. Click to open the panel.
3. Under Result type:, select Element Stresses (2D & 3D)(t) and vonMises.
4. In the field below Averaging method:, select None.
5. Click Apply.
6. Right-click on the left pane and activate menu over Apply Style To > Current Page > All
Selected.
You can now visually compare the von Mises stress results from the dissimilar model with a
uniform mesh model.

OS-1060: Analysis of a Composite Aircraft Structure using
PCOMPG
This tutorial takes you through the process of developing a ply lay-up definition for a composite
structure using a PCOMPG card, and shows the advantages of post-processing the results with
global ply numbers. The traditional definition method, using PCOMP, is introduced first here to
ultimately show the practical advantages of using PCOMPG for the given scenario. The model for
this tutorial is shown below. Since the structure, loads, and boundary conditions are symmetrical
about the x-axis, only one half of the structure is modeled with suitable boundary conditions
applied to enforce half symmetry.
Torsion frame

 Retrieve the HyperMesh database file
 Review the model set up
 View the results
 Set up the problem in HyperMesh (by redefining the laminate properties with a PCOMPG
card)
 View the results

Retrieve the HyperMesh Database File
the file
1. Launch HyperMesh.
2. Select OptiStruct from the User Profiles dialog and click OK.
Model.
4. Select the frame.hm file you saved to your working directory from the optistruct.zip file.
5. Click Open. The frame.hm database is loaded into the current HyperMesh session, replacing
any existing data.
Step 2: Review the model setup in HyperMesh

The structural model has been already set up and can be solved without any further
modifications. Review the model setup before submitting the job.
The model is set up for linear static analysis. As mentioned earlier, only half of the structure is
modeled; and to impose the half symmetry boundary conditions, all the nodes on the symmetry
plane are constrained in dof1, dof5, and dof6.
All of the components are modeled with the PCOMP property which lists the plies (stacking
sequence) from the bottom surface upwards, with respect to the element’s normal direction, as
shown in the image below.
Ply stacking sequence with respect to element normal
Components in this model that have names starting with the word "Flange" represent junctions in
which different components are connected together. While reviewing, closely watch the flange
area formed by the Skin and Rib components (highlighted in the following figure). Review the
ply lay-up of the Skin_inner, Rib, Flange1_Rib_Skin, and Flange2_Rib_Skin components
(laminate layout is shown in the bottom portion of the following figure). Note that few plies are
common for the Skin_inner, Flange1_Rib_Skin, Flange2_Rib_Skin, and Skin_outer
components, but appear in different stacking sequence in each component. For example, the 4th
ply in Skin_inner is the 3rd ply in Flange2_Rib_Skin and the 2nd ply in Skin_outer
components.

Ply stacking for the Skin_inner, Rib, Skin_outer, Flange1_Rib_Skin, and Flange2_Rib_Skin components
1. From the 2D page, click HyperLaminate to enter the Graphic User Interface (GUI).
This opens the HyperLaminate (GUI) in which the ply lay-up information can be defined,
reviewed and edited. Material properties and design variables can also be created and edited
here.
2. Expand the Laminates portion of the tree structure on the left-hand side of the screen.
3. Select the Skin_inner PCOMP.
Details of the laminate appear in the GUI.
4. Verify that the lay-up definition for Skin_inner matches the first 5 entries of the table below,
which is the lay-up information of Flange1_Rib_Skin component.
5. Select the Rib PCOMP and verify that the 3rd and 4th lay-up definition for Rib matches the
6th and 7th entries in the following table.
6. Select the Flange1_Rib_Skin PCOMP to view the ply lay-up definitions. Verify that the lay-
up definition for Flange1_Rib_Skin matches the following table.
Observe that the first 5 layers are the same as Skin_inner lay-ups and that the last two lay-
ups are the same as the 3rd and 4th lay-up of Rib, as shown in the last figure. You can verify
how other flanges are modeled.
Laminate properties of Flange1_Rib_Skin:
Ply
Material Thickness T Orientation SOUT
Number
1 carbon_fiber 1.2 45 YES
2 matrix 0.2 90 YES

Laminate properties of Flange1_Rib_Skin:
Ply
Number
3 carbon_fiber 1.2 -45 YES
4 matrix 0.2 -90 YES
7. You can also review the other components. Once the review is completed, select Exit from
the File menu. Exit the HyperLaminate GUI and return to HyperMesh.
Step 3: Submit the Job

2. Following the input file: field, click Save as. A Save As browser window opens.
name for the model, frame_PCOMP.fem, in the input file: field.
4. Click Save.
The name and location of the frame_PCOMP.fem file displays in the input file: field.
If the analysis is successful, no error messages are reported to the shell. The analysis is
complete when the message Process completed successfully appears in the shell.
frame_PCOMP.html HTML report of the analysis, giving a summary of the problem

frame_PCOMP.out OptiStruct output file containing specific information on the file

setup, the set up of your optimization problem, estimates for the
frame_PCOMP.h3d HyperView binary results file.
frame_PCOMP.stat Summary of analysis process, providing CPU information for each


The frame_PCOMP.out file is a good place to look for error messages that will help to debug
Step 4: View the results/Post-processing

1. Click HyperView from the OptiStruct panel. HyperView launches and the model results are
automatically loaded into HyperView.
2. Click Close to close the message window.
3. Click the Contour toolbar .
4. Select the first switch below Result type: and select Composite Stresses(s).
5. Select the second switch and select the P1 (major) Stress.
6. Select 3 for the Layers option.
7. In the field below Averaging method:, select None.
8. Click Apply. This contours the maximum principle stress for the 3rd ply of all the components
in the model.
9. Click the Isometric View icon in the Standard Views toolbar to see the model, as shown
in the following figure.

Stress distribution on the top face of the frame
The stress value does not vary gradually in the top face region, but suddenly decreases to a
lower value across the Flange2_Rib_Skin component. Looking at the table of laminate
properties of Flange1_Rib_Skin again, observe that the 3rd ply property of the
Flange2_Rib_Skin component is of a matrix material and the third plies in the components
adjacent to it (Flange1_Rib_Skin and Skin_outer) are of a carbon fiber material. The sudden
changes in the stress values occur because we are looking at stress on two different
materials. This example shows that, for the results to be meaningful during post-processing of
the PCOMP results, you have to correlate the ply results to their corresponding ply property.
This highlights that, during the post-processing of PCOMP components, plotting results based
on just the ply number is not sufficient. You have to keep track of ply properties (material,
thickness, orientation, failure index, etc.) on your own during post-processing with this
method. In cases that use large and complex models, it becomes tedious to track the
individual ply properties during post-processing.
This drawback to using PCOMP can be avoided with the use of the PCOMPG card for property
definition. Using the PCOMPG card, you can assign a global ply number for each ply and post-
process the results based on global ply number. The following steps explain the procedure to
redefine the model with PCOMPG property.
Step 5: Redefine the model setup in HyperMesh

1. Close the HyperView window and return to HyperMesh.
Note: Click to return to the previous page where HyperMesh is

open, if you are using HyperMesh Desktop.
2. From the 2D page, select the HyperLaminate panel. This opens the HyperLaminate GUI in
which the ply lay-up information can be defined, reviewed and edited.

3. Click Tools > Laminate Options. This opens a new window in which the default ply lay-up
options can be set.
4. Click the Convention: switch and select Total.
5. Click OK to close the window. This sets up Total as the default option whenever a new
component is created.
Laminate information with global ply number
Now you create new PCOMPG components with global ply numbers defined as shown in the
above figure. As discussed earlier, the 4th ply in Skin_inner is the 3rd ply in Flange2_Rib_Skin
and the 2nd ply in Skin_outer components. Therefore, all of these plies will be defined with
the same global ply ID 4. Similarly, all other plies are to be defined, as shown in the above
figure.
6. Expand the laminates portion of the tree structure on the left-hand side of the screen.
7. Right-click PCOMPG. A menu appears.
8. Click New. This creates new component, which is named NewLaminate1 by default, and the
tree structure is expanded.
9. Rename the component to Skin_inner_GPLY by right-clicking and select Rename in the text
field and overwrite the default component name.
10. In the Add/Update plies: section under the field GPLYID, enter 1.
11. Select the pull-down menu below Material and select carbon_fiber.
12. Below the Thickness T1 field, enter 1.2.
13. Below the Orientation field, enter 45.
14. Select the pull-down menu below SOUT and select YES.
15. Click Add New Ply to add the ply information.
16. Repeat this procedure to add 4 more plies with the properties shown in the table:
GPLY
ID
2 matrix 0.2 90 YES
3 carbon_fiber 1.2 -45 YES

17. Click Update Laminate at the bottom of the window to update the lay-up information. The
graphical display of lay-up information now appears in the field below the Review tab, on the
right side of the GUI.
18. Create a new PCOMPG component with name Rib_GPLY and the ply lay-up, as shown in the
following table:
GPLY
ID
12 matrix 0.2 45 YES
Referring to the figure showing laminate information with global ply number above, you will
create the Flange1_Rib_Skin_GPLY component.
19. Right-click Skin_inner_GPLY and select Duplicate from the menu to create an identical
component.
20. Rename the component as Flange1_Rib_Skin_GPLY by right-clicking and select rename in
the text field and overwrite the component name.
21. Add 2 more plies with the properties shown in the following table using the Add New Ply
feature.
GPLY
ID
The new component Flange1_Rib_Skin_GPLY was created. Its first 5 plies are the same as
Skin_inner_GPLY and its last 2 plies are the 3rd and 4th plies of the Rib component.
To reduce the number of steps in this tutorial, the ply lay-up information of other components
is already defined with PCOMPG property and appropriate laminate information in the
updated_PCOMPG_properties.fem file you saved to your working directory from the
optistruct.zip file. This file is imported into HyperMesh to update (overwrite) the properties
instead of manually updating them.
The updated_PCOMPG_properties.fem file is saved in OptiStruct input file format. Open this
in any text editor to review how the components are defined with PCOMPG properties. A
section of the file is shown below.

Components defined with PCOMPG
22. Click File > Exit. This will exit the HyperLaminate GUI and return to HyperMesh.
23. Click File > Import > Solver Deck.
24. Toggle and expand the Import options and check the box next to FE overwrite.
This option overwrites the old PCOMP properties with PCOMPG properties defined in the
updated_PCOMPG_properties.fem file.
25. Click on the folder icon next to File: and select the updated_PCOMPG_properties.fem file
and click Import.
26. Click Close.

Step 6: Review the imported properties in HyperLaminate
1. From the 2D page, go to the HyperLaminate panel.
2. Expand the laminates portion of the tree structure on the left-hand side of the screen.
All of the components now appear under PCOMPG. The components created earlier
(Skin_inner_GPLY, Rib_GPLY, and Flange1_Rib_Skin_GPLY) are still present. There is no
element associated with these components. Review the PCOMPG components to view the
laminate definitions.
3. Click File > Exit.

2. Following the input file: field, click Save as.
3. In the Save file browser window, select the directory where you would like to write the
OptiStruct model file and enter frame_PCOMPG.fem as the name for the model.
4. Click Save.
The name and location of the frame_PCOMPG.fem file displays in the input file: field.
If the job is successful, new results files can be seen in the directory where the model file was
written. The frame_PCOMPG.out file is a good place to look for error messages that will help to
debug the input deck, if any errors are present.
frame_PCOMPG.html HTML report of the analysis, giving a summary of the problem
frame_PCOMPG.out OptiStruct output file containing specific information on the file

setup, the set up of your optimization problem, estimates for the
frame_PCOMPG.res HyperMesh binary results file.
frame_PCOMPG.h3d HyperView binary results file.
frame_PCOMPG.stat Summary of analysis process, providing CPU information for


Step 8: View the results/Post-processing
1. When the message Process completed successfully is received in the command window, click
HyperView in the OptiStruct panel. The results are automatically loaded into HyperView.
A message window may appear with information about the successful loading of the model
and result files into HyperView.
4. Select the first switch below Result type: and select Composite Stresses (s).
5. Select the second switch and select P1 (major) Stress.
6. For the Layers field, select PLY 3.
7. For Averaging method:, select None.
8. Click Apply. This plots the maximum principle stress for global ply 3. The results are not
plotted in the regions where global ply 3 is not present.
9. Click the Isometric View icon in the Standard Views toolbar.
Post-processing the results based on global ply number eliminates the need to track the ply
number and corresponding ply properties on the components. The results are displayed based on
the global ply number, irrespective of the ply order, so you can chose any one global ply number
and view results across the whole component. If a particular ply is not present in any given
region, no result is displayed.

OS-1070: Analysis of an Axi-symmetric Structure using
OptiStruct
In this tutorial the method of modeling an axi-symmetry problem in OptiStruct is covered. The
figure below shows the model that is used for this tutorial.
Full model; Elements, material, props and BCs

1. Analysis with the full model
 Retrieving the HyperMesh database file
 Viewing the results in HyperView
2. Analysis with a small portion of the full model with axi-symmetry boundary conditions
 Setting up the axi-symmetric structure in HyperMesh

Exercise 1: Analysis with the Full Model

2. A User Profiles Graphic User Interface (GUI) appears, select OptiStruct.
3. Click OK. This loads the user profile. It includes the appropriate template, macro menu, and
import reader, paring down the functionality of HyperMesh to what is relevant for generating
models for OptiStruct.
Step 2: Open the File axi-symmetry_full_geometry.hm

Model.
2. Select the axi-symmetry_full_geometry.hm file you saved to your working directory from
the optistruct.zip file. Refer to Accessing the Model Files.
3. Click Open.
The axi-symmetry_full_geometry.hm database is loaded into the current HyperMesh
session, replacing any existing data. The database only contains geometric data.
You will find that the structural model has already been set up with the necessary elements,
boundary conditions, property, and material data so that it is ready to solve. Pressure load is
applied on the top face of the geometry and constraints are defined at the bottom face. Note that
the model is symmetrical about the z-axis and that loads and boundary conditions are
symmetrical about the same axis as well. These represent the conditions necessary for modeling
axi-symmetry problems. First, obtain the result for the full model and then you model a small
part of the model with boundary conditions suitable to enforce the axi-symmetric behavior.
Finally, you compare the results of the axi-symmetric model with the full model results.
Solving the job and post-processing the results is explained in the next sectioin.
Step 3: Submitting the Job

2. Click save as following the input file: field. A Save As browser window appears.
name for the model, axi-symmetry_full_geometry.fem, in the File name: field. The .fem
file name extension is the suggested extension for OptiStruct input decks.
4. Click Save.
The name and location of the axi-symmetry_full_geometry.fem file displays in the input
file: field.

8. Click OptiStruct. This launches the OptiStruct job. A command window opens up and
indicates the start of the OptiStruct run.
model file was written. The axi-symmetry_full_geometry.out file is a good place to look for
error messages that will help to debug the input deck if any errors are present.
Step 4: Viewing the Results

When the message Process completed successfully is received in the command window, click
HyperView in the OptiStruct panel of HyperMesh.
The HyperView Graphic User Interface (GUI) window opens and the results automatically get
loaded into HyperView. A message window appears to inform about the successful loading of the
model and result files in to HyperView. Close the message window.
Displacement and stress results are output for each subcase to the axi-
symmetry_full_geometry.h3d file from OptiStruct. This section describes how to view those
results in HyperView.
Step 5: View the displacements of the structure

It is helpful to view the deformations of the model first, to determine if the boundary conditions
have been defined correctly and also to see if the model is deforming as expected.
1. Set the Animation mode to Linear.
2. Click the Contour icon on the toolbar.
3. Select the first pull-down menu below Result Type and select Displacement [v].
4. Select the second pull-down menu below Result Type and select Mag.
5. Click Apply to display the displacement contour.

To view the displacement variation across the thickness, one half of the structure can be
masked.
6. Expand the Components folder in the Results browser.

7. Click the elements icon in front of the component bottom_half to mask the component from
display.
8. Click XZ Left Plane View to display the Left view.

9. The following figure shows the displacements through the thickness.

Exercise 2: Analysis with a Small Portion of the Full Model with Axi-
symmetry Boundary Conditions
Setting up the New Analysis

Return to HyperMesh to delete the all the elements, except for a small portion and to set up the
axi-symmetry boundary conditions.
Before proceeding to the next section, let’s look at the criteria for modeling an axi-symmetry
problem. Note that even if the geometry is symmetrical about an axis, if any of the loads or
boundary conditions are not symmetrical about the same axis, then it cannot be modeled as an
axi-symmetry model. Therefore, the models shown below are examples that cannot be modeled
as axi-symmetry models.
Non axi-symmetric loads Non axi-symmetric boundary conditions
Step 1: Setup the axi-symmetry model

1. Click to enter the Delete panel, or click F2.
2. Make sure the entity selection switch is set to elems.
3. Click the yellow button elems to open the extended entity selection window and select by
sets.
4. Click in the check box in front of SetA. A check mark appears before SetA to indicate that it
is selected.
5. Click select. The selected elements are highlighted.

6. Click delete entity to delete the selected elements.
7. Click return to exit the Delete panel.
Use the retained portion to model the axi-symmetric model with suitable boundary conditions.
Step 2: Apply the additional boundary conditions to model axi-symmetry

conditions
The axi-symmetry conditions are applied by constraining all of the nodes from moving in the
tangential direction. This is done by first assigning all of the nodes to a cylindrical coordinate
system and then constraining all of them in tangential degrees of freedom.
1. From the Analysis page, enter the systems panel.

2. Select the assign radio button.
3. Make sure the entity selection switch in front of set: is set to nodes.
4. Click the yellow button nodes to open the extended entity selection window and select all.
5. Click the yellow button system to activate it and select the red colored system from the
graphic window.
6. Click set displacement.
The message on the footer bar “The analysis system has been assigned” appears.
7. Click return.
All of the nodes in the model are assigned to a cylindrical coordinate system. Note that the z-axis
of the cylindrical coordinate system coincides with the axis about which the model is symmetrical.
Now, constraining the nodes that are assigned to the cylindrical coordinate system in tangential
degrees of freedom enforces the axi-symmetry boundary condition.
Step 3: Create constraints

1. Expand the Load Collectors folder in the Model browser.
2. Right-click on SPCs and click Make Current to make SPCs the current component, if not
already done.
4. Make sure the entity selection switch is set to nodes.
5. Click the yellow button nodes to open the extended entity selection window and select all.
6. Constrain dof2.
DOFs with a check will be constrained, while dofs without a check will be free.
DOFs 1, 2, and 3 are radial, tangential and translation degrees of freedom.
DoOFs 4, 5, and 6 are radial, tangential and translation rotational degrees of freedom.
7. Click create. This applies these constraints to the selected nodes.

2. Solve the job with file name as axi-symmetry_model.fem by following the same steps as
explained in the earlier section.
model file was written. The axi-symmetry_model.out file is a good place to look for error
Step 5: Viewing the Results

Displacement and Stress results are output for each subcase to axi-symmetry_model.h3d file
from OptiStruct. Results from the axi-symmetry model should match with the results of the full
model. Use load the result file in the previously opened HyperView session to compare the
results.
1. Click HyperView to view the results.

2. Click the Page Layout icon .
3. Select the two window layout .
4. Activate the new window by clicking in the graphic area of the new window.
5. Click to open the Load model and results panel.
6. Click the Load model icon on the toolbar and load the axi-symmetry_model.h3d. This
loads the complete path of the selected .h3d file in the field. Also note that the same file path
is loaded next to the field Load results.
7. Click Apply.
8. Click XZ Left Plane View to display the Left view.
9. Click the Contour icon on the toolbar and contour the displacements.
10. Compare the displacement results of the axi-symmetry model with the result from the full
model. The results should match, as shown in the below picture. Similarly, stress and other
results will also match.
Comparison of displacement results

OS-1080: Coupled Linear Heat Transfer/Structure Analysis
A coupled heat transfer/structure analysis on a steel pipe is performed in this tutorial. As shown
in Figure 1, the pipe is fixed on the ground at one end and the heat flux is applied on the other
end. A linear steady state heat conduction solution is defined first. Then it is referred by a
structure solution by TEMP to perform the coupled thermal/structural analysis. The problem is
defined in HyperMesh and solved with OptiStruct implicit solver. The heat transfer and structure
results are post processed in HyperView.
Figure 1: Model review

 Create the thermal/structural material and property
 Apply thermal loads (QBDY1) and boundary conditions (CHBDYE)
 Submit the job to OptiStruct
 Post-process the results in HyperView
Set up the Model in HyperMesh
Step 1: Load the OptiStruct User Profile and import the model
2. Select OptiStruct in the User Profile dialog and click OK. This loads the user profile. It
includes the appropriate template, macro menu, and import reader, paring down the
functionality of HyperMesh to what is relevant for generating models for OptiStruct.
3. Click the Import Solver Deck panel toolbar icon . An Import panel opens. The File type:
is OptiStruct.
4. Click the open file icon in the File: field. A Select OptiStruct file browser window opens.
5. Select the pipe.fem file you saved to your working directory from the optistruct.zip file.
6. Click Open. The location of pipe.fem displays in the file: field.
7. Click Import. The pipe.fem database is loaded into the current HyperMesh session.
8. Click Close.

Step 2: Create the coupled thermal/structural material properties
Create the material and property collectors before creating the component collectors.
3. Click the box next to MAT4.
The MAT4 card image appears below MAT1 in the material information area. The MAT1 card
defines the isotropic structural material. MAT4 card is for the constant thermal material. MAT4
uses the same material ID as MAT1.
If a quantity in brackets does not have a value below it, it is turned OFF. To change this, click
the quantity in brackets and an entry field appears below it. Click the entry field and enter a
value.
4. Enter the following values for the material, steel, in the Entity Editor.
[E] Young’s modulus = 2.1 x 1011Pa
[NU] Poisson’s ratio = 0.3
[RHO] Material density = 7.9 x 103 Kg/m3
[A] Thermal expansion coefficient = 1 x 10-5 / C
[K] Thermal conductivity = 73W / (m * C)

A new coupled thermal/structural material, steel, is created.

Figure 2: The material Entity Editor
6. For Name, enter solid.

Figure 3: Assigning the material steel to the property solid
9. For Card Image, select PSOLID from the drop-down menu and click Yes to confirm.
The property of the solid steel pipe has been created as 3D PSOLID. Material information is
Step 3: Link the material and property to the existing structure

Once the material and property are defined, they need to be linked to the structure.
1. In the Model browser, click on the pipe component. The component template displays in the
Entity Editor.
3. In the Select Property dialog, select solid and click OK.

Figure 4: Assigning the property solid to the component pipe
Apply Thermal Loads and Boundary Conditions to the Model
A structural constraint spc_struct is applied on the RBE2 element to fix the pipe on the ground.
Two empty load collectors, spc_heat and heat_flux have been pre-created. In this section, the
thermal boundary conditions and heat flux are applied on the model and saved in spc_heat and
heat_flux, respectively.
Step 4: Create thermal constraints

1. Click the Set Current Load Collector panel located at the right corner of the footer bar, as
shown below. A list of load collectors appears.
Figure 5: Setting the current load collector
2. Select spc_heat as the current load collector.

3. From the Analysis page, click constraints.
4. Go to the create subpanel.
5. Click the entity selection switch and select nodes from the pop-up menu.
6. Click nodes >> by sets.
7. Select the predefined entity set heat and click select. The selected nodes on the fixed end
should be highlighted.
8. Uncheck the boxes in front of dof1, dof2, dof3, dof4, dof5, and dof6 and enter 0.0 in the
entry fields.

9. Click load types = and select SPC from the pop-up list.
10. Click create. This applies these thermal constraints to the selected nodal set.
11. Click return to go to the Analysis page.
Step 5: Create CHBDYE surface elements

The heat flux will be applied on the surface of the free end of the pipe. Therefore, the surface
elements CHBDYE for defining heat transfer boundaries must be created first.
1. Click BCs > Create > Interfaces.
2. For Name, enter heat_surf.
3. For Card Image, select CONDUCTION from the drop-down menu.
4. Select an appropriate color from the palette.
5. For Slave Entity IDs, click Elements. The Slave Entity IDs panel is now displayed below the
Graphics browser.
6. Click the switch button for elems and select faces from the pop-up list.
7. Click the highlighted solid elems and select by sets from the pop-up selection menu.
8. Select element set solid elems and click select.
9. Click nodes in the face nodes field.
10. Select four nodes on one face of a solid element where the heat flux is applied, as shown in
Figure 6.
Figure 6: Nodes on the surface element

11. Click add. This adds the CHBDYE surface elements on all the solid elements following the
same side convention, as shown in Figure 7.
Figure 7: CHBDYE surface elements
12. Click return to return to the Entity Editor.

13. Click Close.
Step 6: Create heat flux on surface elements

In this step, the uniform heat flux into CHBDYE elements is defined with QBDY1 entries.
1. Set your current load collector to heat_flux.
2. From the Analysis page, click flux to enter the flux panel.
4. Click elems >> by group.
5. Select heat_surf and click select. The surface elements are highlighted.
6. Click load types= and select QBDY1.
7. In the value= field, enter 1.0.
8. Click create. The uniform heat flux in the surface elements is defined.
9. Click return to go back to Analysis page.

Step 7: Create a heat transfer loadstep
An OptiStruct steady state heat conduction loadstep is created, which references the thermal
boundary conditions in the load collector spc_heat and the heat flux in the load collector
heat_flux. The gradient, flux, and temperature output for the heat transfer analysis are also
requested in the load step.
2. For Name, enter heat_transfer.
3. Click the drop-down menu in the Value field next to Analysis type in the Entity Editor and
select Heat transfer (steady state).
5. In the Select Loadcol dialog, select spc_heat and click OK.
Figure 8: Selecting the constraints
6. For LOAD, click Unspecified < Loadcol.

7. In the Select Loadcol dialog, select heat_flux and click OK.
8. Verify that the Analysis type is set to HEAT.
9. Check the box next to OUTPUT.
10. Activate the options of FLUX and THERMAL on the sub-list.
11. Under each result selection, click the space next to FORMAT and select H3D format from the
drop-down menu. For THERMAL, click the Table icon and select H3D from the drop-down
menu in the table that opens.

12. Click the button under OPTION and select ALL, as shown in Figure 9.
Flux and Thermal output can also be requested in control cards panel on Analysis page.
Figure 9: Setting up the heat transer loadstep
Step 8: Create a structure loadstep

To perform a coupled thermal/structural analysis, the heat transfer SUBCASE needs to be
referenced by a structural SUBCASE through TEMP card. Since this is not directly supported in
HyperMesh, a linear static structual subcase is created and temperature is added using
SUBCASE_UNSUPPORTED or by editing the .fem file after the model export.
2. For Name, enter structure_temp.
3. Click on the drop-down menu in the Value field next to Analysis type in the Entity Editor
and select Linear Static.
5. In the Select Loadcol dialog, select spc_struct and click OK.
6. Check the box next to SUBCASE_UNSUPPORTED.
7. Click the Table icon to the right of Data: Comments and enter the following text in the
first row of the pop-out table.
TEMP=1
Note the TEMP ID used above could be different from your model. Make sure the ID of the
heat transfer subcase is selected for TEMP.
8. Click Close.

Submit the Job
Step 9: Launch OptiStruct

1. Select the OptiStruct panel on the Analysis page.
name for the model, pipe_complete.fem, in the File name: field. The .fem filename
extension is the recommended extension for OptiStruct input decks.
4. Click Save.
The name and location of the pipe_complete.fem file displays in the input file: field.
8. Click OptiStruct. This launches the job.
If the job is successful, you should see new results files in the directory from which
pipe_complete.fem was selected. The pipe_complete.out file is a good place to look for
error messages that could help debug the input deck if any errors are present.
View and Post process the Results
Gradient temperatures and flux contour results for the steady state heat conduction analysis and
the stress and displacement results for the structural analysis are computed from OptiStruct.
HyperView is used to post-process the results.
Step 10: View the results for heat transfer analysis

1. When the message Process completed successfully is displayed in the HyperWorks Solver
View dialog, click HyperView. HyperView is launched and the results are loaded.
2. Click Close to close the message window (if one appears).

4. Select Subcase 1 - heat transfer as the current load case in the Results tab, as shown
below.
Figure 10: Results tab in HyperView.
5. In the Contour panel, select the first pull-down menu below Result type: and select Element
Fluxes (V).
6. Click Apply. A contoured image representing thermal fluxes should be visible.
7. Select the first pull-down menu below Result type: and select Grid Temperatures (s).
8. Click Apply. Both flux and temperature results are shown below.
Figure 11: Results of heat transfer analysis

Step 11: View the results for the coupled thermal/structure analysis
1. Select the structure analysis subcase as the current load case in the Load Case and
Simulation Selection window.
2. Select the first pull-down menu below Result type: and select Element Stresses [2D &
3D] (t).
4. Click Apply.
model is assigned a legend color, indicating the von Mises stress value for that element,
resulting from the applied loads and boundary conditions.
6. Select the second pull-down menu below Result type: and select Mag.
7. Click Apply. Both stress and displacement contours are shown below.
Figure 12: Results of the structural analysis

OS-1085: Linear Steady State Heat Convection Analysis
This tutorial performs a heat transfer analysis on a steel pipe, as shown in Figure 1. The
temperature on the inside surface of the pipe is 60 C. The outside surface is exposed to the
surrounding air, which is at 20 C. The temperature distribution within the pipe can be
determined by solving the linear steady state heat conduction and convection solution.

 Create the thermal material and property
 Create and apply the thermal boundary conditions on the model
Set up the Model in HyperMesh
2. Select OptiStruct in the User Profiles dialog and click OK. This loads the user profile. It
3. Click the Import Solver Deck panel toolbar icon . An Import window opens. The File
type: is OptiStruct.
4. In the File: field, click the open file icon . A Select OptiStruct file browser window opens.
5. Select the thermal.fem file you saved to your working directory from the optistruct.zip
6. Click Open. The location of thermal.fem displays in the File: field.
7. Click Import > Close. The thermal.fem database is loaded into the current HyperMesh
session.

Step 2: Create the thermal material properties
Create the material and property collectors before creating the component collectors.
3. Check the box in front of MAT4.
MAT4 card image appears below MAT1 in the Entity Editor. The MAT1 card defines the
isotropic structural material. MAT4 card is for the constant thermal material. MAT4 uses the
same material ID as MAT1.
4. Enter the following values for the material, steel, in the Entity Editor.
[E] Young’s modulus = 2.1 x 1011 Pa
[NU] Poisson’s ratio = 0.3
[RHO] Material density = 7.9 x 103 Kg/m3
[A] Thermal expansion coefficient = 1.0 x 10 -5 / C
[K] Thermal conductivity = 73W / m C
[H] Heat transfer coefficient = 40W / m2 C

Figure 2: The Material Entity Editor
A new material, steel, is created with both structural and thermal properties.
7. For Card Image, select PSOLID and click Yes to confirm.
The property of the solid steel pipe has been created as 3D PSOLID. Material information is

Step 3: Link the material and property to the existing structure
1. In the Model browser, click the component pipe. The Entity Editor opens.
3. In the Select Property dialog, select solid and click OK.
The material steel now is automatically linked to the component pipe.
Apply Thermal Boundary Conditions on the Model
In this exercise the thermal boundary conditions are applied on the model and saved in a
predefined load collector spc_temp. A predefined node 4679 specifies the ambient temperature. A
predefined node set node_temp contains the nodes on the inside surface of the pipe.
Step 4: Create temperatures on the inner surface of the pipe

4. Make sure the current selection field is set to nodes.
5. Click nodes >> by sets.
6. Select node_temp and click select.
7. Uncheck the box in front of dof1, dof2, dof3, dof4, dof5, and dof6 and verify that the entry
fields are set to 0.0.
8. Set load types = to SPC.
9. Click create.
This applies the temperature 0.0 on the inside nodes. In the next step, the temperature value
is updated to 60.
10. Click the Card edit icon .

11. Click loads >> by collector.
12. Check the box in front of spc_temp and click select.
13. Click config= and select const.
14. Click type= and select SPC.
15. Click edit.
16. In the field of D, enter 60.0.
17. Click return three times to go back to the Analysis page.

Step 5: Create ambient temperature
1. Make sure spc_temp is the current load collector.
2. From the Analysis page, select the constraints panel.
4. Click nodes >> by id.
5. Input the ID of the predefined node 4679. Node 4679 should be highlighted.
6. Uncheck the box in front of dof1, dof2, dof3, dof4, dof5, and dof6 and verify that the entry
fields are set to 0.0.
7. Click create.
8. Click Card edit icon .

9. Select loads entry.
10. Select the ambient spc just created on the screen.
11. Click config= and select const.
12. Click type= and select SPC.
13. Click edit.
14. In the field of D, enter 20.0. The temperature boundary conditions are created, as shown in
the following figure.
Figure 3: Thermal boundary conditions.

Step 6: Create CHBDYE surface elements for heat convection
Surface elements are to be created to simulate the heat exchange between the solid pipe and the
surrounding air. A predefined element set elem_convec, which contains the solid elements on the
outer surface of the pipe, is used to define the surface elements.
1. Click BCs > Create > Interfaces.
2. For Name, enter convection.
3. For Card Image, select CONVECTION from the drop-down menu.
4. Click Color and select a color from the palette.
5. Click MID to activate it.
An element group convection and a free convection property PCONV are created.
8. For Slave Entity IDs, select Elements. A panel appears under the graphics area.
9. Click on the switch button beside elems and select faces from the list.
10. Click the highlighted solid elems and select by sets from the selection menu.
11. Select element set elem_convec and click select.
12. Click nodes in face nodes field.
13. Select 4 nodes on the surface face of a solid element, as shown in the following figure.
Figure 4: Selected surface nodes on the solid element outside the pipe.

14. In the break angle = field, enter 89.0.
15. Click add. This adds the CHBDYE surface elements to the solid elements on the outer surface
following the same side convention, as shown in the following figure.
Figure 5: Surface elements on the outer layer of the pipe.
16. Click return to go back to the Create group window.
Step 7: Define the convection boundary condition to surface elements

1. Click the Card Edit icon .
2. Select elems entry.
3. Click elems >> by group.
4. Check the box in front of CONVECTION and click select.
5. Click config= and select slave4.
6. Click type= and select CHBDYE4.
7. Click edit and go to the CHBDYE card image panel.
8. Check the box in front of CONV.
9. Click TA1 and input the ambient node ID 4679, as shown below.

Figure 6: Defining the convection boundary condition
Step 8: Create a heat transfer loadstep

An OptiStruct steady state heat convection loadstep is created, which references the thermal
boundary conditions in the load collector spc_temp. The gradient, flux, and temperature output
for the heat transfer analysis is also requested in the loadsteps panel.
1. In the Model browser, right-click and select Create > Load Step. A default loadstep displays
2. For Name, enter heat_transfer.
3. Click on the Analysis type field and select Heat transfer (steady state) from the drop-
down menu.
5. In the Select Loadcol dialog, select spc_temp and click OK.
6. Check the box next to Output.
8. Activate the FORMAT fields for both outputs and select H3D format.
9. Activate the OPTION fields for both outputs and select ALL.
The FORMAT and OUTPUT fields for THERMAL output may open up a new window. Click on the
first field in the window to select the corresponding values.
FLUX and THERMAL output can also be requested in the Control cards panel on the Analysis
page.
Submit the Job

name for the model, thermal_complete.fem, in the File name: field. The .fem filename
extension is the recommended extension for Bulk Data Format input decks.

4. Click Save.
The name and location of the thermal_complete.fem file displays in the input file: field.
thermal_complete.fem was selected. The thermal_complete.out file is a good place to look
for error messages that could help debug the input deck if any errors are present.
View and Post process the Results
Gradient temperatures and flux contour results for the steady state heat conduction analysis and
the stress and displacement results for the structural analysis are computed from OptiStruct.
HyperView will be used to post process the results.
Step 10: View the results for heat transfer analysis

1. When the message Process completed successfully is received in the HyperWorks Solver View
dialog, click HyperView. HyperView is launched and the results are loaded. A message
window appears to inform of the successful model and result files loading into HyperView.
2. Click Close to close the message window, if one appears.
4. Select the first pull-down menu below Result type: and select Grid Temperatures(s).
5. Click Apply. A contour plot of grid temperatures is created.
You may have to use Edit Legend in the Contour panel to get the contour, as shown in Figure
7.
6. Select the first pull-down menu below Result type: and select Element Fluxes (V).
7. Click Apply.
You may have to use Edit Legend in the Contour panel to get the contour. Both temperature
and flux contour plots are shown in Figure 7.


OS-1090: Linear Transient Heat Transfer Analysis of an
Extended Surface Heat Transfer Fin
This tutorial outlines the procedure to perform a linear transient heat transfer analysis on a steel
extended-surface heat transfer fin attached to the outer surface of a system generating heat flux
(Example: IC engine). The extended surface heat transfer fin analyzed in this tutorial is one of
many from an array of such fins connected to the system. The fins draw heat away from the
outer surface of the system and dissipate it to the surrounding air. The process of heat transfer
out of the fin depends upon the flow of air around the fin (Free or forced convection). In the
current tutorial, the focus is on transient heat transfer through heat flux loading and free
convection dissipation.
An extended surface heat transfer fin made of steel is illustrated in Figure 1. To meet certain
structural design requirements, the fin is bent at 90° at approximately a quarter of its length.
Tip: A free convection analysis is conducted in this tutorial; however,

if forced fluid flow (forced convection) is allowed over the outer
surface of the system, then offsetting the fins from each other
periodically, interrupts the growth of a thermal boundary layer
and a reduction in flow velocity occurs due to form drag,
resulting in a higher heat transfer rate.
Figure 1: Extended surface heat transfer fin for convective and conductive transient heat transfer.
The extended surface heat transfer fin shown in Figure 1 is meshed with CHEXA elements in
HyperMesh and a transient heat transfer analysis is performed in HyperMesh using the Altair
OptiStruct solver. A typical heat flux load of 100 KW/m 2 is applied to the face connected to the
outer surface of the system. An ambient temperature of 25°C is assumed and all material
properties are assumed to remain constant with temperature and time. Free (Natural) convection
is assumed over the entire surface of the material, wherein heat transfer between the surface of
the fin and the surrounding air occurs due to a complex mechanism of density differences as a
result of temperature gradients.

Tip: In its simplest form, natural convection can be explained as the transfer
of heat from the hot surface to a layer of cold air just above it, leading
to an increase of temperature within that layer causing a drop in air
density. The hot air (less dense) then rises vacating space for a layer of
cold air (more dense) that takes its place and so on in a continuous
pattern until (if) steady-state is reached. In reality, however, the
process of natural convection is highly complex due to the complexities
in fluid flow and extensive experimental correlation is required for
accurate analysis.
Tutorial Prerequisites
1. The latest version of Altair HyperMesh, Altair HyperView and Altair OptiStruct software
installations. Transient heat transfer analysis is available only in Altair HyperMesh version-
12.0.110, Altair HyperView version-12.0.110 and Altair OptiStruct version-12.0.202 and later.
2. The heat_transfer_fin.fem solver deck is available from the optistruct.zip file. Refer to
Figure 2: Heat exchanger fin model for Transient Heat Transfer Analysis.
Brief Introduction to Linear Transient Heat Transfer Analysis

Linear transient heat transfer analysis can be used to calculate the temperature distribution in a
system with respect to time. The applied thermal loads can either be time-dependent or time-
invariant; transient thermal analysis is used to capture the thermal behavior of a system over a
specific period in time.
The basic finite element equation for transient heat transfer analysis is given by:
(1)
Where,
[C] is the heat capacity matrix
[K] is the conductivity matrix
[H] is the boundary convection matrix due to free convection

is the temperature derivative with respect to time
{T} is the unknown nodal temperature
{p} is the thermal loading vector.
The differential equation (1) is solved to find nodal temperature {T} at the specified time steps.
The difference between equation (1) and the steady-state heat transfer equation is the term,
that captures the transient nature of the analysis.
Checkpoint
Steady-state heat transfer analysis, generally, is sufficient for a wide variety of applications.
However, in situations where the system properties vary significantly over time the transient
nature of heat transfer must be considered. Some examples are the relatively slow heating up of
airplane gas turbine compressor disks compared to the turbine casing leading to aerodynamic
issues during takeoff or the analysis of the time taken for the onset of frostbite in fingers or toes.
 Creating the thermal material and the solid property for the given component
 Assigning the material and property to the component
 Creating flux and convective loads and boundary conditions for the model
 Submitting the job to Altair OptiStruct
 Post-processing the results using Altair HyperView
Setting up the Model in HyperMesh
Step 1: Loading the OptiStruct User Profile and importing the model into
HyperMesh
2. Select OptiStruct in the User Profiles dialog.
3. Click OK. This loads the OptiStruct user profile. It includes the appropriate template, macro
menu, and import reader, paring down the functionality of HyperMesh to what is relevant for
generating models for OptiStruct.

Figure 3: Alternate method for accessing the "User Profiles" option from the Preferences menu.
4. Click the Import Solver Deck icon . An Import panel opens.
Figure 4: Importing the solver deck into HyperMesh.
5. Set the File type: to OptiStruct.
7. Select the heat_transfer_fin.fem file you saved to your working directory from the
optistruct.zip file. Refer to Accessing the Model Files.
8. Click Open. The location of heat_transfer_fin.fem displays in the File: field.
9. Click Import. The heat_transfer_fin.fem database is loaded into the current HyperMesh
session.
Step 2: Creating the thermal material and property

The imported model only contains the component and predefined element sets for boundary
condition creation. Now create a thermal material that can be assigned to this component.

3. For Card Image, select MAT4 and click Yes to confirm.
4. Enter the following material property values for the MAT4 data entry.
[K] Thermal Conductivity = 7.3 x 10-2 W/mm °C.
[CP] Heat Capacity at constant pressure = 508 J/Kg °C
[RHO] Density of the material = 7.9 x 10-6 Kg/mm3
[H] Coefficient of heat transfer = 4 x 10-5 W/mm2 °C
Since you are conducting a purely heat transfer analysis, structural isotropic properties (for
example, MAT1 card) are not required. Also, it is assumed that the thermal material
properties (MAT4) are temperature independent.
A new material, steel, is created with thermal properties necessary for a transient heat
transfer analysis.
Now, create the solid property for this model referencing the PSOLID entry and connect the
material, steel, to this property; the property can then be assigned to the existing
component.
7. For Card Image, select PSOLID and click Yes to confirm.

Step 3: Linking the material and property to the existing structure
1. In the Model browser, click the component auto1. The Entity Editor opens.
3. In the Select Property dialog, select solid and click click OK.
The material steel now is automatically linked to the component auto1.

Step 4: Creating time-steps for the transient heat transfer analysis
A transient analysis captures the behavior of the system over a specific period of time. Therefore,
a time period of interest for your system is defined. A time period of 500 seconds (8 minutes, 20
seconds) is defined with results output every 10 seconds. A load collector is created for this
purpose and the TSTEP entry is referenced, as shown below:
1. In the Model browser, right-click and select Create > Load Collector.
2. For Name, enter Time Steps.
3. For Card Image, select TSTEP.
4. For TSTEP_NUM, enter a value of 1.
5. Click and enter the number of time steps (N) = 50 and set each time increment (DT) to
10.
This encompasses a total time period of 500 seconds in which to capture the behavior of the
system.
6. Click Close.
Step 5: Creating initial conditions for the transient heat transfer analysis
Since the temperature profile of the system varies over time, the initial grid point temperature
profile must be set to specify the starting point for the analysis. You assume that the
temperature of the entire system is equal to 25°C at T=0 seconds, the TEMPD bulk data entry
sets the initial temperatures.
2. For Name, enter Initial Conditions.
3. For Card Image, select TEMPD.
4. For T1, enter a value of 25.

Applying Ambient Temperature Boundary Conditions on the Model
Ambient temperature thermal boundary conditions is applied on the model by creating specific
load collectors for each. The ambient temperature is controlled using an SPCD entry, as this will
allow an ambient temperature variation over time to help mimic such physical requirements (if
any).
Step 6: Creating a time-variant ambient temperature

A time variable ambient temperature can be created by referencing an SPCD entry via a TLOAD1
data entry. The time variable nature of the ambient temperature can be captured using a
TABLED1 entry also referenced by the TLOAD1 data.
2. For Name, enter Ambient SPCD TLOAD1.
3. For Card Image, select TLOAD1. The TLOAD1 fields will be updated after the creation of the
corresponding SPCD and TABLED1 data entries.
4. Create another load collector named Ambient SPCD, and for Card Image, select None. The
newly created Ambient SPCD load collector is the current load collector (look at the right
bottom corner of the screen to verify that Ambient SPCD is displayed).
5. If the Ambient SPCD load collector is not specified, right-click Ambient SPCD in the Model
browser and click Make Current.
Figure 5: Displaying the current load collector - Ambient SPCD
6. Next, create the amplitude (constant part) of the time variant ambient temperature using an
SPCD data entry. Click BCs > Create > Constraints.

7. The ambient temperature is set by using the SPCD data entry to control an existing node
outside the actual structure. In the Constraints panel, click nodes > by id, enter 5672 in the
id= field and press ENTER. The ambient node is highlighted in the graphics window above the
structure.
8. Enter 5.0 in the size= field and uncheck the boxes beside all the degrees of freedom (dof1
through dof6) and enter 0.0 in all the fields next to the dof#.
9. For load types =, select SPCD.
Figure 6: Creating an SPCD entry to control the ambient temperature.
10. Click create/edit and enter 25.0 in the D field on the SPCD data entry. This creates an SPCD
referencing the ambient node specifying a temperature of 25°C.
11. Click return twice to go back to the Analysis page.
12. Next, create another load collector to define the time variant nature of the ambient
temperature. This is done by specifying a TABLED1 entry referenced by the previously created
TLOAD1 entry.
13. Create a new load collector (refer to Step 6.1) named Ambient SPCD Table, and set Card
Image, as TABLED1.
14. For TABLED1_NUM, enter 2 and press ENTER.
15. In the table, enter x(1) = 0.0, y(1) = 1.0, x(2) = 500.0, and y(2) = 1.0.
16. Click Close.
Tip: In this tutorial, a constant ambient temperature (the values of y(1)

and y(2) are the same leading to a constant temperature
distribution over the first 500 seconds) is defined; however, this
demonstrates the procedure to use a TABLED1 entry to specify a
time variant ambient temperature as well. To do this, specify
different values for the y# fields and depending on the type of
variation required, select from LINEAR or LOG options.
Checkpoint
The SPCD and its corresponding table are linked to the previously created TLOAD1 entry.

Figure 7: Process to specify a time-variant SPCD
17. In the Model browser, click the Ambient SPCD TLOAD1 load collector. It is displayed in the
Entity Editor.
18. For EXCITEID, select the Ambient SPCD load collector from the menu.
19. For TYPE, select DISP, then click TID and select the Ambient SPCD Table load collector
menu.
All entities referenced by SPCD entries should also be constrained by SPC data entries. The
value of the corresponding SPC referencing an ambient point controlled via an SPCD by
TLOAD1/2 entries should be equal to zero (0.0).
20. Create a new load collector (refer to Step 6.1) named Ambient SPC and for Card Image,
select None.
21. Make sure that the newly created load collector Ambient SPC is current and click BCs >
Create > Constraints and click nodes in the Constraints panel. Select by id from the
extended menu, enter 5672 and press ENTER. The ambient node is highlighted in the
graphics window above the structure.
22. Enter 5.0 in the size= field and uncheck the boxes beside all the degrees of freedom (dof1
through dof6) and enter 0.0 in all the fields next to the dof#.
23. For load types =, select SPC.
Figure 8: Creating the SPC boundary condition.
24. Click create/edit and enter 0.0 in the D field on the SPC data entry. This creates an SPC
referencing the same ambient node that is controlled by the SPCD data entry.

Applying a Heat Flux Load to the Model
Ambient temperature thermal boundary conditions have been assigned to the model and heat
flux load from the outer surface of the engine (to which the fin is attached) is applied on the
model. A time-varying heat flux load of 0 to 0.1 W/mm2 from 0 to 500 seconds is used for the
analysis of this fin. This load is applied on the model by creating specific load collectors for the
corresponding TLOAD1, QBDY1 and TABLED1 entries similar to the procedure used for the
ambient temperature SPCD definition.
Step 7: Creating a time-variant linearly increasing heat flux load

A time variable ambient temperature can be created by referencing an SPCD entry via a TLOAD1
data entry. The time variable nature of the ambient temperature can be captured using a
TABLED1 entry also referenced by the TLOAD1 data.
1. Create a new load collector (refer to Step 6.1) named Heat Flux TLOAD1 and select TLOAD1
as the Card Image. The TLOAD1 fields will be updated after the creation of the corresponding
QBDY1 and TABLED1 data entries.
2. Create another load collector (refer to Step 6.1) named Heat Flux QBDY1 and select None as
the Card Image. The newly created Heat Flux QBDY1 load collector is the “current” load
collector (look at the right bottom corner of the screen to verify if Heat Flux QBDY1 is
displayed).
3. If the Heat Flux QBDY1 load collector is not specified, right-click Heat Flux QBDY1 in the
Model browser and click Make Current.
Figure 9: Displaying the current load collector - Heat Flux QBDY1.
4. An interface is now created between the heat flux source and the solid elements on the
surface of the fin. This is done by clicking BCs > Create > Interfaces and specifying
conduction_interface in the Name field of the Create group dialog.
5. For Card Image, select CONDUCTION from the drop-down menu and click Yes to confirm.
6. For Slave Entity IDs, click on the yellow Elements panel. A panel appears under the
graphics area.
9. Check the box next to Element_set_Flux and click select. The predefined element set is
now highlighted in white on the model.

Figure 10: Highlighted element set is displayed in white.
Tip: The break angle helps find adjacent solid faces for the same element
set, however, since this surface element set generation requires only
one face, the value of the break angle is not germane in this situation.
10. Click nodes and select the nodes in the Figure 11.
Figure 11: Selecting the nodes on the highlighted surface for conduction surface element creation.

11. Click add and return to go back to the Create group dialog.
12. Click Close.
13. A conduction interface is created because QBDY1 data can only reference surface elements
and the conduction interface helps us create a set of surface elements at the surface where
heat flux is input.
Figure 12: Newly generated surface elements are displayed in blue as shown above.
14. Next, create the amplitude (constant part) of the time variant heat flux using a QBDY1 data
entry. Do this by clicking on BCs > Create > Flux.
Figure 13: Accessing these Flux creation panel.
15. Click elems, select by group and select conduction_interface. The newly created surface
elements are highlighted in white on the model.

16. Enter 0.1 in the value= field and select QBDY1 in the load types = field. Specify any low
value in the magnitude% = field to assign a value to the size of the display label for the flux
load.
Figure 14: Heat flux load panel.
17. Click create and return to go back to the Analysis page.

18. Next, create another load collector to define the linear time variant nature of the heat flux.
This is done by specifying a TABLED1 entry referenced by the previously created TLOAD1
entry.
19. Create a new load collector (refer to Step 6.1) named Heat Flux Table and select TABLED1
as the Card Image.
21. Click next to Data. In the pop-out window, enter x(1) = 0.0, y(1) = 0.0, x(2) = 500.0
and y(2) = 1.0.
Tip: In this tutorial, a linearly incremental heat flux load (the

values of y(1) and y(2) are 0 and 1 leading to a linearly
increasing heat flux distribution over the first 500 seconds) is
defined.
Checkpoint
The QBDY1 flux load and its corresponding table are linked to the previously created TLOAD1
entry.
22. In the Model browser, click the Heat Flux TLOAD1 load collector. The entry is displayed in
the Entity Editor.

23. For Card Image, select TLOAD1.
24. For EXCITEID, select the Heat Flux QBDY1 load collector from the pop-out table and click
OK.
25. For TYPE, select LOAD, then click TID and select the Heat Flux Table from the pop-out
table and click OK.
Adding Free Convection to the Model
Free convection is assigned in a similar manner to the procedure used for the creation of the
conduction interface. Free convection is, however, automatically assigned to all heat transfer
subcases and the PCONV and CONV entries should refer to the material, steel, and the ambient
temperature. The ambient temperature calculates the amount of heat transferred through free
convection.
Step 8: Creating surface elements for free convection

Surface elements are to be created to simulate the heat exchange between the fin surface and
the surrounding air. A predefined element set Element_set_convection, which contains the solid
elements on the outer surface of the fin defines the surface elements at the interface.
1. An interface is now created between the surrounding air and the solid elements on the surface
of the fin. This is done by clicking BCs > Create > Interfaces and specifying
convection_interface in the Name field of the Create group pop-up table.
2. For Card Image, select CONVECTION from the drop-down menu and click Yes to confirm.
3. For Slave Entity IDs, click on the yellow Elements panel. A panel appears under the
graphics area.
6. Select element set Element_set_Convection and click select. The predefined element set is
now highlighted in white on the model.

Figure 16: The highlighted element set is displayed in white.
7. Click nodes next to face nodes:, this highlights the same element set in black. Click any four
nodes on all highlighted faces of the model as shown in Figures 17 and 18 and specify a break
angle of 89°.
Tip: The break angle helps find adjacent solid faces for the same element set, all
adjacent faces with the angle between surface normals less than the
specified break angle are selected for surface element creation.
8. Click add and return to go back to the Analysis page.

9. Click the MID field and select steel from the menu.
Figure 17: Selecting the nodes on four of the seven highlighted surfaces for convection surface element creation.

Figure 18: Selecting nodes on the three remaining highlighted surfaces for the creation of a convection interface
The newly created CHBDYE surface elements are displayed in yellow, as shown in Figure 19
below.
Figure 19: Newly generated CHBBDYE surface elements are displayed in yellow on the model.
A new group convection_interface is created in the Model browser.

10. Click Close.
11. Next, the convection boundary condition is defined by referencing the ambient temperature in
the CONV data entry. This is done by clicking on the Card Edit icon and selecting the
elems entry.

12. Click elems > by group and select convection_interface from the menu.
13. Click config= and select slave4.
14. Click type= and select CHBDYE4.
15. Click edit and go to the CHBDYE card image panel.
16. Check the box beside CONV. Click TA1 and input the ambient node ID 5672.
Step 9: Combining the two TLOAD1 entries into one DLOAD entry.
Two different TLOAD1 entries have been defined and since they are to be referenced in the same
subcase they should be combined using a DLOAD data entry.
1. Create a new load collector (refer to Step 6.1) named Combined Flux and Convection and
select DLOAD as the Card Image.
2. For S, enter 1.0.
3. As only a simple linear addition of the two TLOAD1 entries are required, for DLOAD_NUM,
enter 2 and press ENTER.
4. Click next to Data below the DLOAD_NUM field. In the DLOAD_NUM pop-up window,
enter S(1) = 1.0 and S(2) = 1.0.
5. For L(1), select Ambient SPCD TLOAD1 from the menu and for L(2), select Heat Flux
TLOAD1 from the menu.
Checkpoint
The DLOAD entry is created as a linear combination of two TLOAD1 entries – Heat Flux
TLOAD1 and Ambient SPCD TLOAD1.
6. Click Close.

Step 10: Creating a transient heat transfer loadstep
An OptiStruct transient heat transfer loadstep is created which references the time steps in the
load collector Time Steps, the initial conditions in the load collector Initial Conditions, the heat
flux and free convection setup in the load collector Combined Flux and Convection, and the SPC
boundary condition in the load collector Ambient SPC. The gradient, flux, and temperature output
for the heat transfer analysis is also requested in the loadsteps panel.
1. In the Model browser, right-click and select Create > Load Step.
2. For Name, enter transient heat transfer.
3. Click the Analysis type field and select Heat transfer (transient) from the drop-down
menu.
5. In the Select Loadcol dialog, select Ambient SPC from the list of load collectors and click
OK to complete the SPC selection.
6. For IC, select Initial Conditions.
7. For TSTEP, select Time Steps.
8. For DLOAD, select Combined Flux and Convection.
9. Check the box next to Output.
11. Activate the FORMAT fields for both outputs and select H3D format.
12. Activate the OPTION fields for both outputs and select ALL. The FORMAT and OUTPUT
fields for THERMAL output may open up a new window. Click on the first field in the window
to select the corresponding values.
FLUX and THERMAL output can also be requested in control cards panel on Analysis page.
Submitting the job to OptiStruct

1. From the Analysis page, select the OptiStruct panel.
2. Click save as following the input file: field. A Save As browser window opens.
name for the model, heat_transfer_fin_complete.fem, in the File name: field. The .fem
filename extension is the recommended extension for OptiStruct input decks.
4. Click Save.
The name and location of the heat_transfer_fin_complete.fem file displays in the input
file: field.
6. Click the run options: switch and select analysis.

heat_transfer_fin_complete.fem was selected. The heat_transfer_fin_complete.out file
is a good place to look for error messages that could help debug the input deck if any errors
are present.
Viewing and Post-processing the Results
Grid temperatures, element temperature gradients and flux contour results are computed for the
transient heat transfer analysis and HyperView are used to post-process the results.
Step 12: Viewing the results of the transient heat transfer analysis
HyperView. HyperView is launched and the results are loaded.
A message window appears to inform of the successful model and result files loading into
HyperView.
Figure 21: Contour plot panel in HyperView.
5. Click Apply, select Time = 5.0000000E+02 from the Results browser. A contour plot of
grid temperatures at the final time step is created as shown in Figure 22.

Figure 22: Grid temperature contour for the final time step (500 seconds) – WITH FREE CONVECTION.
Checkpoint
In Figure 22, this is the grid point temperature plot after 500 seconds. The system is input a
linearly increasing heat flux from 0 to 0.1 W/mm 2 from 0 to 500 seconds respectively. Therefore,
a physical correlation can be the effect of starting an IC engine to full capacity wherein the flux
transmitted to the outer surface linearly increases with time. Note that the flux patterns in
actuality may be different and may fluctuate based on the duration of the power cycles. The
maximum temperature of 81.3°C predictably occurs at the elements closest to the heat flux
loading site and the minimum temperature of 29.5°C occurs at elements farthest from the heat
source.
6. Click Apply, select Time = 2.0000000E+01 from the Results browser. A contour plot of grid
temperatures is created, as shown in Figure 23.
Figure 23: Grid temperature contour plot after 20 seconds – WITH FREE CONVECTION.

7. Select the first pull-down menu below Result type: and select Element Fluxes (V).
8. Click Apply, select Time = 5.0000000E+02 from the Results browser to view the element
flux results after 500 seconds in Figure 25.
Checkpoint
In a practical setting, you can also see the effect of free convection in the reduction of
temperature at the outer surface of the system. Convection (due to the extended surface area)
allows a larger amount of heat to be drawn out of the system when compared to the absence of
an extended surface fin. This is evident in the temperature of the outer surface of the system
after 500 seconds in the absence of convection heat loss.
Figure 24: Grid Temperature Contour Plot after 500 seconds - WITHOUT FREE CONVECTION
The maximum temperature at the outer surface of the heat source system is 125.3°C which is an
increase of 44°C in 500 seconds. Therefore using an extended surface fin is a very effective way
to reduce the temperature of a system.
Figure 25: Contour plot of Element fluxes after 500 seconds.

OS-1100: Thermal Stress Analysis of a Printed Circuit Board
with Anisotropic Material Properties
Purpose
Printed Circuit Boards (PCB’s) are used in electronic components to both mechanically support
and provide electrical connections between components. Construction involves etching a thin
copper layer that has been deposited onto a non-conductive, glass-fiber/epoxy composite
substrate. Electrical components are then mounted to the board and connected to the copper
traces with electrical solder.
The concentrated, intense heating that occurs during the soldering process creates stresses in
the substrate material. In this exercise, you will simulate this process and determine if the
stresses and strains resulting from this process are acceptable or not.
The model makes use of solid hexahedral (CHEXA8) elements with a thin skin of shell elements
(CQUAD4) on the outside faces.
The consistent unit system used in this simulation are: kg, mm, GPa, kN and °C
Problem Statement
In this tutorial, you learn how to:

 Create MAT2 and MAT9 material definition cards
 Create PSOLID and PSHELL element property cards
 Create applied temperature loads and constraints (TEMP and SPC cards)
 Create a temperature loading subcase
 Request strain output with the STRAIN control card

Exercise

1. Launch HyperMesh. The User Profiles dialogs appears.
Step 2: Open the File circuit_board.hm

Model.
2. Select the circuit_board.hm file you saved to your working directory from the
3. Click Open. The circuit_board.hm database is loaded into the current HyperMesh session,
replacing any existing data. The database only contains geometric data.
Step 3: Create a MAT9 material definition for the solid elements

The MAT9 material type defines the properties for linear, temperature independent, anisotropic
materials. This material model is well suited to this tutorial, due to the composite structure of the
substrate. The X, Y and Z orientations of the laminated material have different elastic moduli and
thermal expansion coefficients. The MAT9 material applied to solid elements allows a
simplification of the model over using a shell model of the composite, with the individual ply layer
properties and orientations defined.
1. In the Model browser, right-click and select Create > Material.
2. For Name, enter PCB_solids.
3. For Card Image,select MAT9 and click Yes to confirm.
4. Enter the following values for the oriented elastic and shear modulus of the composite:
G11 G22 G33 G44 G55 G66
17.0 16.2 7.00 4.93 4.70 2.03
5. Enter the following values for the thermal expansion rates and reference temperature:
A1 A2 A3 TREF
1.6e-5 1.9e-5 8.0e-5 10.0

Step 4: Create a MAT2 material definition for the shell elements
You should still be in the materials/create panel from the previous step.
2. For Name, enter PCB_shells.
3. For Card Image, select MAT2 and click Yes to confirm.

4. Enter the following values for the shell element material properties:
G11 G22 G33 A1 A2 TREF
17.0 16.2 4.90 1.6e-5 1.9e-5 10.0
Step 5: Create properties with a material reference and update the

existing components
1. In the Model browser, right-click and select Create > Property.
2. For Name, enter shell.
3. For Card Image, select PSHELL.
5. In the Select Material dialog, select PCB_shells from the list of materials and click OK to
complete the material selection.
6. Enter the thickness for the shell component by clicking T, and enter 0.001.
7. Repeat steps 1 to 6 to create another property with name Solids, with Card Image set as
PSOLID and Material as PCB_solids.
8. In the Model browser, click the pcb_solids component. The component entry is displayed in
the Entity Editor below.
10. In the Select Property dialog, select Solids and click OK to complete the property selection.
11. Repeat steps 8 to 10 for both solder_pads and shell_faces selecting shell for the property
name.

Step 6: Create displacement constraints at the mounting holes
3. Leave Card Image set to None.
4. Select a suitable color.
6. Click nodes > by sets.
7. Select the constrain_nodes entity set and click select.
8. Leave all 6 degrees of freedom selected and click create.
9. Click return to go back to the main menu.
Step 7: Create applied temperature loads at the solder pad locations

1. Create a new load collector named temperature_loads.
3. Click BCs > Create > Temperatures to open the Temperatures panel.
4. Click nodes > by collector.
5. Check the box next to the solder_pads component.
6. Click select.
7. Verify that constant value (the field label specifies value=) is selected and enter 345.0.
8. Verify the load types= is set to TEMP.
9. Click create to create the temperature_loads.

Step 8: Create a thermal stress analysis subcase
2. For Name, enter thermal_loading.
3. Set the Analysis type to Linear Static.
5. In the Select Loadcol dialog, select constraints from the list of load collectors and click OK to
complete the selection.
6. For TEMP, click Unspecified > TEMP.

7. In the Select Loadcol dialog, select temperature_loads from the list of load collectors and
click OK to complete the selection.
Step 9: Add OUTPUT, STRAIN and SCREEN control cards to the analysis
deck
2. Click next to advance until OUTPUT is available, click OUTPUT to add card requesting output
results format.
3. For the number_of_outputs field on the lower part of the panel, enter 2.
4. Set one of the KEYWORD to OP2 to request the OP2 format results file, and set the second
output as H3D format. The frequency (FREQ) of the output can be set as ALL.
5. Click return to go back to the Control Cards panel.
6. Click next to advance to the second page of control cards, then once more to go to the third
page.

7. Activate the SCREEN card with the OUT option.
8. Then return to the Control Card panel.
9. Select GLOBAL_OUTPUT_REQUEST on the first page to access the output settings.
10. Activate the STRAIN option to request strain results output. Leave the default settings for
this card.
11. Click return twice to get back to the main menu.
Step 10: Run the analysis and review the results

2. Click Save as and enter the file name as <your_file_name>.fem.
3. Click OptiStruct to submit the job.
4. Once the job has completed, the results can be reviewed in HyperView.

OS-1110: Setting up a Modal Analysis
In this tutorial, you continue to gain an understanding of the basic concepts for creating a
OptiStruct input file. More specifically, learn how to set up a model for modal analysis, specify
solver specific controls and also submit an input file to the solver from HyperMesh.
Problem Statement
The channel_brkt_modal.hm file is used for this tutorial. It contains the bracket and channel
assembly pictured below.
To complete the setup of the model for a modal analysis with OptiStruct, you need to define a
normal modes SUBCASE, containing METHOD and SPC statements.

 Create constraints (SPC) on the channel’s geometry lines, as shown in the image above.
Then map the constraints to the channel nodes associated to the geometry lines.
 Define a load step (OptiStruct loadsteps)
Name the load step modal_run. For METHOD, point to the EIGRL card, and for SPC point to
the constraints collector.

 Use OUTPUT on control cards panel to control the format of results output.
Specify a h3d file as the output format. Add a second OUTPUT line and select the option HM
for a HyperMesh .res file.
 Export the model to a OptiStruct input file
Specify a filename with the extension *.fem.
 Submit the OptiStruct input file to OptiStruct
Exercise
Step 1: Select User Profile and retrieve the HyperMesh model file
1. Launch HyperMesh. The User Profiles dialogs appears.
Model.
4. Select the channel_brkt_modal.hm file you saved to your working directory from the
Step 2: Review and edit the materials for this analysis

This step can be done from the Model browser.
1. In the Model browser, expand the Material folder to show the two materials in the model.
2. Click on aluminum and the material entry is displayed in the Entity Editor.
3. For RHO, enter 2.7e-9.
4. Repeat steps 1 to 3 to input an RHO value of 7.9e-9 for the steel entry.
Step 3: Create a load collector named modal

This can be done using the Load Collectors panel and the create subpanel. You need a card image
for the EIGRL modal collector and no card image for the constraints collector.
2. For Name, enter modal.
4. For ND, enter 10. Here, ND specifies the number of modes that need to be extracted.

Step 4: Create a load collector named constraints
3. Leave the Card Image set to None.
Step 5: Apply constraints (OptiStruct SPC) on the channel

Display the geometry for the component channel and set the view to iso1. Then set the
HyperMesh constraint configuration to SPC.
1. Expand the Component folder in the Model browser.
2. Click the geometry icon next to the channel component to turn the geometry display on.
3. Click the Isometric View icon in the toolbar.
You are going to create the SPC constraints on the nodes along the lines on the perimeter of
the channel’s bottom surface, as shown in the image below.

Apply constraints on the channel
5. Switch the entity selector to lines.
6. Select the six lines on the perimeter of the channel’s bottom surface.
To view the selected lines clearly, switch to the Transparent Elements mode, as shown
below:
7. Activate degrees of freedom (dof) 1 through 6.

For an OptiStruct linear static analysis, dof 1, 2, and 3 represent translations in the global x,
y, and z directions respectively. Dof 4, 5, and 6 represent rotations about the global x, y and
z axis, respectively.
8. For size =, enter 10. The display size of the constraints is reduced.
9. Click create > return to exit the panel.

Step 6: Map the constraints (OptiStruct SPC) on the geometry lines to
the channel nodes associated to the lines
Use the load on geom panel in this step.
1. From the Analysis page, click load on geom.
2. Click loadcols, and select constraints.
3. Click select to complete the selection of load collectors.
4. Click map loads. A constraint is at each node associated to the geometry lines.
Step 7: Define the load step (OptiStruct loadsteps) for the modal load
case
Use the Load Step Entity Editor in this step. Define the loadstep to contain the load collectors
constraints and modal.
2. For Name, enter normal_modes.
3. For Analysis type, select Normal modes.
4. For METHOD(STRUCT), select modal.
5. For SPC, select the load collector constraints.
Step 8: Define the formats of result files to be output from OptiStruct

In the Control Cards panel, use the OUTPUT card to add two output requests for the Altair H3D
and HyperMesh .res formats.
2. Click next to go to the next panel menu of control cards.
3. Select the control card OUTPUT.
Notice in the card image the one OUTPUT line is set to a default value. This specifies
OptiStruct to output the results to a HyperMesh command file.
4. Click the default value and select H3D from the pop-up menu.
5. For number_of_outputs =, enter 2. A second OUTPUT line appears in the card image.
6. Click the default value again and select HM for the second output type.
This specifies OptiStruct to output results to a H3D file and a .res file, which can be viewed in
HyperView Player. Also, an HTML report file is output and the H3D file is embedded in it.
7. Click return to return to the Control Cards panel.
Notice: The OUTPUT button is green. This indicates the card is exported to the OptiStruct
input file.

Step 9: Run the analysis and review the results
2. Click save as and enter the file name as modal_analysis.fem.
3. Click OptiStruct to submit the job.
4. Once the job has completed, the results can be reviewed in HyperView.

Advanced Small Displacement Finite Element Analysis
OS-1300: Direct Frequency Response Analysis of a Flat Plate

This tutorial demonstrates how to import an existing FE model, apply boundary conditions, and
perform a finite element analysis on a flat plate. The flat plate is subjected to a frequency-
varying unit load excitation using the direct method. Post-processing is done in HyperView and
HyperGraph to visualize deformations, mode shape response, and frequency-phase output
characteristics.
 Viewing the results (HyperMesh and HyperGraph)
The following file found in the optistruct.zip file is needed to perform this tutorial. Refer to
direct_response_flat_plate_input.fem Original ASCII OptiStruct input deck
Exercise

1. Launch HyperMesh. A User Profiles dialog appears.
Step 2: Import the Finite Element Model File

3. Select the Files icon . A Select OptiStruct File browser opens.

4. Select the direct_response_flat_plate_input.fem file from the optistruct.zip file. Refer
to Accessing the Model Files.
5. Click Open > Import.
6. The direct_response_flat_plate_input.fem OptiStruct input file is loaded into the current
HyperMesh session.
7. Click Close to exit the tab.

Setting up the Problem in HyperMesh (Steps 3 - 11)
Step 3: Apply Loads and Boundary Conditions to the Model

In the following steps, the model is constrained at one edge. A unit vertical load is applied acting
upwards in the positive z-direction at a point on a free edge corner of the plate.
4. Click Color and select a color from the color palette.
5. Set the Card Image to None. A new load collector, spcs is created.
7. For Name, enter unit-load.
8. Click Color and select a different color from the color palette. A new load collector, unit-load
is created.
Step 4: Create Constraints

1. In the Model browser, expand Load Collector, right-click spcs > Make Current.
2. Click the Display Numbers icon .

3. Click nodes >> displayed.
4. Select on (green button). All of the node numbers on the flat plate should now be displayed.
5. Click return to get to the main menu.

6. Click BCs > Create > Constraints to open the Constraints menu.
8. Click nodes and select nodes 5, 29, 30, 31 and 32 (see figure).
Illustration of which nodes to select for applying single point constraints
9. Constrain dof1, dof2, dof3, dof4 and dof5.

DOFs with a check will be constrained, while dofs without a check will be free.
DOFs 1, 2, and 3 are x, y and z translation degrees of freedom.
DOFs 4, 5, and 6 are x, y and z rotational degrees of freedom.
You need only to uncheck dof6.
10. Click create. The selected nodes will be free to rotate about the z-axis since dof6 was not
checked.
Step 5: Create a Unit Load at a Point on the Flat Plate

1. In the Model browser, right-click on the load collector unit-load and select Make Current.
2. From the Analysis page, click load types.
3. Select constraint = and select DAREA from the extended entity selection menu.
4. Click return to exit the Load Types panel.
5. Click BCs > Create > Constraints to open the Constraints menu.
6. Select node number 19 on the plate by clicking on it (see figure).

Node selected for creating unit vertical load.
7. Uncheck all the dof's; except dof3, and click the = to the right of dof3 and enter a value of
20.
8. Click load types= and verify that DAREA is selected from the extended entity selection
menu.
9. Click create, and then click return.
Step 6: Create a Frequency Range Table

2. For Name, enter tabled1.
4. For Card Image, select TABLED1 from the drop-down menu.
5. For TABLED1_NUM, input a value of 2 and press Enter.
6. Click the Table icon below TABLED1_NUM and enter x(1) = 0.0, y(1) = 1.0, x(2) =
1000.0 and y(2) = 1.0 in the pop-out window.
7. Click Close. This provides a frequency range of 0.0 to 1000.0 with a constant 1.0 over this
range.
Step 7: Create a Frequency Dependent Dynamic Load

2. For Name, enter rload2.
4. For Card Image, and select RLOAD2 from the drop-down list.
5. For EXCITEID, click Unspecified > Loadcol.
6. In the Select Loadcol dialog, select unit-load from the list of load collectors and click OK to

7. Similarly select the tabled1 load collector for the TB field.
The type of excitation can be an applied load (force or moment), an enforced displacement,
velocity or acceleration. The field Type in the RLOAD2 card image defines the type of load.
The type is set to applied load by default.
Step 8: Create a Set of Frequencies to be used in the Response Solution

2. For Name, enter freq1.
4. For Card Image, select FREQi from the drop-down menu.
5. Check the FREQ1 option and enter 1 in the NUMBER_OF_FREQ1 field.
6. Click and enter F1= 20.0, DF = 20.0, NDF = 49, in the pop-out window.
7. Click Close. This provides a set of frequencies beginning with 20.0, incremented by 20.0 and
49 frequencies increments.
Step 9: Create an OptiStruct Loadstep (also referred to as a subcase)

2. For Name, enter subcase1.
3. For Analysis type, select Freq.resp (direct) from the drop-down menu.
4. For SPC, select spcs from the Select Loadcol pop-out window.
5. For DLOAD, select rload2 from the Select Loadcol pop-out window.
6. For FREQ, select freq1 from the Select Loadcol pop-out window.
spc and the unit load in the load collector rload2 with a set of frequencies defined in load
collector freq1.
Step 10: Create a Set of Nodes for Output of Results

1. In the Model browser, right-click and select Create > Set.
2. For Name, enter SETA.
3. For Card Image, select None.
4. Leave the Set Type switch set to non-ordered type.
5. For Entity IDs, select Nodes from the selection switch.
6. Click Nodes and select nodes with IDs 15, 17 and 19.
7. Click proceed.

Step 11: Create a Set of Outputs and Mass Factors Specific to Frequency
Response Analysis
2. Select GLOBAL_OUTPUT_REQUEST and check the box next to DISPLACEMENT.
3. Under FORM(1), select PHASE from the pop-up menu.
4. Under OPTION(1), select SID from the pop-up menu. A new field appears in yellow.
5. Double-click the SID(1) box and select SETA.
A value of 1 now appears below the SID field box. This sets the output for only the nodes in
set 1.
6. Click return to exit the GLOBAL_OUTPUT_REQUESTS menu.

7. From the Control Cards panel, select FORMAT. A new window appears in the work area
screen.
8. Click number_of_formats = and input a value of 2.
9. On the extended menu in the work area, click on the first FORMAT_V1 field box and select
OPTI from the pop-up menu.
Using OPTI generates OptiStruct ASCII result files like .disp, .strs, etc. as the output once
the run is complete. These files are used during post-processing.
10. Make sure the second field box is set to H3D.
11. Click return to exit the Format menu and return to the Control Cards menu.
12. Click next and select the PARAM subpanel.
13. Scroll down the list using the arrow in the left corner and check the box next to COUPMASS.
A new PARAM card appears in the work area screen.
14. Click NO below COUPM_V1 and select YES from the pop-up menu selection.
Selecting YES uses the coupled mass matrix approach for eigenvalue analysis.
15. Scroll down the list using the arrow in the left corner and check the box next to G. A new
PARAM card appears in the work area screen.

16. Click below G_V1 and input a value of 0.06 into the field box.
This value specifies a uniform structural damping coefficient and is obtained by multiplying
the critical damping [] ratio by 2.0.
17. Scroll down using the arrow in the left corner and check the box next to WTMASS.
A new window appears in the work area screen.
18. Click below WTM_V1 and input a value of 0.00259 into the field box. Three PARAM
statements now appear in the pop-up menu on the work screen.
This factor is used to input all mass entries in weight units. Using this PARAM multiplies all
terms in the mass matrix by this factor.
19. Click return to exit the PARAM menu.

20. Select the OUTPUT subpanel.
21. Verify that KEYWORD is set to HGFREQ.
Using HGFREQ results in a frequency output presentation for HyperGraph.
22. Click on the box beneath FREQ and select ALL from the pop-up selection to choose all
outputs results for all frequencies.
23. Leave number_of_outputs set equal to 1.
24. Click return to exit OUTPUT.
25. Click return to exit the Control Cards panel.

Submitting the Job
Step 12: Run OptiStruct

2. Click save as.
3. Select the directory where you would like to write the OptiStruct model, enter the name
flat_plate_direct_response.fem for the model in the File name: field, and click Save.
If the job is successful, new result files can be seen in the director where the OptiStruct
model file was written. The flat_plate_direct_response.out file is a good place to look for
flat_plate_direct_response.html HTML report of the analysis, giving a summary

of the problem formulation and the analysis
results.
flat_plate_direct_response.out OptiStruct output file containing specific

information on the file set up, the set up of
your optimization problem, estimates for the
amount of RAM and disk space required for the
run, information for each of the optimization
iterations, and compute time information.
Review this file for warnings and errors.
flat_plate_direct_response.h3d HyperView compressed binary results file.
flat_plate_direct_response.stat Summary of analysis process, providing CPU

information for each step during the analysis
process.
Viewing the Results (HyperMesh and HyperGraph)
Step 13: Review the Results

This step describes how to view displacement results (.mvw file) in HyperGraph and also explains
the displacement output (.disp file) from this run. The HyperView results (.h3d file) contains
only the displacement results for the three nodes specified in the node set output.
1. Click HyperView to launch HyperView.
2. Click Close to close the Message Log window, if one appears.
3. In the HyperView window, click File > Open > Session. The Open Session File window is
displayed.

4. Select the directory where the job was run and select the file
flat_plate_direct_response_freq.mvw.
5. Click Open.
6. A warning appears asking whether to discard the existing contents. Click Yes.
Two graphs per page and a total of three pages are displayed.
The graph title shows Subcase 1 Displacement of grid 15 on page 1.
There are two sets of results on this page. The top graph shows Phase Angle verses
Frequency (log). The bottom graph shows Magnitude versus Frequency (log) (see figure) for
Displacement of grid 15.
Frequency response of node 15.
7. Click the Next Page icon .

This displayed page 2, which shows Subcase 1 (subcase1) - Displacement of grid 17 (see
figure).

8. Select the Next Page icon again to display page 3 containing Subcase 1 (subcase1) -
Displacement of grid 19 (see figure).
This concludes the HyperGraph results processing.

9. Open the displacement file (.disp) using a text editor.
The first field on the second line shows the iteration number, the second field shows the
number of data points, and the third field shows the iteration frequency.

Line 3, first field shows node number, then x, y, and z displacement magnitudes and x, y and
z rotation magnitudes.
Line 4, first field shows node number, then x, y, and z displacement phase angles and x, y
and z rotation angles.

OS-1305: Modal Frequency Response Analysis of a Flat Plate
This tutorial demonstrates how to import an existing FE model, apply boundary conditions, and
perform a modal frequency response analysis on a flat plate. The flat plate is subjected to a
frequency varying unit load excitation using the modal method. Post-processing tools will be used
in HyperView and HyperGraph to visualize deformations, mode shape response, and frequency-
phase output characteristics.
 Review the results (HyperMesh and HyperGraph)
modal_response_flat_plate_input.fem Original ASCII OptiStruct input deck.
Exercise

1. Launch HyperMesh. A User Profiles dialog appears.

2. Click the Open file icon in the File: field. A Select OptiStruct File file browser window
opens.
3. Select the modal_response_flat_plate_input.fem file you saved to your working directory
from the optistruct.zip file and click Open. Refer to Accessing the Model Files.
The location of the file displays in the File: field.
4. Click Import to import the model file.
5. Click Close to close the Import tab.


In the following steps, the model is constrained at one edge. A unit vertical load is applied acting
upwards in the positive z-direction at a point on a free edge corner of the plate.
First, the two load collectors (spcs and unit-load) are created.
4. For Card Image, set to None. A new load collector, spcs is created.
7. Click Color and select a color from the color palette. A new load collector, unit-load is
created.
8. Click the Display Numbers icon to open the Numbers panel.
9. Click nodes > displayed.
10. Check the box next to display.
11. Select the green on button. All of the node numbers on the flat plate should now be
displayed.

1. In the Model browser, right-click the load collector spcs and select Make Current.
4. Click nodes and select nodes 5, 29, 30, 31 and 32 (see figure).

Illustration of which nodes to select for applying single point constraints
5. Constrain dof1, dof2, dof3, dof4, and dof5.

DOFs with a check will be constrained while dofs without a check will be free.
DOFs 1, 2, and 3 are x, y, and z translation degrees of freedom.
DOFs 4, 5, and 6 are x, y, and z rotational degrees of freedom.
You will need only to un-check dof6.
6. Click create. The selected nodes will be free to rotate about the z-axis since dof6 was not
checked.

1. In the Model browser, right-click unit-load and select Make Current.
3. Select node number 19 on the plate by clicking on it. (see figure).
Node selected for creating unit vertical load.
4. Uncheck all dofs except dof3, and click the = to the right of dof3 and enter a value of 1.

5. For load types =, select DAREA from the extended entity selection menu.
6. Click create. This applies a unit load to the selected node.

5. For TABLED1_NUM, enter a value of 2 and press ENTER.
6. Click below TABLED1_NUM and enter x(1) = 0.0, y(1) = 1.0, x(2) = 1000.0 and y(2) =
1.0 in the pop-out window.
7. Click Close. This gives a frequency range of 0.0 to 1000.0 with a constant 1.0 over this
range.

4. For Card Image, select RLOAD2 from the drop-down list.
7. Similarly select the tabled1 load collector for the TB field.
velocity, or acceleration. The field TYPE in the RLOAD2 card image defines the type of load.

5. Check the FREQ1 option and enter 1 in the NUMBER_OF_FREQ1 field.
6. Click and enter F1= 20.0, DF = 20.0, NDF = 49, in the pop-out window.
7. Click Close. This gives a set of frequencies beginning with 20.0, incremented by 20.0 and 49
frequencies increments.

Step 9: Create the modal method for eigenvalue analysis using the
Lanczos method and specify the frequency range for eigenvalue
extraction
2. For Name, enter eigrl.
5. Click V1 and enter a value 0.0, then click V2 and enter a value of 1000.0.
This specifies a range of frequency between 0 Hz and 1000 Hz for eigenvalue extraction using
the Lanczos method.
Step 10: Create an OptiStruct Loadstep

3. For Analysis type, select Freq.resp (modal) from the drop-down menu.
4. For METHOD(STRUCT), select Unspecified > Loadcol.
5. From the Select Loadcol dialog, select eigrl.
6. For SPC, select Unspecified > Loadcol.
7. From the Select Loadcol dialog, select spcs.
8. For DLOAD, select Unspecified > Loadcol.
9. From the Select Loadcol dialog, select rload2.
10. For FREQ, select Unspecified > Loadcol.
11. From the Select Loadcol dialog, select freq1.
An OptiStruct subcase is created which references the constraints in the load collector spc,
the unit load in the load collector rload2 with a set of frequencies defined in load collector
freq1 and modal method defined in the load collector eigrl.
Step 11: Create a set of nodes for output of results

3. For Card Image, select None from the drop-down menu.
5. For Entity IDs, select Nodes from the selection switch.
6. Click on the yellow Nodes button and select nodes with IDs 15, 17 and 19.
7. Click proceed.

Step 12: Create a set of outputs and mass factors specific to frequency
response analysis
2. Select GLOBAL_OUTPUT_REQUEST and check the box next to DISPLACEMENT
3. Click the field box FORM(1) and select PHASE from the pop-up menu.
4. Click the field box OPTION(1) and select SID from the pop-up menu. A new field appears in
yellow.
5. Double-click the yellow SID box and select SETA from the pop-up selection on the bottom
left corner.
set 1.
6. Click return to exit the GLOBAL_OUTPUT_REQUEST menu.
7. Click next and select PARAM subpanel.
8. Scroll down the list using the arrow in the left corner and check the box next to COUPMASS.
A new PARAM card appears in the work area screen.
9. Below COUPM_V1 click NO and select YES from the pop-up menu selection. Selecting YES
uses the coupled mass matrix approach for eigenvalue analysis.
10. Check the box next to G. A new window appears in the work area screen.
11. Click below G_V1, and input a value of 0.06 into the field box. This value specifies a uniform
structural damping coefficient and is obtained by multiplying the critical damping [C/C 0] ratio
by 2.0.
12. Scroll down using the arrow to the left corner and check the box next to WTMASS. A new
window appears in the work area screen.
13. Click below WTM_V1, and input a value of 0.00259 into the field box. Three PARAM
statements now appear in the pop-up menu on the work screen.
15. Select the OUTPUT card. A new window appears in the work area.
16. Enter 3 in the number_of_outputs field.
17. Set the first KEYWORD to HGFREQ. Using HGFREQ results in a frequency output
presentation for HyperGraph.
18. Set the second KEYWORD to OPTI.
19. Set the third KEYWORD to H3D.
20. Double-click on the box beneath FREQ and select ALL from the pop-up selection for all
keywords. Choosing ALL will output all optimization iterations.
21. Click return to exit OUTPUT.
22. Click return to exit the Control Cards menu.

Submitting the Job

1. From the Analysis panel, select OptiStruct.
2. Following the input file: field text box and click save as.
3. Select the directory where you would like to write the OptiStruct model file, enter the name
flat_plate_modal_response.fem in the File name: field, and click Save.
4. Select run options: switch and select analysis.
model file was written. The flat_plate_modal_response.out file is a good place to look for
flat_plate_modal_response.html HTML report of the analysis, giving a summary
of the problem formulation and the analysis
results.
flat_plate_modal_response.out OptiStruct output file containing specific

information on the file setup, the setup of your
optimization problem, estimates for the amount
of RAM and disk space required for the run,
information for all optimization iterations, and
compute time information. Review this file for
warnings and errors.
flat_plate_modal_response.h3d HyperView binary results file.
flat_plate_modal_response.stat Summary of analysis process, providing CPU

information for each step during analysis
process.

Review the Results (HyperMesh and HyperGraph)
Step 14: Review the results

This step describes how to view displacement results (.mvw file) in HyperGraph and also how to
understand the displacement output (.disp file) from this run. The HyperView results file (.h3d)
contains only the displacement results for the three nodes specified in the node set output.
1. When the analysis process completes, click HyperView to open a HyperView session.
2. Close the Message log menu, if one appears.
3. In the HyperView window, click File > Open > Session. An Open Session File window opens.
4. Select the directory where the job was run and select file
flat_plate_modal_response_freq.mvw.
5. Click Open.
6. A discard warning appears. Click Yes.
Two graphs per page and a total of three pages are displayed in HyperGraph. The graph title
shows Subcase 1 (subcase 1) - Displacement of grid 15 on page 1.
7. Click the Axis toolbar icon . Select Logarithmic option and use the parameters shown
below (see figure) to make logarithmic plots of the results.
Frequency (log). The bottom graph shows Magnitude verses Frequency (log) (see figure) for

Frequency response of node 15
8. Directly underneath the blue graph border, click the Next Page icon . Page 2 displays,
which shows Subcase 1 (subcase1) - Displacement of grid 17.

9. Click the Next Page icon again to display page 3 containing Subcase 1 (subcase1) -

10. Open the displacement file (.disp) using a text editor.
The first field on the second line shows the iteration number, the second field shows number
of data points, and the third field shows iteration frequency.
Line 3, first field shows node number, then x, y and z displacement magnitudes and x, y and
z rotation magnitudes.
Line 4, first field shows node number, then x, y and z displacement phase angles and x, y and
z rotation phase angles.

OS-1310: Direct Transient Dynamic Analysis of a Bracket
In this tutorial, an existing finite element model of a bracket is used to demonstrate how to
perform direct transient dynamic analysis using OptiStruct. HyperGraph is used to post-process
the deformation characteristics of the bracket under the transient dynamic loads.
Finite element model of the bracket
The bracket is constrained at the bottom of the two legs. Transient dynamic loads are to be
applied at the grid points of the top, flat surface of the bracket around the hole in the negative z
direction. The time history of the loading is shown in the next figure. The direct transient analysis
is run for a total time of 4 seconds with the time being divided into 800 increments (that is time
step is 0.005). Structural damping has been considered for the model. A concentrated mass
element is defined at the center of the spider and z displacements are monitored at the
concentrated mass at the center of this hole.

Time history of applied loading
This tutorial uses the following exercises to set up a direct transient dynamic analysis:
 Create the time dependent dynamic load or the variation of load vs time
 Create the time step for transient analysis
 Create the grid point forces on the top flat surface of the bracket
 Create the transient response dynamic excitation
 Create the subcase to include all the necessary loads as defined above
 Specify structural damping and output requests
 Run direct transient dynamic analysis
 Post-process results using Altair HyperGraph

Exercise

Step 2: Retrieve the file

Model.
2. Select the bracket_transient.hm file you saved to your working directory from the
Setting up the Transient Dynamic Analysis Problem (Steps 3 - 9)
Step 3: Create a TABLED1 (Table to define time dependent dynamic

load)
6. Click the table icon below TABLED1_NUM and enter the values in the pop-out window, as
shown in the figure below.

7. Click Close. The load collector TABLED1 that defines the time history of the loading has been
created.
Step 4: Create a TSTEP (Transient time step to define the time step
intervals at which solution is generated and output)
2. For Name, enter tstep.
4. For Card Image, select TSTEP on the pop-up menu.
5. For TSTEP_NUM, enter 1 and press ENTER.
6. For N, enter the number of time steps as 800.
7. For DT, enter the time increment of 0.005. The total time applied to the load is: 800 x 0.005
= 4 seconds.
NO has a default value of 1.0. This is the time step at which output is requested.
8. Click Close.
Step 5: Create a DAREA to define forces on the top surface of the

bracket
2. For Name, enter darea.
6. Click nodes > by sets.
7. Two sets are displayed, select force and click select. The nodes that belong to the set force
get selected.
8. Uncheck all degrees of freedom (dof); except dof3 by clicking the box next to each, indicating
that dof3 is the only active degree of freedom.
9. For dof3, enter a value of -1500.
10. For load types=, select DAREA.
11. Click create. This creates a force of 1500 units applied to the selected nodes in the negative z
direction.
Step 6: Create a TLOAD1 (the transient dynamic response excitation)

2. For Name, enter tload1.

4. For Card Image, select TLOAD1 from the drop-down list.
5. For EXCITEID , click Unspecified > Loadcol.
6. In the Select Loadcol dialog, select darea from the list of load collectors (created in the last
section to define the forces on the top surface of the bracket).
7. Click OK to complete the selection.
8. Similarly select the tabled1 load collector for the TID field (to define the time history of the
loading).
velocity, or acceleration. The field [TYPE] in the TLOAD1 card image defines the type of
load. The type is set to applied load by default.
Step 7: Create a Load Step to perform Direct Transient Analysis

2. For Name, enter transient.
3. For Analysis type, select Transient (direct) from the drop-down menu.
4. For SPC, select spc from the Select Loadcol pop-out window.
5. For DLOAD, select tload1 from the Select Loadcol pop-out window.
6. Activate TSTEP(TIME) and select the load collector tstep created previously. A subcase is
created that specifies the loads and boundary conditions for direct transient dynamic analysis.
Step 8: Create Damping parameters for transient dynamic analysis

1. Click Setup > Create > Control Cards to enter the Control Cards panel.
2. Click next to see more cards.
3. Click PARAM to define parameter cards.
4. Scroll down to activate G, click on G_V1, and enter 0.2.
This parameter specifies the uniform structural damping coefficient for the direct transient
dynamic analysis.
5. Scroll down to activate W3, click on W3_V1, enter 300.
This parameter is used in transient analysis to convert structural damping to equivalent
viscous damping.
6. Click return.
Step 9: Create Output requests for Transient Dynamic Analysis

1. Click GLOBAL_OUTPUT_REQUESTS and select DISPLACEMENT and leave the space
beneath FORMAT blank.
2. For FORM(1), select BOTH.
3. For OPTION(1), select SID. A yellow button labeled SID appears.

4. Double-click on SID and select center.
5. Select the option for center.
This set represents the node at the center of the spider attached to the mass element that is
node 395.
6. Click return > next.
7. Click OUTPUT.
8. Under number_of_outputs =, enter 2.
9. For KEYWORD, select H3D and HGTRANS.
10. For FREQ, select ALL for both.
11. Click return twice to exit from the Control Cards panel.
Submit the Job

1. Click File > Save as > Model to set the directory in which to save the file.
2. In File name:, enter bracket_transient_direct.hm.
3. Click Save.
Step 11: Running direct transient dynamic analysis

3. Select the directory where you would like to write the file and enter the name
bracket_transient_direct.fem in the File name: field.
4. Click Save.
The name and location of the bracket_transient_direct.fem file displays in the input file:
field.
6. Set the run options: togle to analysis.
model file was written. The bracket_transient_direct.out file is a good place to look for

bracket_transient_direct.html HTML report of the analysis, giving a summary of the

problem formulation and the results.
bracket_transient_direct.out OptiStruct output file containing specific information on

the file setup, the setup of the problem, estimates for
the amount of RAM and disk space required for the run
and compute time information. Review this file for
warnings and errors that are flagged from processing
the bracket_transient_direct.fem file.
bracket_transient_direct.h3d HyperView binary results file
bracket_transient_direct_tran.mvw HyperView session file. This file is only created when

transient analysis is performed. This file automatically
creates plots for the displacement, velocity and
acceleration results contained in the file.
bracket_transient_direct.stat Summary of analysis process, providing CPU information

for each step during analysis process.
Review the Results using HyperGraph
Step 12: Post-process displacement results of node 395

1. From the OptiStruct panel, click HyperView to launch HyperView.
2. Click File > Open > Session.
3. Select the HyperView session file bracket_transient_direct_tran.mvw from the directory in
which the input file was run. The following prompt appears:
4. Click Yes to close the message window. This file automatically creates plots for the
displacement results contained in the file.
Since the loading is applied only in the z-direction, you are interested in the z-displacement
time history of node 395.
5. Click on the Curve Attributes toolbar icon and turn off the curves X Trans and Y Trans.
This can be done by selecting the individual curves (X Trans and Y Trans) and then by clicking
the line attributes Off, as shown below:

6. Click to fit the y-axis (that is Z displacement) of node 395 in the GUI.
7. You can change the color and/or line attributes of the curve if you wish to.
Z-displacement time history of the concentrated mass at center of spider for direct transient dynamic analysis
As can be observed from the above image, the displacements of node 395 are in the negative
z-direction as the loading is in the –z direction too. The displacements eventually damp out
due to the structural damping present in the model.

OS-1315: Modal Transient Dynamic Analysis of a Bracket
In this tutorial, an existing finite element model of a bracket is used to demonstrate how to
perform modal transient dynamic analysis using OptiStruct. HyperGraph is used to post-process
the deformation characteristics of the bracket under the transient dynamic loads.
Finite element model of the bracket
The bracket is constrained at the bottom of the two legs. Transient dynamic loads are to be
applied at the grid points of the top, flat surface of the bracket around the hole in the negative z-
direction. The time history of the loading is shown in the next figure. The modal transient
analysis is run for a total time of 4 seconds with the time being divided into 800 increments (that
is time step is 0.005). Modal damping has been defined as 2% critical damping for all the modes.
Modes up to 1000 Hz have been considered. A concentrated mass element is defined at the
center of the spider and z-displacements are monitored at the concentrated mass at the center of
this hole.

Time history of applied loading
This tutorial uses the following exercises to set up a modal transient dynamic analysis:
 Define the time dependent dynamic load or the variation of load vs time
 Define the time step for transient analysis
 Define the grid point forces on the top flat surface of the bracket
 Define modal damping table
 Define load collector to extract normal modes up to 1000 Hz using the Lanczos method
 Define the transient response dynamic excitation
 Define the subcase to include all the necessary loads as defined above
 Specify output requests
 Run modal transient dynamic analysis
 Post-process results using Altair HyperGraph

Exercise

Step 2: Open the File

Model.
2. Select the bracket_transient.hm file you saved to your working directory from the
3. Click Open. The bracket_transient.hm database is loaded into the current HyperMesh
session, replacing any existing data.
Step 3: Create a TABLED1 card to define time dependent dynamic load

6. Click the Table icon below TABLED1_NUM and enter the values in the pop-out window, as
shown in the figure below.

7. Click Close. The load collector TABLED1 that defines the time history of the loading has been
created.
Step 4: Create a TSTEP card (the transient time step to define the time
step intervals at which solution is generated and output)
2. For Name, enter tstep.
4. For Card Image, select TSTEP on the pop-up menu.
5. For TSTEP_NUM, enter the number 1 and press ENTER.
6. In the dialog, under N, enter the number of time steps as 800.
7. To specify the time increment, enter 0.005 under DT. The total time applied to the load is:
800 x 0.005 = 4 seconds. NO has a default value of 1.0. This is the time step at which output
is requested.
8. Click Close to go back to the Entity Editor.
Step 5: Create DAREA card to define forces on the top surface of the
bracket
2. For Name, enter darea.
6. Click nodes >> by sets from the pop-up menu. Two sets are displayed.
7. Select force and click select. The nodes that belong to the set force are selected.
8. Unselect (right-click) all degrees of freedom (dof); except dof3 indicating that dof3 is the
only active degree of freedom.
9. For dof3, enter a value of -1500.
10. Set load types = to DAREA.
11. Click create. This creates a force of 1500 units applied to the selected nodes in the negative
z-direction.
12. Click return.

Step 6: Create a TABDMP1 card (the modal damping table to define
damping as a tabular function of frequency)
2. For Name, enter tabdmp1.
4. For Card Image, select TABDMP1 from the drop-down list.
5. For TABDMP1_NUM, enter a value of 2 and press ENTER.
6. Click below TABDMP1_NUM and enter the values in the pop-out window, as shown in the
figure below.
7. Populate the frequency and damping values for frequencies 0 and 1000 Hz and damping to be
0.02, as shown below. This provides a table of damping values for the frequency range of
interest.
8. Click Close to return to the Entity Editor.

9. For TYPE, switch to CRIT to specify critical damping.
Step 7: Create an EIGRL load collector to extract modes up to 1000 Hz

5. For V1, enter 0.0.
6. For V2, enter 1000.
7. Leave the ND field blank to extract modes up to 1000 Hz.
Step 8: Create a TLOAD1 card (transient dynamic response excitation)

2. For Name, enter tload1.

4. For Card Image, select TLOAD1 from the drop-down list.
6. In the Select Loadcol dialog, select darea from the list of load collectors (created in the last
section to define the forces on the top surface of the bracket).
7. Click OK to complete the selection.
8. Similarly select the tabled1 load collector for the TID field (to define the time history of the
loading).
velocity, or acceleration. The field TYPE in the TLOAD1 card image defines the type of load.
Step 9: Create the load step to perform the modal transient dynamic
analysis
2. For Name, enter transient.
3. For Analysis type, select Transient (modal) from the drop-down menu.
4. For SPC, select spc from the Select Loadcol pop-out window.
5. For DLOAD, select tload1.
6. For TSTEP(TIME), select tstep.
7. For METHOD (STRUCT), select the load collector eigrl created previously.
8. For SDAMPING (STRUCT, select the load collector tabdmp1 created previously. A subcase
is created that specifies the loads, boundary conditions, and damping for modal transient
dynamic analysis.
Step 10: Create output requests for transient dynamic analysis

1. Click Setup > Create > Control Cards panel and select GLOBAL_OUTPUT_REQUEST.
2. Select DISPLACEMENT and leave the field for FORMAT(1) blank.
3. For FORM(1), select BOTH.
4. For OPTION(1), select SID – . A yellow button SID appears.
5. Double-click SID and select center.
The center set represents the node at the center of the spider attached to the mass element,
which is node 395.
6. Click return > next.
7. Click OUTPUT.
8. For number_of_outputs =, enter 2.
9. For KEYWORD, select H3D and HGTRANS.
10. For FREQ, select ALL for both.

11. For the H3D KEYWORD you will have another field, set this to the blank option.
12. Click return twice to exit from the Control Cards panel.
Step 11: Run the modal transient dynamic analysis

2. Click save as following the input file: field. A Save Model browser window opens.
bracket_transient_modal.fem in the File name: field.
4. Click Save.
The name and location of the bracket_transient_modal.fem file displays in the input file:
field.
model file was written. The bracket_transient_modal.out file is a good place to look for
bracket_transient_modal.html HTML report of the analysis, giving a summary of

the problem formulation and the results.
bracket_transient_modal.out OptiStruct output file containing specific

information on the file setup, the setup of the
problem, estimates for the amount of RAM and
disk space required for the run and compute time
information. Review this file for warnings and
errors that are flagged from processing the
bracket_transient_modal.fem file.
bracket_transient_modal.h3d HyperView binary results file.
bracket_transient_modal_tran.mvw HyperView session file. This file is only created

when transient analysis is performed. This file
automatically creates plots for the displacement,
velocity and acceleration results contained in the
file.
bracket_transient_modal.stat Summary of analysis process, providing CPU

information for each step during analysis process.

Step 12: Post-process displacement results of node 395 using HyperGraph
1. From the OptiStruct panel, click HyperView to launch HyperView.

2. Click File > Open > Session.
3. Select the HyperView session file bracket_transient_modal_tran.mvw from the directory in
which the input file was run. This file automatically creates plots for the displacement results
contained in the file.
Since the loading is applied only in the z-direction, you are interested in the z-displacement
time history of node 395.
4. Click Close and the Message Log opens.
5. Click on the Curves Attributes toolbar icon and turn off the curves X Trans and Y Trans.
This can be done by selecting the individual curves (X Trans and Y Trans) and by then clicking
the line attributes Off, as shown below.
6. Click to fit the y-axis (that is Z displacement) of node 395.

7. You can change the color and/or line attributes of the curve, if you wish.
Z-displacement time history of the concentrated mass at center of spider for direct transient dynamic analysis
As can be observed from the above image, the displacements of node 395 are in the negative z-
direction as the loading is in the –z direction too. The displacements eventually damp out due to
the structural damping present in the model.

OS-1320: Nonlinear Gap Analysis of an Airplane Wing Rib
In this tutorial, an existing finite element model of an aluminum wing rib model is used to
demonstrate how to perform nonlinear gap analysis using OptiStruct. HyperView is used to post-
process the stress and deformation characteristics of the rib.
Wing rib model
There are four shell components in the model: the mounting flange, the web, the top and bottom
flanges, and the lug. Gap elements have already been defined in the model and they connect the
web to the lug. Coupling forces are applied to the lug and pressure loading has been defined on
the top and bottom flanges of the rib joint. The mounting flange is constrained in all degrees of
freedom at the four mounting hole locations and the lug is constrained for the z-displacements
and rotations to prevent rigid body motion.
Exercise 1: Linear gap analysis on the aircraft rib

 Create a cylindrical coordinate system and assign it to the gap elements
 Create a gap property and assign it to the gap elements
 Run a linear gap analysis
 Post-process the results from the linear gap analysis using HyperView
Exercise 2: Nonlinear gap analysis on the aircraft rib
 Create a load collector to define nonlinear parameters
 Update the subcases to include the nonlinear load collectors
 Run a nonlinear gap static analysis
 Post-process results using HyperView

Exercise 1: Linear Gap Analysis
Step 1: Load the User Profile and Retrieve the Model File
2. Select OptiStruct in the User Profiles dialog. This loads the user profile. It includes the
appropriate template, macro menu, and import reader, paring down the functionality of
Model.
4. Select the rib.hm file you saved to your working directory from the optistruct.zip file.
5. Click Open. The rib.hm database is loaded into the current HyperMesh session, replacing any
The location of rib.hm displays in the file: field.
Step 2: Create a cylindrical coordinate system and assign it to the gap

elements
For gap elements with coincident nodes as is the case here, the gap coordinate system MUST be
specified. For detailed information, refer to the Help section on CGAP.
1. In the Model browser, right-click and select Create > System Collector.
2. For Name, enter cylindrical.
4. In the Model tab, hide all load collectors by right-clicking on Load Collector > Hide.
5. In the Model browser, click the Isolate Shown icon .
6. Expand the Component list and select the Lug component. This isolates the display of only
the Lug component.
7. Click the XY Top Plane View icon to set the model view.
8. Click Geometry > Create > Systems > Axis Direction to open the Systems panel.
9. The cyan halo around the yellow nodes button indicates that it is the current option. Select
the center node on the upper lug.
10. Click origin and select the center node again, click x-axis, select any node on the
circumference and for xy plane, select any node on the plane of the lug, as shown in the
following figure:

Nodes to select for creating cylindrical coordinate system
11. Click the switch beside rectangular and select cylindrical.

12. Click create.
For cylindrical systems, the x-axis defines the radial direction (q= 0) and the xy plane defines
the r-q plane.
13. Repeat this process for the bottom lug (steps 9 through 12 of this sequence).
14. Click return.
15. Click the Model tab to activate the Model browser, if you left it.
16. Select only the gap component. With Isolate Shown still active this displays only the gap
component.
17. Click the Card Editor icon .
18. Click the entity selection switch on the top left of this panel and select elems.
19. Click elems >> by window from the pop-up menu.
20. Select the gap elements that are connected to the top lug, as shown by the selected window

Gap elements connected to top lug
21. Click select entities.

22. Click config= and select gap from the pop-up menu.
23. Click edit.
24. Click CID, and select the system that was created at the center of the top lug, as shown
below.
25. Click return twice to go back to the main menu.

26. Repeat this process for the gap elements that are connected to the bottom lug. The gap
elements have now been assigned with a cylindrical coordinate system.

Step 3: Define a property card and assign it to the gap elements
2. For Name, enter gap_prop.
4. For Card Image, select PGAP and click Yes to confirm.
5. Make sure the check box next to U0_opts is checked. This way the initial gap opening is
calculated automatically.
6. Make sure the check box next to KA_opts is checked. This determines the value of KA for
each gap element using the stiffness of surrounding elements automatically.
7. Click Mesh > Create > 1D Elements > Gaps to open the Gaps panel.
8. Select the update subpanel.
9. Click elems >> by collector.
10. Select gap by checking the box beside it.
11. Click the green select button.
12. Click property= and click on gap_prop.

13. Click update.
14. Check beside property.
15. Click update. The gap elements have now been updated to the new property collector.
16. Click return.
Step 4: Run a linear gap analysis

Two loadsteps have already been created in this HyperMesh model.
rib_linear.fem in the File name: field.
4. Click Save.
The name and location of the rib_linear.fem file displays in the input file: field.
model file rib_linear.fem was written. The rib_linear.out file is a good place to look for
rib_linear.html HTML report of the analysis, giving a summary of the problem

formulation and the results.
rib_linear.out OptiStruct output file containing specific information on the file

setup, the setup of the problem, estimates for the amount of RAM
and disk space required for the run and compute time
information. Review this file for warnings and errors that are
flagged from processing the rib_linear.fem file.
rib_linear.h3d HyperView binary results file.
rib_linear.res HyperMesh binary results file.
rib_linear.stat Summary of analysis process, providing CPU information for each

Step 5: Post-process the results using HyperView

1. From the OptiStruct panel, click HyperView. This will launch HyperView and load the
rib_linear.mvw file, reading the model and results.

2. Click the Curves Attributes icon and hide all components except the Web component. You
can do this by activating the Auto apply mode: check box, (activating Display Off) and
then clicking on the components that you want turned off in the Graphic User Interface (GUI).
3. Go to the Contour panel.

3D).
6. Above the Results browser in the left hand panel are the Load Case and Simulation Selection
drop-down menus.
7. Select Subcase 1 (Coup_Vert) from the Load Case drop-down menu.
8. Click the XY Top Plane View icon to display a top view of the Web.
9. Click Apply. This should show the contour of stresses on the Web component under the
coupled loading.
Stress results on the Web from linear gap analysis
10. Click Delete Page to end the HyperView session.

Exercise 2: Nonlinear Gap Analysis
Step 1: Create a load collector defining parameters for nonlinear static

analysis
2. For Name, enter nonlinear.
4. For Card Image, select NLPARM from the menu.
5. Click NINC and enter 10.
NINC denotes the number of load sub-increments. If NINC is blank, then the entire loading is
applied at once. An NINC of 10 signifies that the load will be sub-divided into 10 equal
increments.
6. Click MAXITER and leave the default value of 25.
7. The error tolerances EPSU, EPSP and EPSW can be left at their default values.
For details on these tolerances, read the section Nonlinear Quasi-static Gap and Contact
Analysis in the online help.

Step 2: Update the loadsteps to include the nonlinear step
1. Open the Load Step folder in the Model browser.
2. Click the Coup_Vert load step to open the Entity Editor.
3. For NLPARM, click Unspecified > Loadcol.
4. In the Select Loadcol dialog, select the nonlinear load collector and click OK.
5. Repeat this process for the Pressure load step.
Step 3: Run a nonlinear gap analysis

3. Select the directory where you would like to write the file and enter the name for the
rib_nonlinear.fem, in the File name: field.
4. Click Save.
The name and location of the rib_nonlinear.fem file displays in the input file: field.
model file rib_nonlinear.fem was written. The rib_nonlinear.out file is a good place to
look for error messages that will help to debug the input deck, if any errors are present.

rib_nonlinear.html HTML report of the analysis, giving a summary of the problem

formulation and the results.
rib_nonlinear.out OptiStruct output file containing specific information on the file

setup, the setup of the problem, estimates for the amount of
RAM and disk space required for the run and compute time
flagged from processing the rib_nonlinear.fem file.
rib_nonlinear.res HyperMesh binary results file.
rib_nonlinear.h3d HyperView binary results file.
rib_nonlinear.stat Summary of analysis process, providing CPU information for

Step 4: Post-process results using HyperView

1. From the OptiStruct panel, click HyperView. This will launch HyperView and load the
rib_nonlinear.h3d file, reading the model and results.
2. Go to the Curves attributes panel and hide all the components except the Web
component. You can do that by activating the Auto apply mode: to Display Off and then
clicking the components that you want turned off in the GUI.
3. Click the Contour panel toolbar icon .

3D).
6. Above the Results browser in the left hand panel are the Load Case and Simulation Selection
drop-down menus.
7. Click Load Case > Subcase 1 (Coup_Vert).
8. Click the XY Top Plane View icon to display a top view of the Web.
9. Click Apply. This should show the contour of stresses on the Web component under the
coupled loading.

Stress results on the Web from nonlinear gap analysis.
Analysis Review
Even though the deformation patterns are similar for both linear and nonlinear analyses, the
stress patterns differ. Though the horizontal loads are in opposing directions in the lug, the stress
distribution in the web for the linear run are the same around both the lug holes which is not
correct. This happens as all the gaps are in a closed condition for the linear analysis. Nonlinear
gap analysis gives more accurate representation. The gap status, open or closed, depending on
loading condition can also be observed from the .out file (shown below):
ITERATION 0
NONLINEAR ITERATION SUMMARY Subcase 1
LOAD FACTOR: 0.1000

------------------------------------------------------------
Nonlinear Error Measures Gap Elem Status
ITER EUI EPI EWI Open Closed
------------------------------------------------------------
1 9.9000E+01 1.1659E+00 1.1659E+00 23 25
2 2.9097E-02 2.5218E+02 1.1274E+01 23 25
3 8.4208E-05 1.9063E+01 1.9427E-02 22 26
4 1.4632E-06 0.0000E+00 0.0000E+00 22 26

OS-1325: Random Response Analysis of a Flat Plate
This tutorial demonstrates how to set up the random response analysis for the existing frequency
response analysis model. The setup for frequency response analysis is that the flat plate has two
loading conditions that will be subjected to a frequency-varying load excitation using the direct
method.
The PSD (power spectral density) for displacement at node 19 is output in the .rand file, and the
peak values of PSD and RMS (root mean square) results are output to a .peak file. PSD and RMS
stress results are output to a .op2 file and post-processed in HyperView.
 Submit the OptiStruct job from within HyperMesh
Exercise
Setting up the Problem in HyperMesh
the structural model
Model.
5. Select the direct_psd.hm file you saved to your working directory from the optistruct.zip
6. Click Open. The direct_psd.hm database is loaded into the current HyperMesh session,
replacing any existing data. The database only contains model data.

The frequency analysis setup is already made for this model where the one end of plate is
clamped and the loading is applied on the other end (two different sources of the loading, thus
two subcases). The loading frequency is defined by the FREQ1 card; from 20 to 1000 Hz with an
interval of 20. The same loading frequency is applied on both the subcases.
Step 2: Create Load Collectors RANDPS and TABRND1

In this step, two PSDF of individual subcases and one coupled PSDF (meaning that those two
subcases are correlated) are defined through RANDPS bulk data entry. RANDPS points to the
table entity, TABRNDi.
2. For Name, enter tabrnd1.
3. For Card Image, select TABRND1 from the drop-down menu.
4. For TABRND1_NUM, enter a value of 4 and press ENTER.
5. Input the parameters, as shown in the following image.
6. Click Close.

7. Create another load collector named randps.
8. For Card Image, select RANDPS.
9. Three RANDPS entries need to be defined. Input the values, as shown in the following image.
The TABRND1 load collector is selected for the TID(i) column entries.
Step 3: Add the RANDOM subcase information entry and output request
The RANDOM subcase information entry needs to be added to the frequency analysis model and
the output commands for RMS and PSD results will be added as well.
1. From the Analysis page, click control cards.
2. Go to GLOBAL_CASE_CONTROL panel.
3. Check the box in front of RANDOM and double-click the highlighted ID button and select
randps.
4. Return to Control Cards and click GLOBAL_OUTPUT_REQUEST. Check the box for
STRESS to activate the card edit panel.
5. Select OUTPUT2 as the FORMAT, PSDF under RANDOM, and YES under OPTION. RMS
and PSDF stress are output to a .op2 file.
6. Click return to go back to the Control Cards panel.
7. Select CASE_UNSUPPORTED_CARDS and add the following cards:
XYPLOT,DISP,PSDF/ 19(T3)
OptiStruct will output the PSDF for the translational displacement in z direction at node 19.
8. Click OK, and then click return.
Step 4: Submit the job

2. Click Save as following the input file: field. A Save As browser window opens.
3. Select the directory where you would like to write the file and enter the name for the
direct_psd.fem in the File name: field.
4. Click Save.

The name and location of the file displays in the input file: field.
6. Set the run options: toggle to Analysis.
If the job completed successfully, new results files can be seen in the directory where the
OptiStruct model file was written. The direct_psd.out file is a good place to look for error
direct_psd.html HTML report of the analysis, giving a summary of the

problem formulation and the results.
direct_psd.out OptiStruct output file containing specific information on the

file set up, the set up of the problem, estimate for the
amount of RAM and disk space required for the run and
compute time information. Review this file for warnings and
errors that are flagged from processing the direct_psd.fem
file.
direct_psd.h3d HyperView binary results file.
direct_psd.stat Summary of analysis process, providing CPU information for

Also, the following files will be output and which are specific to the random response analysis.
direct_psd.peak ASCII result file, containing RMS and peak values of PSD.
direct_psd.rand ASCII result file, containing PSD results.
direct_psd_rand.mvw HyperView script file. This file will automatically create the
plot of PSD over the frequency for the results contained in
.rand file.
direct_psd.op2 Binary file containing RMS and PSD results.
Step 5: View the RMS and PSD results

This step describes how to post-process the RMS and PSD results in HyperView. The PSD for
displacement at node 19 is output to direct_psd.rand file and the plot of PSD vs. frequency can
be viewed by loading the direct_psd_rand.mvw file. The RMS and PSD stress results are
available in .op2 file. The RMS and the peak values of PSD for displacement at node 19 are
output to .peak file, which can be reviewed with any text editor.
1. Open a HyperView session.
2. Load the Direct_psd.op2 file.

3. Go to Contour panel.
4. In the Load Case and Simulation Selection window, select the random subcase and the
frequency = 20.0 Hz as the Simulation.
5. Select result type PSD STRESS (t), vonMises, and click Apply. The PSD vonMises stress
contour at frequency 20.0 Hz are displayed as below:
6. Change the Simulation to Simulation 1.

7. Select the result type RMS stress, vonMises, and click Apply. The RMS stress contour is
displayed.
8. In the HyperView window, click File > Open > Sessions. The Open Session File window
opens.
9. Select the directory where the job was run and select the file direct_psd_rand.mvw.
10. Click Open.


OS-1330: Acoustic Analysis of a Half Car Model
The purpose of this tutorial is to evaluate the vibration characteristics of a half car model
subjected to Fluid – Structure interaction. The fluid that is being referred to is air. Essentially,
the noise level or the sound level is evaluated inside the car at a location near the ear of the
driver which is the main response location inside the fluid (shown below).
Half Car Model
The half car model is excited at the bottom of the car, as shown by a red constraint symbol
(triangle) in the above figure. The excitation provided is with the application of a unit load along
the direction of the height of the car (Z-axis).
Process Overview
 Retrieve the HyperMesh model

 Create material and geometric properties
 Create modal frequency response subcase in order to perform acoustic analysis
 Perform the finite element analysis and view the results

Exercise
the file
3. Click OK. This loads the user profile. It includes the appropriate template, macro menu and
4. Click File > Open. An Open file browser opens.
Model.
5. Select the Half_Car.hm file you saved to your working directory from the optistruct.zip
6. Click Open.
Step 2: Create isotropic and fluid materials and properties and assign
them to their structural and fluid elements
2. For Name, enter MAT1_shells.
3. For Card Image, select MAT1 from the drop-down menu.
4. Fill in the fields for E, Nu and Rho respectively as 2.1e04, 0.33 and 8.0e-10.

6. For Name, enter MAT10_Solids.
7. For Card Image, select MAT10 from the drop-down list.
8. Fill in the fields for Rho and C respectively as 1.2e-13 and 3.4e5.
10. For Name, enter Shells.
11. For Card Image, select PSHELL from the drop-down menu.
13. In the Select Material dialog, select MAT1_shells from the list of materials and click OK to
14. Enter the thickness for the shell component by clicking T, and entering 2.0.
16. For Name, enter Solids.
17. For Card Image, select PSOLID from the drop-down menu.
19. In the Select Material dialog, select MAT10_Solids.
20. For FCTN, select PFLUID.
21. Click on the fluid component, the component entry is displayed in the Entity Editor.

23. In the Select Property dialog, select the property solids.
24. Click on the structure component, the component entry is displayed in the Entity Editor.
26. In the Select Property dialog, select the property shells.

In the following steps, the model is unconstrained and a unit vertical load is applied acting
upwards in the positive z-direction at a point on the base of the car (shown in page 1). The
model can be unconstrained as the solver applies PARAM, INREL -2 by default to avoid the model
from experiencing a rigid body motion.
First, the load collector (unit-load) is created.
5. Make sure the current load collector is set to unit_load by clicking the Set Current Load
Collector field at the bottom right corner on HyperMesh window.
This opens a panel that displays the list of load collectors.

6. Click unit-load > return.
Step 4: Create a Unit Load at a Point on the bottom of the car

2. Select the create subpanel using the radio buttons on the left-hand side of the panel.
3. Select node number 19072 on the car model by clicking nodes >> by id.
4. Uncheck all dofs, except dof3 and click the = to the right of dof3 and enter a value of 1.
5. For Load Types =, select DAREA from the extended entity selection menu.
6. Click create. This applies a unit load to the selected node.

7. Click return.

5. For TABLED1_NUM, enter a value of 2, press ENTER.
6. Click the Table icon next to Data field and enter x(1) = 0.0, y(1) = 1.0, x(2) = 200.0
and y(2) = 1.0 in the pop-out window.
This provides a frequency range of 0.0 to 200.0 with a constant 1.0 over this range and it
would appear, as shown below on the GUI.

4. For Card Image, select RLOAD1 from the drop-down menu.
7. Similarly select the load collector tabled1 for the TC field.
velocity, or acceleration. The field TYPE in the RLOAD1 card image defines the type of load.
A typical RLOAD1 card appears, as shown below.

5. Check the box next to FREQ1.
6. For NUMBER_OF_FREQ1, enter a value of 1, press ENTER.
7. Click next to the Data field and enter, F1= 0.0, DF= 1.0,and NDF= 200.
This provides a set of frequencies beginning with 0.0, incremented by 1.0 and 200
frequencies increments and the card appears as shown below on the GUI.

Step 8: Create the modal method for eigenvalue analysis using the
Lanczos method and specify the frequency range for eigenvalue
extraction
2. For Name, enter eigrl1.
5. For V2, enter a value of 600.0.
6. For ND, enter a value of 50.
This specifies a range of frequency between an initial frequency and 600 Hz for eigenvalue
extraction using the Lanczos method.
7. Similarly, follow steps 8.1 to 8.6 to create another load collector named eigrl2.

4. For Analysis type, select Freq.resp (modal) from the drop-down menu.
5. For METHOD(STRUCT), select eigrl1 from the list of load collectors.
6. For METHOD(FLUID), select eigrl2 from the list of load collectors.
7. For DLOAD, select rload1 from the list of load collectors.
8. For FREQ, select freq1 from the list of load collectors.
An OptiStruct subcase has been created which references the constraints, the unit load in the
load collector rload1 with a set of frequencies defined in load collector freq1 and modal
method defined in the load collector eigrl.
Step 10: Create a node set for output of results

5. For Entity IDs, click the yellow Nodes panel and select nodes with ID 18881.

6. Click proceed.
Step 11: Create a set of outputs specific to frequency response analysis

2. Click on ACMODL.
This defines the model parameters for fluid-structure interface.
3. Click [INTER] and select DIFF.
4. Click [INFOR] and select ALL.
5. Click return to exit this menu.
6. Select GLOBAL_OUTPUT_REQUEST. Then check the box to the left of DISPLACEMENT. A
new window appears in the work area screen.
7. Click the field box FORM and select PHASE from the pop-up menu.
8. Click the field box OPTION and select SID from the pop-up menu. A new field appears in
yellow.
9. Double-click the yellow SID box and select SETA from the pop-up selection on the bottom
left corner. A value of 1 now appears below the SID field box. This sets the output for only
the nodes in set 1.
11. Select GLOBAL_CASE_CONTROL.
12. Check the box next to FREQ.
13. Click FREQ and select the load collector freq1.
14. Click return to exit this menu and click next.
15. Select the OUTPUT subpanel. A new window appears in the work area.
16. Specify number of outputs = 4.
17. Verify KEYWORD is set to HGFREQ.
Using HGFREQ results in a frequency output presentation for HyperGraph.
18. Double-click on the box beneath FREQ and select ALL from the pop-up selection.
Choosing ALL outputs results for all frequencies.
19. Verify KEYWORD is set to OPTI.
20. Double-click on the box beneath FREQ and select ALL from the pop-up selection.
21. Similarly under KEYWORD select PUNCH and H3D.
23. Select PARAM.
24. Click AUTOSPC.
25. Scroll down and check the box next to G. A new window appears in the work area screen.
26. Click below G_V1, and input a value of 0.06 into the field box.

This value specifies a uniform structural damping coefficient and is obtained by multiplying
the critical damping [C/C0] ratio by 2.0.
27. Check the box next to GFL.

28. Click below [VALUE] and enter 0.12.
30. Click return to exit the control cards menu.
Submitting the Job

1. Click Applications > OptiStruct.
2. Following the input file: field text box and click save as.
Half_car.fem in the File name: field, and click Save.
model file was written. The Half_car.out file is a good place to look for error messages that
will help to debug the input deck if any errors are present.
Half_car.html HTML report of the analysis, giving a summary of the problem

Half_car.out OptiStruct output file containing specific information on the file setup,
the setup of your optimization problem, estimates for the amount of
RAM and disk space required for the run, information for all
optimization iterations, and compute time information. Review this file
Half_car.h3d HyperView binary results file.
Half_car.stat Summary of analysis process, providing CPU information for each step
Review the Results (HyperMesh and HyperGraph)
Step 13: Review the results

This step describes how to view displacement results (.mvw file) in HyperGraph. The HyperView
results file (.h3d) contains only the displacement results for the node specified in the node set
output.
1. When the analysis process completes, click HyperView to open a HyperView session.

2. Close the Message log menu, if one appears, by clicking Close.
3. In the HyperView window, click File > Open > Session. An Open Session File window opens.
4. Select the directory where the job was run and select the file Half_Car_freq.mvw.
5. Click Open. A discard warning appears.
6. Click Yes.
Two graphs per page and a total of one page are displayed in HyperGraph. The graph title
shows Subcase 1 (subcase 1) pressure at grid 18881.
7. Click the Axis toolbar icon .

8. Make sure the Axis is set to Primary and Horizontal.
9. Click the Scale and Tics tab.
10. Make sure the toggle is set to Linear.
11. In the Axis, toggle from Horizontal to Vertical.

12. Click on the Scale and Tics (Magnitude) tab.
13. Make sure the toggle is set to dB10.
Frequency (log). The bottom graph shows Magnitude verses Frequency (log) (see figure
below) for Pressure at grid 18881.


OS-1340: Fatigue (Stress - Life) Method
Fatigue using S-N (Stress - Life) Method

OptiStruct uses the S-N approach for calculating the fatigue life. The S-N approach is suitable for
high cycle fatigue, where the material is subject to cyclical stresses that are predominantly within
the elastic range. Structures under such stress ranges should typically survive more than 1000
cycles.
The S-N approach is based on elastic cyclic loading, inferring that the S-N curve should be
confined to numbers greater than 1000 cycles. This ensures that no significant plasticity is
occurring. This is commonly referred to as high-cycle fatigue.
Figure 1: Low Cycle and High Cycle regions on the S-N curve
Since S-N theory deals with uniaxial stress, the stress components need to be resolved into one
combined value for each calculation point, at each time step, and then used as equivalent
nominal stress applied on the S-N curve.
In OptiStruct, various stress combination types are available with the default being “Absolute
maximum principle stress”. In general “Absolute maximum principle stress” is recommended for
brittle materials, while “Signed von Mises stress” is recommended for ductile material. The sign
on the signed parameters is taken from the sign of the Maximum Absolute Principal value.
A flowchart of the fatigue setup in HyperMesh can be described as shown in the image below.

Figure 2: Fatigue analysis flowchart.
The three aspects to the fatigue definition are the fatigue material properties, the fatigue
parameters and the loading sequence and event definitions.
The fatigue material properties: (S-N curve)
Figure 3: Two segment S-N curve

FATDEF: Defines the elements and associated fatigue properties that will be used for the
fatigue analysis.
PFAT: Defines the finish, treatment, layer and the fatigue strength reduction factors for
the elements.
MATFAT: Defines the material properties for the fatigue analysis. These properties should be
obtained from the material’s S-N curve (Figure 3). The S-N curve, typically, is
obtained from completely reversed bending on mirror polished specimen. S-N
curves can be one segment or two segments.
The fatigue parameters
Figure 4: Mean Stress correction
FATPARM: Defines the parameters for the fatigue analysis. These include stress combination
method, mean stress correction method (Figure 4), Rainflow parameters, Stress
Units.

The fatigue sequence and event definition
Figure 5: Load Time History
FATSEQ: Defines the loading sequence for the fatigue analysis. This card can refer to another
FATSEQ card or a FATEVNT card.
FATEVNT: Defines loading events for the fatigue analysis.
FATLOAD: Defines fatigue loading parameters.
The following files found in the optistruct.zip file are needed to perform this tutorial. Refer to
ctrlarm.fem, load1.csv and load2.csv

Exercise
In this tutorial, a control arm loaded by brake force and vertical force is used, as shown in Figure
6. Two load time histories acquired for 2545 seconds with 1 HZ, shown in Figure 7(a) and 7(b),
are adopted. The SN curve of the material used in the control arm is shown in Figure 8. Because
a crack always initiates from the surface, a skin meshed with shell elements is designed to cover
the solid elements, which can improve the accuracy of calculation as well.
Figure 6: Model of the control arm for fatigue analysis
(a)

(b)
Figure 7: Load time history (a) for vertical force (b) for braking force
Figure 8: SN curve

Step 1: Load and review the model
The model being used for this exercise is that of a control arm, as shown in Figure 6. Loads and
boundary conditions and two static loadcases have already been defined on this model.
1. Launch HyperMesh 2017.
3. Import the ctrlarm.fem file you saved to your working directory from the optistruct.zip
Step 2: Define TABFAT cards

The first step in defining the loading sequence is to define the TABFAT cards. This card represents
the loading history.
1. Make sure the Utility menu is selected in the View menu. Click View > Browsers >
HyperMesh > Utility.
2. Click on the Utility tab beside the Model tab in the browser. In the Tools section, click on
TABLE Create.
3. Set Options: to Import table.
4. Set Tables: to TABFAT.
5. Click Next.
6. Browse for the loading file.
7. In the Open the XY data File dialog box, set the Files of type filter to CSV (*.csv).
8. Open the load1.csv file you saved to your working directory from the optistruct.zip file.
9. Create New Table with Name: table1.
10. Click Apply to save the table. The load collector “table1” with TABFAT card image is
created.
11. Browse for a second loading file load2.csv.
created.
14. Exit from the Import TABFAT window.
Tables appear under Load Collector in the Model browser.
Note: A file in DAC format can very easily be imported in Altair

HyperGraph and converted to CSV format to be read in
HyperMesh.
Step 3: Defining FATLOAD cards


2. For Name, enter FATLOAD1.
4. For Card Image, select FATLOAD from the drop-down menu.
5. For TID (table ID), select table1 from the list of load collectors.
6. For LCID (load case ID), select SUBCASE1 from the list of load steps.
7. Set LDM (load magnitude) to 1.
8. Set Scale to 3.0.
9. Repeat the process to create another load collector named FATLOAD2 with FATLOAD as card
image and pointing to table2 and SUBCASE2.
10. Set LDM to 1 and Scale to 3.0.
Step 4: Defining FATEVNT card

2. For Name, enter FATEVENT,.
3. For Card Image, select FATEVNT.
4. Set FATEVNT_NUM_FLOAD to 2.
5. Click on the Table icon next to the Data field and select FATLOAD1 for FLOAD(1) and
FATLOAD2 for FLOAD(2) in the pop-out window.
Step 5: Defining the FATSEQ card

2. For Name, enter FATSEQ.
3. For Card Image, select FATSEQ.
4. For FID (Fatigue Event Definition), select FATEVENT from the list of load collectors.
Defining the sequence of events for the fatigue analysis is completed. The Fatigue parameters
are defined next.
Step 6: Defining the Fatigue parameters

2. For Name, enter fatparam,.
3. For Card Image, select FATPARM.
4. Make sure TYPE is set to SN.
5. Set STRESS COMBINE to SGVON (Signed von Mises).
6. Set STRESS CORRECTION to GERBER.
7. Set STRESSU to MPA (Stress Units).
8. Set RAINFLOW RTYPE to LOAD.

9. Set CERTNTY SURVCERT to 0.5.
Step 7: Defining the Fatigue material properties

The material curve for the fatigue analysis can be defined on the MAT1 card.
1. In the Model browser, click on the Aluminum material. The Entity Editor opens.
2. In the Entity Editor, set MATFAT, as SN from the list.
3. Set UTS (ultimate tensile stress) to 600.
4. For the SN curve set (these values should be obtained from the material’s SN curve).
SRI1 = 1420.58
B1 = -0.076
NC1 = 5.0e8
SE = 0.1
Step 8: Defining the PFAT card

2. For Name, enter pfat.
3. For Card Image, select PFAT.
4. Set LAYER to TOP.
5. Set FINISH to NONE.
6. Set TRTMENT to NONE.
Step 9: Defining the FATDEF card

2. For Name, enter fatdef.
3. For Card Image, select FATDEF.
4. Check the box next to PSHELL.
5. Click next to the Data field and select shell for PID(1), and pfat for PFATID(1) in the
pop-out window.
6. Click Close.
Step 10: Defining the fatigue load case

2. For Name, enter Fatigue.
3. Set the Analysis type to fatigue.
4. For FATDEF, select fatdef.

5. For FATPARM, select fatparam.
6. For FATSEQ, select FATSEQ.
Step 11: Submitting the OptiStruct analysis and reviewing the results
1. From the Analysis page, go to the OptiStruct panel.
3. In File name field, enter the name ctrlarm_hm.fem.
4. Click Save. The field input file: is set to the location of ctrlarm_hm.fem.
5. Submit the analysis by clicking on OptiStruct.
6. When the analysis process completes, click HyperView to launch the results.
7. In the Results tab, select Subcase 3 (Fatigue) from the subcase field.
8. Go to the Contour panel in HyperView.
9. Set Result type to Damage and click Apply to contour the elements.
Figure 9: Elemental damage results

Fatigue Process Manager (FPM) using S-N (Stress - Life)
Method
OptiStruct uses the S-N approach for calculating the fatigue life. The S-N approach is suitable for
high cycle fatigue, where the material is subject to cyclical stresses that are predominantly within
the elastic range. Structures under such stress ranges should typically survive more than 1000
cycles.
The S-N approach is based on elastic cyclic loading, inferring that the S-N curve should be
confined to numbers greater than 1000 cycles. This ensures that no significant plasticity is
occurring. This is commonly referred to as high-cycle fatigue.
Since S-N theory deals with uniaxial stress, the stress components need to be resolved into one
nominal stress applied on the S-N curve (Figure 2).

Figure 2: Two segment S-N curve
In OptiStruct various stress combination types are available, with the default being “Absolute
maximum principle stress”. In general “Absolute maximum principle stress” is recommended for
brittle materials, while “Signed von Mises stress” is recommended for ductile material. The sign
In this tutorial, you will be able to evaluate fatigue life with the S-N method through process
manager step by step. In brief, the following contents are covered:
 Launching Fatigue Process Manager
 Import a model
 Creating fatigue subcase
 Defining fatigue analysis parameters
 Defining fatigue elements and S-N properties
 Defining load-time history and loading sequence
 Viewing results summary and launch HyperView for post-processing

Exercise
A control arm loaded by brake force and vertical force is used, as shown in Figure 3. Two load
time histories acquired for 2545 seconds with 1 HZ, shown in Figures 4(a) and 4(b), are applied.
The material of the control arm is aluminum, whose S-N curve is shown in Figure 5. Because a
crack always initiates from the surface, a skin meshed with shell elements is designed to cover
Figure 3: Model of control arm for fatigue analysis
(a)

(b)
Figure 5: S-N Curve of Aluminum
Step 1: Launch HyperMesh and Process Manager

1. Launch HyperMesh 2017. A User Profiles Graphic User Interface (GUI) will appear.

3. Click OK.
4. Click Tools > Fatigue Process > Create New.
5. Input New Session Name and Working Folder and click Create. This creates a new file to
save the instance of the currently loaded fatigue process template.
When finished, the Fatigue Analysis tree will appear.
Figure 6: Glance after launch Fatigue Process Manager (FPM)
Step 2: Import model

1. Make sure the task Import File is selected in the Fatigue Analysis tree.
2. For the Model file type:, select OptiStruct.
3. Click the Open model file icon . A Select File browser window opens.
4. Select the ctrlarm.fem file you saved to your working directory from the optistruct.zip file
and click Open. Refer to Accessing the Model Files.
5. Click Import.
This loads the control arm model. It includes a whole definition of two static subcases,
elements sets, and material static properties, etc.
6. Click Apply. This guides you to the next task Fatigue Subcase of the Fatigue Analysis tree.

Figure 7: Import a Finite Element Model file
Step 3: Create fatigue subcase

1. Make sure the task Fatigue Subcase is selected in the Fatigue Analysis tree.
2. In the Create new fatigue subcase field, enter fatsub_fpmtut.
3. Click Create.
4. For the Select existing fatigue subcase:, select the newly created fatigue subcase
fatsub_fpmtut.
fatsub_fpmtut is selected as the active fatigue subcase. Definitions in the following
processes (analysis parameters, fatigue elements and properties, loading sequences, etc.) will
be for this subcase.
5. Click Apply.
This saves the current definitions and guides you to the next task Analysis Parameters of the
Fatigue Analysis tree.

Figure 8: Create and select active fatigue subcase to process
Step 4: Fatigue Analysis Parameters Definition

1. Make sure the task Analysis Parameters is selected in the Fatigue Analysis tree.
2. Select the following options:
Analysis type S-N
Stress combination Signed von Mises

method
Mean stress correction GERBER
FEA stress unit MPA
Rainflow type STRESS
3. Enter the following values:
Gate 0.0
Certainty of survival 0.5
4. Click Apply.

This saves the current definitions and guides you to the next task Elements and Materials of
the Fatigue Analysis tree. For details, consult the HyperWorks 2017 help.
Figure 9: Fatigue analysis parameters definition.
Step 5: Fatigue Elements and Materials Definition

1. Make sure the task Elements and Materials is selected in the Fatigue Analysis tree.
2. Click Add. A Material Data window opens.
3. For Element entity type, select Property - PSHELL.
4. For Element entity name, select shell. This is the skin coating the solid control arm.
5. Make sure Ultimate tensile strength (UTS) is selected to define the material data.
6. For UTS, enter the value 600.
7. For Input method of defining S-N curve, select Estimate From UTS.
8. Click the Show SN curve definition icon . An SN method description window introducing
how to generate the SN material parameter opens.
9. Click Close.
10. For Material type, select Aluminum Alloys and click Estimate. All the data for SN curve
definition are automatically estimated.
11. Click Plot SN Curve at the bottom of the window to show the SN curve.

12. Close the SN Curve plot window.
13. For Layer of stress results in shell elements, select TOP.
14. For Surface finish, select No Finish.
15. For Surface treatment, select No Treatment.
16. Leave the field after Fatigue strength reduction factor blank.
17. Click Save to save the definition of the SN data for the selected elements.
18. Click Apply.
This saves the current definitions and guides you to the next task Load-Time History of the
Figure 10: Material data definition

Figure 11: Elements and material definition
Step 6: Load-Time History Definition

1. Make sure the task Load-Time History is selected in the Fatigue Analysis tree.
2. Click Add by File. A Load Time History window opens.
3. For Load-time history name, enter lth1.
4. For Load-time history type, select CSV.
5. Click the Open load-time file icon . An Open file browser window opens.
6. Browse for load1.csv.
8. Click Save to write the new load-time history into HyperMesh database.
9. Follow Steps 2 - 8 to create another load-time history lth2 by importing the file load2.csv.
10. Click Plot L-T to show the load-time history.
11. Close the Load Time History window.
12. Click Apply. This saves the current definitions and guides you to the next task Loading
Sequences of the Fatigue Analysis tree.
Note: For a file of DAC format, it can very easily be imported in

Altair HyperGraph and converted to CSV format for use by
FPM.

Figure 12: Load-time history definition
Figure 13: Import load-time history
Step 7: Loading Sequences Definition

In this step, one event consisting of two load time history is created; in other words, the linear
superposition of the stress caused by the two load time history is requested during analysis.
Using this event, one load sequence is constructed.
1. Make sure the task Loading Sequences is selected in the Fatigue Analysis tree.
2. Click Add. A Loading Definition window opens.

3. For Select static loadcase, select SUBCASE1.
4. For Select load-time history, select lth1.
5. For Scale, enter the value 3.0.
6. Make sure Create new is selected using the radio buttons.
7. Enter Event1 for the newly created fatigue event name.
Figure 14: Associate load-time history with static subcase
8. Click Save > Add. A Loading Definition window opens.

11. Enter the value 3.0 for Scale.
12. Make sure Existing is selected using the radio buttons. For Existing, select Event1.
13. Click Save > Apply. This saves the current definitions and guides you to the next task
Submit analysis of the Fatigue Analysis tree.

Figure 15: Loading sequences definition
Step 8: Submit fatigue analysis

1. Make sure the task Submit Analysis is selected in the Fatigue Analysis tree.
2. Click the Save .fem file icon . A Save As browser window opens.
3. Set the directory in which to save the file, and for File name, enter ctrlarm_fpmtut.fem.
4. Click Save to close the window.
5. Click Save to save the OptiStruct model file.
6. For Run Option, select analysis.
7. Click Submit. This launches OptiStruct 2017 to run the fatigue analysis.
model file was written.

ctrlarm_fpmtut.0.3.fat An ASCII format file which contains fatigue results of each fatigue
subcase in iteration step.
ctrlarm_fpmtut.h3d Hyper 3D binary results file, with both static analysis results and
fatigue analysis results.
ctrlarm_fpmtut.out OptiStruct output file containing specific information on the file set
up, the set up of your fatigue problem, compute time information,
etc. Review this file for warnings and errors.
ctrlarm_fpmtut.stat Summary of analysis process, providing CPU information for each

Figure 16: Submit fatigue analysis

Step 9: Post-processing
1. Make sure the task Post-processing is selected in the Fatigue Analysis tree.
When fatigue analysis has completed successfully after the previous submit, it will
automatically go into this task.
2. View the Results type: Life
Check the top 0.1%, 1.0%, 5.0% average life, and Top 1, 2, 3 most damage elements lives.
3. Toggle the Result type to view the damage results summary.
4. Click Load H3D Results (HV). This launches HyperView to load the ctrlarm_fpmtut.h3d
results file for more detailed results.
5. Click Close to unload Fatigue Process Manager.
Figure 17: Life results summary

Figure 18: Damage contour in HyperView

OS-1350: Fatigue (Strain - Life) Method
Fatigue using E-N (Strain - Life) Method

The E-N (Strain - Life) method should be chosen to predict the fatigue life when plastic strain
occurs under the given cyclic loading. S-N (Stress - Life) method is not suitable for low-cycle
fatigue where plastic strain plays a central role for fatigue behavior. If an S-N analysis indicates a
fatigue life less than 10,000 cycles, it is a sign that an E-N method may be a better choice. The
E-N method, while computationally more expensive than S-N, should give a reasonable estimate
for high-cycle fatigue as well.
Since E-N theory deals with uniaxial strain, the strain components need to be resolved into one
nominal strain applied on the E-N curve (Figure 2).

Figure 2: Strain-Life curve
In OptiStruct various strain combination types are available with the default being “Absolute
maximum principle strain”. In general “Absolute maximum principle stain” is recommended for
brittle materials, while “Signed von Mises strain” is recommended for ductile material. The sign
A flowchart of the fatigue setup in HyperMesh can be described as shown in the image below.

Figure 3: Fatigue analysis flowchart.
The three aspects to the fatigue definition are the fatigue material properties, the fatigue
parameters and the loading sequence and event definitions.
FATDEF: Defines the elements and associated fatigue properties that will be used for the
fatigue analysis.
PFAT: Defines the finish, treatment, layer and the fatigue strength reduction factors for the
elements.
MATFAT: Defines the material properties for the fatigue analysis. These properties should be
obtained from the material’s E-N curve (Figure 2). The E-N curve, typically, is
obtained from completely reversed bending on mirror polished specimen.

The fatigue parameters
Figure 4: Mean Stress correction
FATPARM: Defines the parameters for the fatigue analysis. These include stress combination
method, mean stress correction method (Figure 4), Rainflow parameters, and Stress
Units.
The fatigue sequence and event definition
Figure 5: Load Time History

FATSEQ: Defines the loading sequence for the fatigue analysis. This card can refer to another
FATSEQ card or a FATEVNT card.
FATEVNT: Defines loading events for the fatigue analysis.
FATLOAD: Defines fatigue loading parameters.
TABLEFAT: Defines the y values for each point on the time loading history (Figure 5).
Exercise
In this tutorial, a control arm loaded by brake force and vertical force is used, as shown in Figure
6. Two load time histories acquired for 2545 seconds with 1 HZ, shown in Figure 7(a) and 7(b),
are adopted. The material of the control arm is aluminum, whose E-N curve is shown in Figure 8.
Because a crack always initiates from the surface, a skin meshed with shell elements is designed
to cover the solid elements, which can improve the accuracy of calculation as well.
Figure 6: Model of the control arm for fatigue analysis

(a)
(b)

Figure 8: EN curve of Aluminum
Step 1: Load and review the model

The model being used for this exercise is that of a control arm as shown in Figure 6. Loads and
boundary conditions and two static loadcases have already been defined on this model.
2. Change the User Profiles to OptiStruct.
3. Import the ctrlarm.fem file you saved to your working directory from the optistruct.zip
Step 2: Define TABFAT cards

The first step in defining the loading sequence is to define the TABFAT cards. This card represents
the loading history.
1. Click View > Browsers > HyperMesh > Utility.
2. In the Tools section, click on TABLE Create.
3. Set Options: to Import table.
4. Set Tables: to TABFAT.
5. Click Next.
6. Browse for the loading file.
7. In the Open the XY data File dialog box, set the Files of type filter to CSV (*.csv).
8. Open the file load1.csv.

created.
11. Browse for a second loading file named load2.csv.
created.
14. Exit from the Import TABFAT window. In the Model browser, tables appear under Load
Collector.
Note: A file in DAC format can very easily be imported in Altair

HyperGraph and converted to CSV format to be read in
HyperMesh.
Step 3: Defining FATLOAD cards

2. For Name, enter FATLOAD1.
4. For Card Image, select FATLOAD from the drop-down menu.
5. For TID (table ID), select table1 from the list of load collectors.
6. For LCID (load case ID), select SUBCASE1 from the list of load steps.
7. Set LDM (load magnitude) to 1.
8. Set Scale to 5.0.
9. Repeat the process to create another load collector named FATLOAD2 with FATLOAD card
image and pointing to table2 and SUBCASE2.
10. Set LDM to 1 and Scale to 5.0.
Step 4: Defining FATEVNT card

2. For Name, enter FATEVENT,.
3. For Card Image, select FATEVNT.
4. Set FATEVNT_NUM_FLOAD to 2.
5. Click on the Table icon next to the Data and select FATLOAD1 for FLOAD(1) and
FATLOAD2 for FLOAD(2) in the pop-out window.
Step 5: Defining the FATSEQ card

2. For Name, enter FATSEQ.
3. For Card Image, select FATSEQ.

4. For FID (Fatigue Event Definition), select FATEVENT from the list of load collectors.
Defining the sequence of events for the fatigue analysis is completed. The Fatigue parameters
are defined next.
Step 6: Defining the Fatigue parameters

2. For Name, enter fatparam,.
3. For Card Image, select FATPARM.
4. Make sure TYPE is set to EN.
5. Set STRESS COMBINE to SGVON (Signed von Mises).
6. Set STRESS CORRECTION to SWT.
7. Set STRESSU to MPA (Stress Units).
8. Set PLASTI to NEUBER (plasticity correction).
9. Set RAINFLOW RTYPE to STRESS.
10. Set CERTNTY [SURVCERT] to 0.5.
Step 7: Defining the Fatigue material properties

The material curve for the fatigue analysis can be defined on the MAT1 card.
1. In the Model browser, click on the Aluminum material. The Entity Editor opens.
2. In the Entity Editor, set MATFAT as EN from the list.
3. Set UTS (ultimate tensile stress) to 600.
4. For the EN curve set (these values should be obtained from the material’s EN curve).
SF = 1002.000
B = -0.095
C = -0.690
EF = 0.350
NP = 0.110
KP = 966.000
NC = 2E+08
SEE = 0.100
SEP = 0.100
Step 8: Defining the PFAT card

2. For Name, enter pfat.

3. Set the Card Image to PFAT.
4. Set LAYER to TOP.
5. Set FINISH to NONE.
6. Set TRTMENT to NONE.
Step 9: Defining the FATDEF card

2. For Name, enter fatdef.
3. Set the Card Image to FATDEF.
4. Activate PSHELL in the Entity Editor.
5. Click the Data:PID, PFATID option to open the dialog.
6. For PID(1), select shell.
7. For PFATID(1), select pfat.
Step 10: Defining the fatigue load case

2. For Name, enter Fatigue.
3. Set the Analysis type to Fatigue.
4. For FATDEF, select fatdef.
5. For FATPARM, select fatparam.
6. For FATSEQ, select FATSEQ.
Step 11: Submitting the OptiStruct analysis and reviewing the results
3. Enter the name ctrlarm_hm.fem in File name field.
4. Click Save.
5. Submit the analysis by clicking on OptiStruct.
6. When the analysis process completes, click HyperView to launch the results.
7. Go to the Results tab.
8. Change the Load Case to Subcase 3 – fatigue.
9. Go to the Contour panel in HyperView.
10. Set Result type to Damage and click on Apply to contour the elements.

Figure 9: Elemental damage results

Fatigue Process Manager (FPM) using E-N (Strain - Life)
Method
The E-N (Strain - Life) method should be chosen to predict the fatigue life when plastic strain
occurs under the given cyclic loading. S-N (Stress - Life) method is not suitable for low-cycle
fatigue where plastic strain plays a central role for fatigue behavior. If an S-N analysis indicates a
fatigue life less than 10,000 cycles, it is a sign that E-N method might be a better choice. E-N
method, while computationally more expensive than S-N, should give reasonable estimate for
high-cycle fatigue as well.
Since E-N theory deals with uniaxial strain, the strain components need to be resolved into one
nominal strain applied on the E-N curve (Figure 2).

Figure 2: Strain-Life curve
In OptiStruct, various strain combination types are available with the default being “Absolute
maximum principle strain”. In general “Absolute maximum principle stain” is recommended for
brittle materials, while “Signed von Mises strain” is recommended for ductile material. The sign
In this tutorial, you will be able to evaluate fatigue life with the E-N method, which is a new
feature in HW10.0, through Fatigue Process Manager (FPM) step by step. In brief, the following
contents are covered:
 Launching Fatigue Process Manager
 Importing model
 Creating fatigue subcase
 Defining fatigue analysis parameters
 Defining fatigue elements and E-N properties
 Defining load-time history and loading sequence
 Viewing results summary and launch HyperView for post-processing

Exercise
A control arm loaded by brake force and vertical force is used, as shown in Figure 3. Two load
time histories acquired for 2545 seconds with 1 HZ, shown in Figures 4(a) and 4(b), are applied.
The material of the control arm is aluminum, whose E-N curve is shown in Figure 5. Because a
crack always initiates from the surface, a skin meshed with shell elements is designed to cover
Figure 3: Model of control arm for fatigue analysis
(a)

(b)
Figure 5: E-N Curve of Aluminum
Step 1: Launch HyperMesh 2017 and Process Manager

2. Change the User Profiles to OptiStruct.

3. Click OK.
4. Click Tools > Fatigue Process > Create New.
5. Input New Session Name and Working Folder and click Create. This creates a new file to
save the instance of the currently loaded fatigue process template. When finished, the Fatigue
Analysis tree will appear.
Figure 6: Glance after launch Fatigue Process Manager (FPM)
Step 2: Import model

1. Make sure the task Import File is selected in the Fatigue Analysis tree.
2. For the Model file type:, select OptiStruct.
3. Click the Open model file icon . A Select File browser window opens.
4. Select the ctrlarm.fem file you saved to your working directory from the optistruct.zip
5. Click Import. This loads the control arm model. It includes a whole definition of two static
subcases, elements sets, and material static properties, etc.
6. Click Apply. This guides you to the next task Fatigue Subcase of the Fatigue Analysis tree.

Figure 7: Import a Finite Element Model file
Step 3: Create fatigue subcase
1. Make sure the task Fatigue Subcase is selected in the Fatigue Analysis tree.
2. In the Create new fatigue subcase field, enter fatsub_fpmtut.
3. Click Create.
4. For the Select existing fatigue subcase:, select the newly created fatigue subcase
fatsub_fpmtut.
fatsub_fpmtut is selected as the active fatigue subcase. Definitions in the following
processes (analysis parameters, fatigue elements and properties, loading sequences, etc.) will
be for this subcase.
5. Click Apply. This saves the current definitions and guides you to the next task Analysis
Parameters of the Fatigue Analysis tree.

Figure 8: Create and select active fatigue subcase to process

1. Make sure the task Analysis Parameters is selected in the Fatigue Analysis tree.
Analysis type E-N
Stress combination method Signed von Mises
Mean stress correction SWT
FEA stress unit MPA
Rainflow type STRESS
Plasticity correction NEUBER
Gate 0.0
Certainty of survival 0.5

4. Click Apply.
This saves the current definitions and guides you to the next task Elements and Materials of
the Fatigue Analysis tree. For details, consult the HyperWorks 2017 help.
Figure 9: Fatigue analysis parameters definition.

1. Make sure the task Elements and Materials is selected in the Fatigue Analysis tree.
3. For Element entity type, select Property - PSHELL.
4. For Element entity name, select shell. This is the skin coating the solid control arm.
5. Make sure Ultimate tensile strength (UTS) is selected to define the material data.
7. For Input method of defining EN curve, select Estimate From UTS.
8. Click the Show EN curve definition icon . An EN method description window introducing
how to generate the EN material parameter opens.
9. Click Close.

10. For Material type, select Aluminum and Titanium Alloys and click Estimate. All the data
for EN curve definition are automatically estimated.
11. Click Plot EN Curve at the bottom of the window to show the EN curve.
12. Close the EN Curve plot window.
13. For Layer of stress results in shell elements, select TOP.
17. Click Save to save the definition of the EN data for the selected elements.
18. Click Apply.
This saves the current definitions and guides you to the next task Load-Time History of the

Figure 10: Material data definition

Figure 11: Elements and material definition

1. Make sure the task Load-Time History is selected in the Fatigue Analysis tree.
3. For Load-time history name, enter lth1.
4. For Load-time history type, select CSV.
6. Browse for load1.csv.
9. Follow Steps 2 - 8 to create another load-time history lth2 by importing the file load2.csv.
12. Click Apply. This saves the current definitions and guides you to the next task Loading
Sequences of the Fatigue Analysis tree.
Note: For a file of DAC format, it can very easily be imported in

Altair HyperGraph and converted to CSV format for use by
FPM.

Figure 12: Load-time history definition
Figure 13: Import load-time history

In this step, one event consisting of two load time history is created; in other words, the linear
1. Make sure the task Loading Sequences is selected in the Fatigue Analysis tree.

7. Enter Event1 for the newly created fatigue event name.
Figure 14: Associate load-time history with static subcase
8. Click Save > Add. A Loading Definition window opens.

12. Make sure Existing is selected using the radio buttons.
13. For Existing, select Event1.
14. Click Save > Apply.
This saves the current definitions and guides you to the next task Submit analysis of the

Figure 15: Loading sequences definition
Step 8: Submit fatigue analysis

1. Make sure the task Submit Analysis is selected in the Fatigue Analysis tree.
2. Click the Save .fem file icon . A Save As browser window opens.
3. Set the directory in which to save the file, and for File name, enter ctrlarm_fpmtut.fem.
6. For Run Option, select analysis.
7. Click Submit. This launches OptiStruct 2017 to run the fatigue analysis.

ctrlarm_fpmtut.0.3.fat An ASCII format file which contains fatigue results of each

fatigue subcase in iteration step.
ctrlarm_fpmtut.h3d Hyper 3D binary results file, with both static analysis

results and fatigue analysis results.
ctrlarm_fpmtut.out OptiStruct output file containing specific information on

the file set up, the set up of your fatigue problem,
compute time information, etc. Review this file for
warnings and errors.
ctrlarm_fpmtut.stat Summary of analysis process, providing CPU information

for each step during analysis process.
Figure 16: Submit fatigue analysis

1. Make sure the task Post-processing is selected in the Fatigue Analysis tree.
When fatigue analysis has completed successfully after the previous submit, it will
automatically go into this task.
2. View the Results type: Life.
Check the top 0.1%, 1.0%, 5.0% average life, and Top 1, 2, 3 most damage elements lives.
3. Toggle the Result type to view the damage results summary.
4. Click Load H3D Results (HV). This launches HyperView to load the ctrlarm_fpmtut.h3d
results file for more detailed results.
5. Click Close to unload Fatigue Process Manager.
Figure 17: Life results summary

Figure 18: Damage contour in HyperView

OS-1360: NLSTAT Analysis of Gasket Materials in Contact
This tutorial demonstrates how to carry out nonlinear implicit small displacement analysis in
OptiStruct involving gasket materials and contact.
Model and Loading Description
Figure 1 below illustrates the structural model used for this tutorial: A 1mm thick cylindrical
gasket is sandwiched between two co-axial steel cylindrical tubes. The outer cylinder is subjected
to a pressure of 300MPa on the outer surface as shown. Using symmetry boundary conditions,
only a quarter of the geometry has been modeled. The gasket is connected to the inner and outer
cylinders using contact.
Figure 1. Model and Loading Description
Following exercises are included:
 Create gasket material

 Create gasket property
 Assign CGASK elements to gasket component
 Adjust the normals of solid gasket elements
 Define contact between gasket and top/bottom cylinders
 Define nonlinear implicit parameters
 Set up NLSTAT analysis

 Submit job and view result
Exercise
Step 1: Import the model

2. Change the User Profiles to OptiStruct and click OK. This loads the user profile.
3. From the File menu on the toolbar, select Open.
4. Select the gasket_model.hm file you saved to your working directory from the
optistruct.zip file and click Open. Refer to Accessing the Model Files.
Step 2: Create the curves for gasket material

First, define the loading-unloading curves for the gasket material.
2. For Name, enter load-curve.
4. For Card Image, select TABLES1 from the drop-down menu.
5. For TABLES1_NUM, enter 6 (number of rows in the table), and press ENTER.
6. Click the Table icon next to the Data field and enter the following values (X (closure) and
Y (pressure) fields) in the pop-out window.
7. Click Close.
For details on pressure-closure definitions of gaskets, refer to the HyperWorks 2017 online
help.
X Y
0.0 0.0
0.005 200.0
0.05 450.0
0.135 700.0
0.22 820.0
0.287 830.0
Now, unloading curves can be created.

8. Follow steps 1 through 7 to create the unloading curve named unload-curve1 with the
following X-Y data:
X Y
0.08 0.0
0.12 140.0

0.135 700.0
9. Next, create the second unloading curve named unload-curve2 with the following X-Y data:
X Y
0.17 0.0
0.2 250.0
0.22 820.0
10. Finally, create the third unloading curve named unload-curve3 with the following X-Y data:
X Y
0.23 0.0
0.265 360.0
0.287 830.0
Step 3: Define the elasto-plastic gasket material

The membrane behavior of the gasket needs to be defined.
2. For Name, enter gask_membrane.
4. For Card Image, select MAT1 from the drop-down menu.
5. For E, enter 2.0E+04 and for NU, enter 0.2.
6. Next, you will define the nonlinear properties for the gasket material.
7. Create another material named gask_nonlin.
8. For Card Image, select MGASK.
9. Since this is an elasto-plastic gasket material, for gasket behavior leave BEHAV field as 0.
10. For initial yield pressure, leave the YPRS field blank for the solver to determine it
automatically.
11. For tensile modulus EPL, enter 0.001.
12. For GPL to specify the shear modulus, enter 2000.
13. For MGASK_TABLU_NUM, enter 3 to specify the field for # of unloading curves.
14. For TABLD, select load-curve, created in Step 2.
15. Click next to the Data field and select the following:
 For TABLU(1), select unload-curve1

Step 4: Define gasket property

2. For Name, enter gasket_prop.
4. For Card Image, select PGASK from the drop-down menu and click Yes to confirm.
6. In the Select Material dialog, select gask_nonlin from the list of materials and click OK to
7. For MID1, select the gask_membrane material.
8. For STABMT field, select 1 to define some stabilization stiffness.
9. Next, assign this property to the gasket component. Click on the component GASKET in the
Model browser.
10. For Property, select gasket_prop property.
Step 5: Assign eight-noded gasket elements to gasket component

1. Click on the 3D page from the main menu.
2. Click the elem types panel and click 2D & 3D.
3. Click on elems, select by collector type and select the GASKET component.
4. Toggle hex8 =, and select the CGASK8 element type.
5. Click update > return.
Step 6: Review and adjust the normals of the gasket elements

1. Click on 2D page from the main menu.

2. Click on the composites panel.
3. For comps, select the GASKET component and click display normals.
The normals of the gasket elements are not in the thickness direction, but in the Z-direction,
as shown below.
So, adjusting the normals needs to be in thickness direction.

4. Display only the GASKET component.
5. Click on by nodes on bottom face and select the GASKET component.
6. For choosing the face nodes, click on nodes and select three nodes on a face of any gasket
element in the thickness direction and click adjust normals.
The normals are now adjusted to be in thickness direction of gasket, as shown below.
Step 7: Define contact between the cylinders and gasket

Now the contact surface for the bottom surface of the top cylinder needs to be defined.
1. Hide the GASKET component and display only the SOLID1 component.
2. In the Model browser, right-click and select Create > Contact Surface.
3. For Name, enter SOLID1_bottom.
5. For Card Image, select SURF from the drop-down menu.

6. Click on Elements and on the yellow Elements panel.
7. Under the graphics area, select add solid faces from the selection menu.
8. Click elems >> displayed.
9. Click on face nodes, select the three nodes on the bottom surface (i.e. surface contacting the
gasket, as shown below) and click add.
10. Click return.

11. Next, hide the SOLID1 component and display only the SOLID2 component.
12. Repeat steps 7.2 though 7.10 to create the contact surface SOLID2_top for the top surface of
the SOLID2 component contacting the gasket.
13. Similarly, repeat steps 7.2 through 7.10 and create GASKET_top and GASKET_bottom surfaces
for the top and bottom surfaces of the GASKET component, respectively.
14. Now, an interface between the top cylinder and gasket are created.
15. In the Model browser, right-click and select Create > Contact.
16. For Name, enter SOLID1_GASKET.
18. For Card Image, select CONTACT from the drop-down menu.
19. For MSID (master surface), select the SOLID1_bottom surface.
20. For SSID (slave surface), select the GASKET_top surface.
21. For TYPE, select STICK from the drop-down menu.

Next, an interface between the bottom cylinder and gasket are created.
23. For Name, enter SOLID2_GASKET.
26. For MSID (master surface), select the SOLID2_top surface.
27. For SSID (slave surface), select the GASKET_bottom surface.
28. For TYPE, select STICK from the drop-down menu. Next, you create the interface between
the bottom cylinder and gasket.
29. Click on create and for name =, enter SOLID2_GASKET.
30. For type=, enter CONTACT and click create.
31. Click on add to select the master and slave surfaces for this interface.
32. For master:, select the SOLID2_top surface and click update.
33. For slave:, select the GASKET_bottom surface and click update.
34. Click review to review the interface.

Step 8: Define nonlinear implicit parameters
2. For Name, enter NLPARM.
4. For Card Image, select NLPARM from the drop-down menu.
5. For NINC, enter 1.
Keep the remainder of the parameters set at the default values. For details on the nonlinear
implicit parameters, consult the HyperWorks 2017 online help.
Step 9: Create the NLSTAT subcase

2. For Name, enter NLSTAT.
4. Click Analysis type and select non-linear quasi-static from the drop-down menu.
5. For SPC, select SPC from the list of load collectors.
6. For LOAD, select LOAD from the list of load collectors.
7. For NLPARM, select NLPARM from the list of load collectors.

Step 10: Define Output Control parameters
1. From the Analysis page, select control cards.
2. Click on GLOBAL_OUTPUT_REQUEST.
3. Below CONTF, DISPLACEMENT, STRAIN and STRESS, set the option to Yes.

1. From the Analysis page, select OptiStruct.
2. Click save as and select the directory where you want to write the file.
3. For File Name, enter gasket_complete.fem and click Save. The file extension .fem is
necessary for OptiStruct to recognize it as an input file.
4. Set the export options toggle to all.
5. Set the run options toggle to analysis.
6. Set the memory options toggle to memory default.

invoked. The gasket_complete.out file is a good place to look for error messages that will
help you debug your input deck, if any errors are present.
gasket_complete.html HTML report of the analysis, giving a summary of the problem

gasket_complete.out ASCII based output file of the model check run before the
simulation begins and gives nonlinear iteration history as well as
basic information on the results of the run.
gasket_complete.stat Summary of analysis process, providing CPU information for each

step during the process.
gasket_complete.h3d HyperView compressed binary results file.
Step 12: View analysis results

In HyperView, plot the displacement and contact pressure contours at the end of the analysis.
Figure 2. Contour of Displacements in Cylinders and Gasket subject to Loading

Figure 3. Contour of Gasket Thickness direction pressure

Figure 4.
Contour of Contact Pressure

OS-1365: NLSTAT Analysis of Solid Blocks in Contact
This tutorial demonstrates how to carry out nonlinear implicit small displacement analysis in
OptiStruct, involving elasto-plastic materials, contact and continuing the nonlinear solution
sequence from a preceding nonlinear loadcase.
Model and Loading Description
Figure 1 illustrates the structural model used for this tutorial, which is two square solid blocks
made of elasto-plastic steel material. The dimensions of the blocks and the material parameters
can be obtained in the table below.
In the first nonlinear subcase, pressure loading is be applied to the top solid block, the top
corners of which are constrained in X and Y directions. The top solid is in contact with the bottom
solid, the bottom corners of which are constrained in X, Y and Z directions. The second nonlinear
subcase is to simulate the un-loading and is a continuation of the nonlinear solution sequence
from the previous loading subcase.
Figure 1. Model and Loading Description

Units Length: mm; Time: s; Mass: Mgg; (Force: N; Stress: MPa)
Top block 72 mm x 72 mm
Bottom block 100 mm x 100 mm
Thickness of 20. mm
blocks
Material Steel, Elasto-plastic
Initial density ( ): 7.90e-9 kg/mm3
Young's modulus (E): 210000 MPa
Poisson coefficient (ν): 0.3
Yield Stress ( 0): 850.0 MPa
Imposed pressure 1000.0 MPa, applied at the center of top block

 Create elasto-plastic material
 Define contact between the two blocks
 Define nonlinear implicit parameters
 Set up NLSTAT analysis for the 1 st subcase (loading)
 Set up NLSTAT analysis for the 2 nd subcase (unloading)

Exercise

2. A User Profiles Graphic User Interface (GUI) appears, select OptiStruct.
3. Click OK. This loads the user profile.
4. Click File > Open.
Note: If HyperMesh Desktop was launched, use: File > Open > Model.
5. Select the nlstat.hm file you saved to your working directory from the optistruct.zip file.
6. Click Open.
Step 2: Create the elasto-plastic material

First, the stress vs plastic strain curve for the material needs to be defined.
2. For Name, enter stress-strain.
4. For Card Image, select TABLES1 from the drop-down menu.
5. For TABLES1_NU, enter 2 (number of rows in the table), and press ENTER.
6. Click the Table icon next to the Data field and enter the following values (x and y fields) in
the pop-up window.
7. Click Close to close the dialog box.

Now, the elasto-plastic material needs to be updated.

8. In the Model browser, click the material steel. The Entity Editor opens.
9. Click on the checkbox next to MATS1 to define the elastic-plastic material for NLSTAT
analysis.
10. For TID, click Unspecified > Loadcol.
11. In the Select Loadcol dialog, select the stress_strain load collector and click OK.
12. Input the values, as shown below. TYPSTRN of 1 signifies specifying stress (Y) vs plastic
strain (X).
See material parameters for details.
Step 3: Define contact between the two blocks

The contact surfaces for the two blocks need to be defined.
2. For Name, enter top.
3. For Card Image, select SET_ELEM from the drop-down menu.

5. For Entity IDs, click Unspecified > Properties.
6. In the Select Properties dialog, select the top solid block Solid1 and click OK.
7. Similarly create another set named bottom.

8. Repeat steps 3.3 through 3.6, for bottom block select the bottom solid Solid2.
9. Next, the interface needs to be defined.
11. For Name, enter SOLID_CONTACT.
14. For MSID (master surface) and select Set from the extended selection menu.
15. Click the yellow Set panel and select the bottom block bottom in the pop-up window and
click OK.
16. Similarly, for SSID (slave surface), select the top set.
17. For TYPE, select SLIDE from the drop-down menu.
18. For MORIENT, select NORM from the drop-down menu.

Step 4: Define nonlinear implicit parameters
2. For Name, enter nlparm.
Enter the values as shown below:

See nonlinear implicit parameters for details.
Step 5: Create the 1st nonlinear (loading) subcase

2. For Name, enter loading.
3. Click Analysis type and select Non-linear quasi-static from the drop-down menu.
5. From the Select Loadcol dialog, select SPC from the list of load collectors and click OK.
7. From the Select Loadcol dialog, select pressure from the list of load collectors and click OK.
9. From the Select Loadcol dialog, select nlparm from the list of load collectors and click OK.

Step 6: Create the 2nd nonlinear (unloading) subcase
1. For Name, enter unload.
2. The Analysis type should, again, be set to Non-linear quasi-static from the drop-down
menu.
4. For NLPARM, select nlparm from the list of load collectors.
Checkpoint: The unloading subcase (unload) does not contain the pressure load applied
during the loading subcase (loading).

2. Click GLOBAL_OUTPUT_REQUEST.
3. Under CONTF, DISPLACEMENT, and STRESS, set Option to Yes.
4. Under STRAIN, set TYPE(1) to PLASTIC.

3. For File Name, enter nlstat_complete.fem.
4. Click Save. The file extension .fem is necessary for OptiStruct to recognize it as an input file.
5. Set export options to all.

6. Set run options to analysis.
7. Set memory options to memory default.
invoked. The nlstat_complete.out file is where you will find error messages that will help
you debug your input deck, if any errors are present.
nlstat_complete.html HTML report of the analysis, giving a summary of the problem

nlstat_complete.out ASCII based output file of the model check run before the
simulation begins and gives nonlinear iteration history as well as
basic information on the results of the run.
nlstat_complete.stat Summary of analysis process, providing CPU information for

each step during the process.
nlstat_complete.h3d HyperView compressed binary results file.

1. Using HyperView, plot the Displacement, the von Mises stress, plastic strains and contact
pressure contours at the end of the 1st (loading) step.
Figure 3. Contour of Displacements in blocks subject to Loading

Figure 4. Contour of von Mises Stress in blocks subject to Loading
Figure 5. Contour of Plastic Strains in the blocks subject to Loading

Figure 6. Contour of Contact Pressure in the block interface after the 1st (loading) subcase
Next, change the subcase to the 2nd that is unloading subcase and plot the displacement contour
to see the change in displacements in the blocks subject to unloading.
Figure 7. Contour of Displacements in blocks subject to Unloading in 2nd subcase

OS-1370: Complex Eigenvalue Analysis of a Reduced Brake
System
In this tutorial, a modal complex eigenvalue analysis is performed on a simplified brake system
to determine whether the friction effects can cause any squeal noise (unstable modes).
The simplified brake system consists of a brake pad with frictional surface and back plate, and a
contact plate. They were all modeled with solid elements. Spring elements (CELAS1) were
created between the brake pad and the contact plate to measure the normal contact forces, as
shown in Figure 1. The friction forces on the pad and the contact plate are proportional to the
normal contact forces. The stiffness matrix terms representing the relationship between friction
forces and normal displacements on the contact grids were saved in a DMIG bulk data file
DMIG.pch. Assume the brake pad is in full contact with the plate at all time. The back plate of the
brake pad and the contact plate were constrained to the ground.
Figure 1. Model review


Exercise
1. Download both brake.fem and DMIG.pch files and save to your working directory from the
4. Click the Import Solver Deck panel toolbar icon . An Import tab appears. The File type:
is OptiStruct.
5. Click the open file icon in the File: field. A Select OptiStruct file browser window appears.
6. Select brake.fem from your working directory and click Open. The model file brake.fem is
loaded in the File field.
7. Click Import to import the file into the current HyperMesh session.
Step 2: Create EIGRL and EIGC cards

In this step, a modal method is used to solve the complex eigenvalue problem, which is more
computationally efficient compared to extracting the complex modes directly. With this approach,
first, the real modes are calculated via a normal modes analysis. Then, a complex eigenvalue
problem is formed on the projected subspace spanned by the real modes and thus much smaller
than the real space. In this case, both EIGRL and EIGC cards need to be defined.
5. For ND, enter 20. 20 real modes are required to produce the reduced space for complex
eigenvalue analysis.

6. Create another load collector named eigc.
7. For Card Image, select EIGC.
8. For NORM, select MAX. MAX option is used to normalize the eigenvectors.
9. For ND0, enter 12. The desired number of roots to be extracted is 12.
Step 3: Retrieve the friction data from DMIG data and define analysis
parameters
1. Go to the Analysis page, then click control cards.
2. Click INCLUDE_BULK.
3. Input the name of the include file, DMIG.pch.
4. Click return to go back to control cards.
5. Click K2PP.
6. In K2PP panel, set number_of_k2pps = 1.
7. In the field of K2PP=, enter KF.
KF is the name of the DMIG data entry.
8. Click return and back to control cards.
Retrieve the friction coefficients from the DMIG.pch file.
9. Click PARAM.
10. Check the small box in front of parameter G.

11. Click [G_V1] and input 0.2 as the structural damping coefficient.
12. Check the small box in front of parameter FRIC.
13. Click [VALUE] and input 0.05.
Friction factor 0.05 is used to scale the friction coefficient from DMIG data entry.
14. Click return twice and go back to the Analysis page.
Step 4: Define a loadstep for modal complex eigenvalue analysis

2. For Name, enter complex_eigen.
3. Click Analysis type and select Complex eigen (modal) from the drop-down menu.
5. In the Select Loadcol dialog, select SPC from the list of load collectors and click OK.
6. For CMETHOD, click Unspecified > Loadcol.
7. In the Select Loadcol dialog, select eigc from the list of load collectors and click OK.
9. In the Select Loadcol dialog, select eigrl from the list of load collectors and click OK.

3. Select the directory where you would like to write the file and enter the name for
brake_complex.fem in the File name: field.
4. Click Save.
OptiStruct model file was written. The brake_complex.out file is a good place to look for
Step 6: View the results

Complex eigenvalue analysis computes the complex modes of the structure. The eigenvalues of
the complex modes can be found in brake_complex.out file. The complex eigenvectors can be
reviewed in HyperView.

1. Load the brake_complex.out file in a text editor. The complex modes contain the imaginary
part, which represents the cyclic frequency, and the real part which represents the damping
of the mode. If the real part is negative, then the mode is said to be stable. If the real part is
positive, then the mode is unstable. The eigenvalues of the complex modes are shown below:
As you can see, the 5th mode was divergent while all of the other modes were stable. The
friction coefficient parameter can be reduced by setting the PARAM,FRIC factor from a value
of 0.05 to 0.01, and all roots become stable. It illustrates that there is a stability threshold
between the friction factor 0.05 and 0.01. It can be determined by resetting the scale factor
of PARAM, FRIC and rerunning the model till the damping value of this mode approaches zero.
2. Load the brake_complex.h3d file into HyperView to review complex eigenvectors.

OS-1371: Brake Squeal Analysis of Brake Assembly
In this tutorial you will perform a brake squeal analysis on a brake assembly. Disc brakes are
operated by applying a clamping load using a set of brake pads on the disc. The friction
generated between the pads and the disc causes deceleration, and can potentially induce a
dynamic instability of the system. This phenomena is known as brake squeal. For this model
OptiStruct will predict an unstable mode and the instability is seen to occur at the point of mode
coalescence, i.e., a pair of modes occur at the same frequency (mode coupling), and one of them
is unstable. The unstable mode can be identified during complex eigenvalue extraction because
the real part of the eigenvalue corresponding to an unstable mode is positive.
You can further design brake system which can be stabilized by changing the shape of the brake
pads or material properties of the brake components to decouple the modes (which is not shown
in this tutorial). The purpose of this tutorial is to conduct brake squeal analysis and identify the
unstable modes (if they exist).


Exercise
1. Download brsq.fem file from the optistruct.zip file and save to your working directory.
4. Click the Import Solver Deck panel toolbar icon . An Import tab appears. The File type: is
OptiStruct.
6. Select brsq.fem from your working directory and click Open. The model file brsq.fem is
loaded in the File field.
Information observed in the brsq.fem file
 Hexahedral Mesh is created for the brake assembly

 All parts are defined with material MAT1
 All parts are defined with Solid Element Property
 A cylindrical coordinate system is defined with respect to the disc
 S2S Contacts are defined between brake pad and disc
Two sub-cases are defined, as shown below:

1. Sub-case CLAMPLOAD: Nonlinear static analysis
Pressure Load on Insulator (Inner and Outer), with SPC (DOF1).
2. Sub-case ROTOR: Nonlinear static analysis with CNTNLSUB

Pressure Load on Pad and Rotation of the Disc, with non-zero SPC (DOF2).

Tip #1: The prescribed rotation should be large enough to ensure the contact between the
disc and the pad is in kinetic friction, but small enough to ensure small
displacement NLSTAT.
Tip #2: Kinetic friction is a constant value (independent of velocity), hence prescribing
rotation using SPCD is equivalent to prescribing rotational speed. The important
outcome is that the contact nodes are in kinetic friction mode and it does not matter
how fast or how far you move this using SPCD.

problem is formed on the projected subspace spanned by the real modes which is much smaller
than the real space. Here, both EIGRL and EIGC cards need to be defined.
2. In the Name field, enter modal_space.
4. Click Card Image and select EIGRL from the drop-down menu.
5. Click V2 and input 5000. 5000 is defined as the highest frequency bond.
6. Click ND and input 100. 100 real modes are required to produce the reduced space for
complex eigenvalue analysis.
7. Create another load collector named ceig_squeal.
8. Click Card Image, and select EIGC.
9. Click NORM and select MAX. MAX option will be used to normalize the eigenvectors.
10. Click ND0 and input 55. The desired number of roots to be extracted is 55.
Step 4: Define a loadstep for modal complex eigenvalue analysis

2. In the Name field, enter BRSQ.
4. For SPC, select DOF2 from the list of load collectors.
5. For CMETHOD, select ceig_squeal_ from the list of load collectors.
6. For METHOD(STRUCT), select modal_space from the list of load collectors.
7. For STATSUB (BRAKE), select Sub-case ROTOR (ID 2).
Tip: Create STATSUB (BRAKE) manually if this is not yet supported in HyperMesh.


2. Click Save as following the input file: field. A Save As window opens.
3. Select the directory where you would like to write the file.
4. In the File name, enter brsq.fem.
5. Click Save.
Note the name and location of the file displays in the input file: field.
OptiStruct model file was written. Look in the brsq.out file for error messages that will help
to debug the input deck, if any errors are present.

the complex modes can be found in the brsq.out file. The complex eigenvectors can be reviewed
in HyperView.
1. Load the brsq.out file in a text editor.
The complex modes contain the imaginary part, which represents the cyclic frequency, and
the real part which represents the damping of the mode. If the real part is negative, then the
mode is said to be stable. If the real part is positive, then the mode is unstable. The
eigenvalues of the complex modes are shown below:

2. Load the brsq.h3d file into HyperView to review complex eigenvectors.

OS-1372: Rotor Dynamics of a Hollow Cylindrical Rotor
In this tutorial you will perform Rotor Dynamics analysis on a hollow cylindrical rotor.
For rotating components, additional forces like the gyroscopic force and circular damping force
exist and are critical in the study of their response. It is important to determine these effects of
rotating components on the system as a whole. Here the complex eigenvalue analysis for 0, 10K,
30K, and 50K RPM are run.
The objective is to determine critical frequencies, and generate Campbell diagram when
subjected to a static imbalance from the rotor. At the critical frequency you observe
forward/backward cylindrical and conical whirl (mode shapes).

 Setup the problem in HyperMesh
rotor.fem Original ASCII OptiStruct input deck

Exercise
3. Click the Import Solver Deck panel toolbar icon . An Import tab appears. The File type:
is OptiStruct.
5. Select the rotor.fem file you saved to your working directory from the optistruct.zip file.
6. Click Open. The model file rotor.fem is loaded in the File field.
Information you will observe after opening the rotor.fem file
 1D Line Mesh is created using beam elements for the Rotor

 Rotor is defined with Material MAT1
 Rotor is defined with Beam Property
 SPC condition is defined in the model

problem is formed on the projected subspace spanned by the real modes which is much smaller
than the real space. In this case, both EIGRL and EIGC cards need to be defined.
1. Right-click in the Model browser and select Create > Load Collector.
2. In the Name field, enter EIGRL.
4. Click Card Image and select EIGRL from the drop-down menu.
5. Click V2 and enter 250.0.
250.0 is defined as the upper frequency bound.
6. Create another load collector named EIGC.
7. Click Card Image, and select EIGC.
8. Click NORM and select MAX. MAX option will be used to normalize the eigenvectors.
9. Click ND0 and enter 55. The desired number of roots to be extracted is 55.
Step 3: Define Grids for the Rotor Line Model using the ROTORG set
entry and Reference Rotor speeds using the RSPINR entry
1. Right-click in the Model browser and select Create > SET.
2. Click Name and enter ROTORG_SET.

3. Click Card Image and select ROTORG from the drop-down menu.
4. Click Entity IDs and click on nodes. Select nodes by collector and select CBEAM, and
proceed.
5. Check the box next to the RSPINR field since every rotor defined via ROTORG requires a
corresponding RSPINR entry.
6. Click the field next to GRIDA and then Node.
7. In the selection panel, click Node and enter 10000 in the ID= field.
8. Similarly, for GRIDB, enter 10001 .
9. Click on the field next to SPTID and enter 1.0.
Step 4: Create RSPEED entry to define Reference Rotor Speed Values

2. Click Name and enter RSPEED.
3. Click Card Image and select RSPEED from the drop-down menu.
4. Click S1 and enter 0.0, which is first reference rotor speed.
5. Click DS and enter 10000.0, which is increment in reference rotor speed.
6. Click NDS and enter 5, which is the number of reference rotor speed increments.
Step 5: Create RGYRO card

2. Click Name and enter RGYRO.
3. Click Card Image and select RGYRO from the drop-down menu.
4. Click SYNCFLG and select ASYNC from the drop-down menu.
Tip: This is set to run an Asynchronous Rotor dynamics analysis.
5. Click REFROTR and click set.
6. Select ROTORG_SET and click OK.
7. Check the field next to SPEED_ID.
8. Next to the SPEED field, click <Unspecified>. Then click Loadcol and select RSPEED from
the pop-up window.
Step 6: Define a loadstep for Rotor Dynamic analysis

1. Right-click in the Model browser and select Create > Load Step.
2. In the Name field, enter Rotor Dynamics.
5. For CMETHOD, select EIGC from the list of load collectors.

6. For METHOD(STRUCT), select EIGRL from the list of load collectors.
7. Under SUBCASE OPTIONS, check the field next to RGYRO and then RGYRO_ID.
8. Then click on the field next to ID to select load collector RGYRO.
Step 7: Submit the Job 1

rotor_async.fem in the File name: field.
4. Click Save.
OptiStruct model file was written. The rotor_async.out file is a good place to look for error
Step 8: Run the Model for Synchronous Rotor dynamic analysis.

1. Click on the RGYRO card in the Model browser.
2. Click SYNCFLG and change from ASYNC to SYNC from the drop-down menu.
Step 9: Submit the Job 2

rotor_sync.fem in the File name: field.
4. Click Save.
OptiStruct model file was written. The rotor_sync.out file is a good place to look for error

the complex modes can be found in rotor_async.out file. The complex eigenvectors can be
reviewed in HyperView.
1. Read the rotor_async.out in HyperView and follow the instructions in the below link to get
the Campbell Diagram and review the critical frequencies at the intersection points.
http://www.altairhyperworks.com/hwhelp/Altair/hw14.0/help/hg/hg.htm?campbell_diagram.h
tm
TableView in HyperView gives us the summary for the critical frequencies.
2. Load the rotor_sync.out file in a text editor. The Frequencies which you get from the
Synchronous Rotor dynamic analysis give you the critical frequencies. The complex modes
contain the imaginary part, which represents the cyclic frequency, and the real part which
represents the damping of the mode. If the real part is negative, then the mode is said to be
stable. If the real part is positive, then the mode is unstable. The eigenvalues of the complex
modes are shown below:

3. Compare to verify the Critical Frequencies which you obtained from the intersection points of
Step 10.1 and the frequencies you obtained in the rotor_sync.out file from Step 10.2.
4. Load the rotor_async.h3d file into HyperView to review and verify below Cylindrical and
Conical mode shapes.
RPM Cylindrical Modes Cylindrical Modes Conical Modes Conical Modes
Forward Backward Forward Backward
Mode #: 3 Mode #: 4 Mode #: 5 Mode #: 6
10,000 1.253E+001 1.253E+001 2.071E+001 2.263E+001
30,000 1.253E+001 1.253E+001 1.896E+001 2.472E+001
50,000 1.253E+001 1.253E+001 1.738E+001 2.697E+001

OS-1375: Response Spectrum Analysis of a Structure
This tutorial demonstrates how to perform a Response Spectrum Analysis on a structure. This
kind of analysis provides an estimate of peak structural response to a structure subject to
dynamic excitation. The analysis uses response spectra for prescribed dynamic loading and
results of normal modes analysis to calculate this estimate.
In the model used shown below in Figure 1, a building structure is modeled using CBEAM
elements having solid circular x-section (that is type ‘ROD’). The base of the building structure
will be constrained for all degrees of freedom and the structure will be excited in the global Z
direction.
Figure 1. Building structure hm model

 Setup the problem in HyperMesh

Exercise
Step 1: Launch HyperMesh Desktop, set the OptiStruct User Profile and
retrieve the structural model
4. Click Open > Model . An Open Model browser window opens.
Note: If HyperMesh Desktop was launched, use File > Open >
Model.
5. Select the building_ResponseSpectrumAnalysis.hm file you saved to your working directory

from the optistruct.zip file. Refer to Accessing the Model Files.
6. Click Open to load the model into HyperMesh Desktop.
The model is built using CBEAM elements and the PBEAML properties and MAT1 material are
already assigned. The units used for entering beam and material properties are force - Newtons,
length - mm, and mass - tonnes.
Step 2: Create EIGRL card

Define the EIGRL card to calculate the normal modes of the model.
2. For Name, enter eigrl_card.
5. Click ND and enter a value of 10.
Step 3: Create the constraints

5. Go to the Analysis page.
6. Click constraints.

7. In the create subpanel, confirm the entity is set to nodes, click on nodes and select the 4
nodes at the bottom of the model, as shown in the figure below.
Figure 2. Selecting nodes for defining constraints
8. Check all dofs (that is dof1 to dof6) with the value 0.000, confirm load types is set to SPC,
and click create. The constraints are created as shown in the figure below.

Figure 3. Constraints defined for the model
9. Click return to exit the Constraints panel.
Step 4: Define the input response spectrum using the TABLED1 card
1. Go to the Utility tab. If the Utility menu is not displayed, select View > Browsers >
HyperMesh > Utility.
2. At the bottom of the Utility menu, click the FEA panel.
3. Under Tools, click TABLE Create.
4. Select Import Table under Options: and TABLED1 under Tables.
5. Click Next.
6. Under Options, select Create New Table.
7. For Name, enter tabled1_card.
8. Click Browse.
9. For Files of type: change to CSV (*.csv), select the file sourceFileTABELD1.csv (which
contains the ‘x’ and ‘y’ values to define the input response spectrum, with frequency plotted
on the x-axis and acceleration on the y-axis) located in your working directory from the
optistruct.zip file.
10. Click Open. If the Import TABLED1 GUI is minimized, click on it on the taskbar.

11. In the Import TABLED1 GUI, click Apply. A message is displayed indicating the creation of
the TABLED1 card.
12. Click OK for this message.
13. Click Exit on the Import TABLED1 GUI (if you do not see the GUI, check the taskbar and
click on the Import TABLED1 GUI).
14. To see the plot corresponding to the TABLED1 card created above, open the TABLE Create
on the Utility menu on the FEA panel. This time select the option Create/Edit Table, for
Tables: select TABLED1, click Next. Under Options:, select Edit Existing Table,
corresponding to Select: select tabled1_card and click Plot. After reviewing the plot, click
on Close in the Plot window and Exit on the Create/Edit TABLED1 GUI.
Figure 4. Plot of the TABLED1 card
Step 5: Define the DTI, SPECSEL card

This card specifies the type of spectrum and damping values associated with the input response
spectrum defined using TABLED1 card in the previous step.
1. Click the Model tab to bring up the Model browser.
3. For Name, enter dti_card.
4. For Card Image, select DTI.

5. For TYPE, select A since the input response spectrum is a plot of acceleration v/s frequency.
6. Click the Table icon next to the Data field. In the pop-out window, select tabled1_card
for TID(1) and enter 0.02 for DAMP(1). The damping value is in the units of fraction of
critical damping.
Step 6: Define the RSPEC card

This card provides the specifications of the Response Spectrum Analysis.
2. For Name, enter rspec_card.
3. For Card Image, select RSPEC.
4. For directional combination method, DCOMB, select ALG.
5. For modal combination method, MCOMB, select SRSS.
6. Click CLOSE and enter a value of 1.000 in the input box.
7. For RSPEC_NUM_DTISPEC, enter 1.
8. Click next to Data. In the pop-out window, select dti_card for the DTISPEC field, and for
SCALE, enter the value 9800.0.
9. Since the direction of excitation for the structure is the Global Z direction, enter 0.0 for X(0),
0.0 for X(1), and 1.0 for X(2) respectively.
10. Click Close to exit the window.
Step 7: Define the modal damping for the structure

2. For Name, enter tabdmp1_card.
3. For Card Image, select TABDMP1.
4. For TYPE, select CRIT.
5. For TABDMP1_NUM, enter 2.
6. Click next to the Data field and enter the values 0.0, 0.02, 50.0 and 0.02 for f(1),
g(1), f(2) and g(2), respectively in the window.
Step 8: Define the PARAM cards

1. On the Analysis page, click control cards panel > next twice > PARAM panel.
2. Scroll down the list of available params, check the box next to COUPMASS, and for the
value, select YES, so the coupled mass matrix approach is used for eigenvalue analysis.
3. Scroll down the list of available params, check the box next to EFFMASS, and for the value,
select YES, so the modal participation factors and effective mass are computed and output to
the .out file.

Step 9: Define the outputs required

Displacements are output by default.
1. To output stress from the Analysis page, enter the control cards panel.
2. Click next to the page which has the GLOBAL_OUTPUT_REQUEST panel.
3. Click GLOBAL_OUTPUT_REQUEST, scroll down the list to STRESS and check it.
4. For OPTION(1), select ALL.
5. Click return twice to exit the control cards panel.
Step 10: Define the Response Spectrum Analysis loadstep

2. For Name, enter response_spec.
3. Click Analysis type and select Response spectrum from the drop-down menu.
5. In the Select Loadcol dialog, select constraints from the list of load collectors and click OK.
6. For RSPEC, click Unspecified > Loadcol.
7. In the Select Loadcol dialog, select rspec_card from the list of load collectors and click OK.
9. In the Select Loadcol dialog, select eigrl_card from the list of load collectors and click OK.
10. For SDAMPING(STRUCT), click Unspecified > Loadcol.
11. In the Select Loadcol dialog, select tabdmp1_card from the list of load collectors and click
OK.
12. Click return to exit the Loadsteps panel.

2. Click Save as following the input file: field. A Save file browser window opens.
3. Select the directory where you would like to write the file and enter the name for the file in
the File name: field.
Note: Save the file in a folder different from the folders under
HyperWorks installation folder.
4. Click Save.
Note: The name and location of the file displays in the input file:
field.

9. If the job completed successfully, new results files can be seen in the directory where the
OptiStruct model file was written. The .out file is a good place to look for error messages that
will help to debug the input deck if any errors are present and this can be done by clicking on
the view .out button in the OptiStruct panel.
Step 12: View the Results

1. If the analysis completes successfully, click the HyperView button in the OptiStruct panel.
This launches HyperView and loads in the model and result file for the analysis.
2. In the HyperView Results browser, expand the Results folder, then expand the Vector
folder and contour displacement results by selecting Mag under Displacement.
Figure 5. Displacement contour.

3. To contour stresses expand the Scalar folder under Results, expand Element Stresses
(1D) and contour the stress you want to see.
Shown below is the contour of CBAR/CBEAM Long. Stress SAMAX.
Figure 6. Stress contour.

OS-1380: Computation of Equivalent Radiated Power
Computation of the equivalent radiated power (ERP) is a simplified method to gain information
about maximum dynamic radiation of panels for excitations in frequency response analysis. This
tutorial demonstrates how to set up the computation request of ERP on an existing frequency
response analysis. The model is a front cover of catalytic converter in a car exhaust system, as
shown in Figure 1. The frequency analysis setup is already made for this model where the cover
is constrained at two ends, and the excitation loading is applied at the center of the cover. The
loading frequency is defined by FREQ1 card; from 120.0 to 400.0 Hz with an interval of 1.0. You
need to define ERP panels (ERPPNL) and ERP output request.

 Define ERPPNL and request ERP output
 Submit the OptiStruct job

Exercise
4. Click the Import Solver Deck icon . An Import window opens.
5. Click the Open file icon in the File: field. A Select OptiStruct file browser window opens.
6. Select the cover.fem file you saved to your working directory from the optistruct.zip file.
7. Click Open. The location of cover.fem displays in the File: field.
8. Click Import. The cover.fem database is loaded into the current HyperMesh session.
9. Click Close.
Step 2: Create ERPPNL

ERPPNL is defined as a set of elements. An element set ERP_elem has been predefined in the
model. It can be reviewed in HyperMesh.
1. Go to entity sets panel on Analysis page.
2. Click review and select ERP_elem. The elements should be highlighted on the screen.
4. In the Model browser, right-click and select Create > Set. A default set template is now
displayed in the Entity Editor below the Model browser.
5. For Name, enter ERPPNL.
6. For Card Image, select ERPPNL and click Yes to confirm.
7. For Entity IDs, click Unspecified > Sets.
8. In the Select Sets dialog. select the ERP_elem set and click OK.
Step 3: Request ERP output

You will request the ERP output in control cards panel.
2. Go to the GLOBAL_OUTPUT_REQUEST panel.
3. Check the box in front of ERP and enter 2 in the ERP_NUM field.

4. Set FORMATs, GRIDs, and OPTIONs for the ERP output, as shown below.
Figure 3: ERP output
The grid contribution of each grid in addition to the ERP results for the panel is output to an
.h3d file. ERP panel results are output to punch format.
5. Click return twice to return to the Analysis page.

2. Click Save as following the input file: field. A Save file browser window opens.
3. Select the directory where you would like to write the file and enter cover_ERP.fem in the
File name: field.
4. Click Save. The name and location of the file displays in the input file: field.
When the job completed successfully, new results files can be seen in the directory where the
OptiStruct model file was written.
Step 5: Post-process the ERP results in HyperView

When the message Process completed successfully is received in the command window, click
HyperView. HyperView will be launched and a message window appears to inform of the
successful model and result files loaded into HyperView.
1. Select Subcase 1 (frf) as the current load case in the Results browser. Select the last load
step where frequency is 50.0Hz.
3. Select Equivalent Radiated Power (ERP_elem) as Result type and then select Panel.
4. Click Apply. ERP results on panel should be plotted.
5. Select Equivalent Radiated Power (ERP_elem) as Result type and then select Grid
Contributions.
6. Click Apply. The contour of grid contributions to ERP should be loaded.

Figure 4: ERP results in HyperView
Step 6: Post-process the ERP results in HyperGraph

1. Launch HyperGraph.
2. Click Build Plots.
3. Load cover_ERP.pch file in Data file.
4. X Type is Frequency [Hz].
5. Y Type should be Subcase 1 ERP. Select Frf ERP_elem in Y Request and ERP in Y
Component field.
6. Click Apply.
The plot of ERP panel results vs loading frequency should be loaded, as shown below. The ERP
(dB) results are available, as well.
Figure 5: ERP results in HyperGraph

OS-1385: Heat Transfer Analysis on Piston Rings wth GAP
Elements
Piston rings fit on the outer surface of a piston in an engine. They support heat transfer from the
piston to the cylinder wall. This tutorial demonstrates running a heat transfer analysis on a set of
piston rings, as shown in Figure 1. The inner ring takes the heat flux (10.0W/m2) from the
piston. The outer surface of the ring that contacts the cylinder wall has zero degree
temperatures. FREEZE gap elements are used to model the contact between the two rings.
Thermal conduction property PGAPHT is defined for gap elements to simulate the heat transfer
between the rings. The thermal boundary condition, heat flux loading, and a linear steady state
heat conduction subcase have already been defined in the model. You will focus on how to define
PGAPHT for gap elements in this exercise.

 Define PGAP and PGAPHT for gap elements and create CGAPG elements between rings
 Solve the heat conduction analysis with OptiStruct solver

Exercise
4. Click the Import Solver Deck icon . An Import window opens.
The Import type: is FE Model and the File type: is OptiStruct.
5. Click the Open file icon in the File: field. A Select OptiStruct file browser window opens.
6. Select the Rings.fem file you saved to your working directory from the optistruct.zip file.
7. Click Open. The location of Rings.fem displays in the File: field.
8. Click Import. The Rings.fem database is loaded into the current HyperMesh session.
9. Click Close.
Step 2: Create PGAP and PGAPHT property

Create PGAP and PGAPHT property before creating gap elements.
2. In the Entity Editor, set the Name to PGAP.
3. For Card Image, select PGAP from the drop-down menu and click Yes to confirm.
4. Set U0= to 0.0.
5. Check the box next to MU1_opts.
6. Click on the field next to Options and select FREEZE from the drop-down menu.
7. Check the box next to PGAPHT.
8. Check the box next to KAHT_opts.
KAHT=AUTO determines the value of KAHT for each gap element using the conduction of
surrounding elements.
The PGAP and PGAPHT definition should be the same.
The heat transfer conduction property of gap elements has been created.

Step 3: Create CGAPG elements between the rings
Here defining CGAPG elements with predefined node and element sets, GAPgrids and GAPelems
is done. GAPgrids contains the nodes on the outer surface of the inner ring. GAPelems contains
the solid elements on the inner surface of the outer ring. The sets can be reviewed in entity sets
on the Analysis page.
1. In the Model browser, right-click and select Create > Component. A default component
2. For Name, enter PGAP.

4. In the Select Property dialog, select PGAP and click OK. PGAP should be set to current
component automatically.
5. Select the 1D page. Click gaps and go to the create subpanel.

6. Check the option nodes-elems.
7. Click the highlighted nodes and click by sets. Check the box in front of GAPgrids and click
select.
8. Click the highlighted elems and click by sets. Check the box in front of GAPelems and click
select. Face nodes need to be picked for the solid elements in GAPelems.
9. Go to the Model browser and hide Ring2 under Component. The component Ring1 should be
displayed on the screen and the inner layer solid elements should be highlighted.
10. Click face nodes and select the nodes on the inner surface of the highlighted solid elements,
as shown below.
Figure 2: Face nodes

11. Click property= and select PGAP. If the CGAPG elements are created in predefined GAP
component, there is no need to specify the property here since GAP is already linked to PGAP
property.
12. Click create. The CGAPG elements with heat transfer conduction property are created.
Figure 3: Overview of CGAPG elements
As described at the beginning of the tutorial, the heat transfer boundary condition SPC_heat and
heat flux input flux are predefined in the model. An OptiStruct steady state heat conduction
loadstep, referring to SPC_heat and flux, has been defined as well. The heat transfer results are
requested in loadsteps panel. Refer to tutorial OS-1080 for the details on how to define heat
transfer boundary condition, heat flux, and the output request.
Note that without PGAPHT, the heat cannot be transferred through the gap elements. In this
case, the outer ring remains zero degree and the inner ring takes all heat, as shown in the
temperature results in Figure 4. Run the completed model and compare the results with PGAPHT
to the results below.

Figure 4: Temperature results without PGAPHT

name for the model, Rings_complete.fem, in the File name: field. The .fem filename
extension is the recommended extension for OptiStruct input decks.
4. Click Save.
The name and location of the Rings_complete.fem file displays in the input file: field.
Rings_complete.fem was selected. The Rings_complete.out file is a good place to look for
Step 5: Post-process the results of heat transfer analysis

Temperature and flux contour results for the steady state heat conduction analysis are computed
by OptiStruct. HyperView will be used to post-process the results.
HyperView.

4. Select Subcase 1 - heat transfer as the current load case in the Load Case and
Simulation Selection window.
6. Click Apply. A temperature contour plot is now available.
7. Select the first pull-down menu below Result type: and select Element Fluxes(V).
8. Click Apply. Both temperature and flux results are shown below.

OS-1390: 1D and 3D Pretensioned Bolt Analysis of an IC
Engine Cylinder Head, Gasket and Engine Block System
Connected Using Head Bolts
This tutorial outlines the procedure to perform both 1D and 3D pretensioned bolt analysis on a
section of an IC Engine. The pretensioned analysis is conducted to measure the response of a
system consisting of the cylinder head, gasket and engine block connected by four head bolts
subjected to a pretension force of 4500 N each.
Figure 1: Illustration of the model showing the cylinder head, engine block and head bolts.
Checkpoint
The model consists of eight predefined components along with their corresponding property and
material allocations. A contact surface (PT_Surf) has been defined, which is used for 3D
pretensioning of an existing pretension surface. The pretension sections for 1D pretensioning
have also been created on two of the four bolts and the sectioned bolts are reconnected using 1D
beam elements (via rigids). A predefined visualization aid is also available under View, which
allows the user to easily look at the pretensioned sections of the four bolts. Contact surfaces and
Contact Interfaces (TYPE=FREEZE) between the various parts have also been created so you can
focus on the Pretensioning aspect of the tutorial.
Tutorial Prerequisites
1. The latest version of Altair HyperMesh, Altair HyperView and Altair OptiStruct software
installations. Pretensioned Bolt analysis is available only in Altair HyperMesh version-
12.0.110, Altair HyperView version-12.0.110 and Altair OptiStruct version-12.0.202 and later.
2. The pretension.hm solver deck is located in the optistruct.zip file. Refer to Accessing the
Model Files.
Brief Introduction to Pretensioned Bolt Analysis

Many engineering assemblies are put together using bolts, which are usually pretensioned before
application of working loads. A typical sequence is described below. For further detailed
information, refer to Pretensioned Bolt Analysis in the User's Guide.
In Step 1, upon preliminary assembly of the structure, the nuts on respective bolts are tightened,
usually by applying prescribed torque (which translates into prescribed tension force according to
the pitch of the thread).
As a result, the working part of the bolt becomes shorter by a distance L. This distance depends
upon the applied force, the compliance of the bolt and of the assembly being pretensioned.
Figure 2: Step 1 of pretensioned assembly – application of pretensioning loads.
From the perspective of FEA analysis, it is important to recognize that:

 Pretensioning actually shortens the working part of the bolt by removing a certain length of
the bolt from the active structure (in reality this segment slides through the nut, yet the net
effect is the shortening of the working length of the bolt). At the same time the bolt
stretches, since now the smaller effective length of the bolt material has to span the
distance from the bolt mount to the nut.
 Calculation of each bolt’s shortening L, due to applied forces F, requires FEA solution of the
entire model with the pretensioning forces applied. This is because the amount of nut
movement, due to given force depends on the compliance of the bolts, of the assembly
being bolted and is also affected by cross-interaction between multiple bolts being
pretensioned.
At the end of Step 1, the amount of shortening L for each bolt is established and “locked”,
simply by leaving the nuts at the position that they reached during the pretensioning step.
In Step 2, with the shortening L of all the bolts “locked”, other loads are applied to the assembly
(Figure 3). At this stage the stresses and strains in the bolts will usually change, while the length
of material removed L remains constant for each bolt.

Figure 3: Step 2 of pretensioned assembly – application of working loads with “locked” bolt shortening.
Setting up the model in HyperMesh
Step 1: Selecting the OptiStruct User Profile and loading the model into
HyperMesh

Figure 4: Selecting the OptiStruct User Profile
3. Click OK. This loads the OptiStruct user profile. It includes the appropriate template, macro
menu, and import reader, paring down the functionality of HyperMesh to what is relevant for
generating models for OptiStruct.
User Profiles can also be accessed from the Preferences menu on the toolbar.

Figure 5: Alternate method of accessing the "User Profile"
4. Click the Open Model panel toolbar icon and browse to the location that contains the
model.
5. Select the Pretension.hm file you saved to your working directory from the optistruct.zip
6. Click Open. The model is now loaded into HyperMesh.
Checkpoint
This tutorial helps the you apply 1D and 3D bolt pretensioning to the four head bolts (two of
each) and then apply a pressure load to the constrained system. The applied pressure load
models the pressure on the inside walls of an IC engine due to combustion. Pressure within the
engine compartment varies with time (transient); however, you capture the response of the
system at a specific instant frozen in time. A constant single-valued pressure load of 1 Pascal is
applied to the inner walls of the cylinder head and the engine block.
Gasket behavior is nonlinear and it may undergo cycles of loading and unloading which lead to
changes in its properties at each step. In this tutorial, which focuses on 1D and 3D pretensioning,
the loading and unloading paths for the gasket material are pre-populated in the MGASK data
entry via the TABLES# entries referenced by corresponding load collectors. As a quasi-static
analysis is running, the initial applied pressure load is compared with corresponding values within
the loading/unloading path tables and the initial material properties of the gasket are
determined. The nonlinear properties of the gasket via the MGASK data entry are a function of
pressure and the closure distance (Refer to MGASK Bulk Data Entry for more information).
FREEZE contact has been predefined for all parts in contact.

Figure 6: Tutorial Process Flow
Step 2: Reviewing pre-populated information

The imported model contains a large amount of pre-populated information which allows us to
focus on the pretensioning section in this tutorial. As explained in Step 1, all material and
properties are predefined for the gasket, engine block, cylinder head and head bolts. The
material properties of steel are assigned to all components except the gasket.
1. In the Model browser, right-click and select Expand All.
2. Click on STEEL in the Model browser under Material. The MAT1 entry is displayed in the
Entity Editor with pre-populated field values.
3. Make sure that the values on the MAT1 bulk data entry for the material properties of steel
are input, as shown below.

Figure 7: Reviewing the material – Steel.
4. Next, select MAT1_gask in the Model browser.

5. Make sure that the values on the MAT1 bulk data entry for the material properties of the
gasket are input, as shown below.
Figure 8: Reviewing the material - Gasket

6. Click on MGASK.
7. Make sure that the values on the MGASK bulk data entry for the material properties of the
gasket are input, as shown below.
Figure 9: Reviewing the nonlinear Gasket material properties - MGASK
Tip: The TABLD and TABLU(1) fields (Gasket loading and

unloading paths) in Figure 9 are defined by TABLES1 bulk
data entries in separate load collectors named Gask_Load and
Gask_Unload1, respectively.
8. Click on Gask_Load, in the Load Collector folder and then click the table icon next to the
Data: field.
9. Make sure that the values on the TABLES1 bulk data entry defining the gasket loading paths
are input, as shown below.
Figure 10: Reviewing the gasket loading paths – TABLES1

10. Similarly, make sure that the values on the TABLES1 bulk data entry defining the gasket
unloading paths (load collector Gask_Unload1) are input, as shown below.
Figure 11: Reviewing the gasket unloading paths – TABLES1
Tip: You can review, in a similar manner, the remaining

predefined data entries like properties and load collectors.
The procedure for load collector review is not as straight
forward, as shown above in some cases; however, this has
been thoroughly illustrated in various other tutorials for the
user’s benefit.
11. The gasket normal direction is now reviewed by clicking on normals in the Tool panel.
12. To select the gasket component, use the Show/Hide tool (Figure 12) to hide the cylinder
head thereby exposing the gasket to view.
Figure 12: Masking (Show/Hide) tool.
13. Click on the Show/Hide icon, shown in Figure 12 and right-click on the cylinder head to hide
it from view. The gasket should now be visible.

Figure 13: Exposing the gasket component to view using the masking tool.
14. In a similar fashion, hide (right-click) the engine block from view to be able to better visualize
the gasket normals.
15. Click the Show/Hide icon again to deselect it and select the gasket directly from the
graphics area and click display normals.
16. The gasket normals can be seen in the graphics window, as shown in Figure 14. Notice that all
the normals point in the negative Z direction.
Figure 14: Selecting the gasket component.

Figure 15: Displaying the gasket normals (negative Z direction).
Checkpoint
This concludes the review section of the tutorial. You will now focus on generating contact
interfaces, contact surfaces and applying pretensioning to the head bolts.
Step 3: 1D and 3D bolt pretensioning

Bolt pretensioning analysis determines the response of a system which contains bolts holding two
or more components together as a result of pretensioning. In OptiStruct, pretensioning is applied
in an earlier subcase and it is subsequently referenced to in the subcase where its effect is
sought (STATSUB(PRETENS)).
1. Right-click on Component in the Model browser and select Show.
2. Hide the CYLINDER_HEAD component by clicking the Elements icon next to it in the Model
browser.
Tip: View1, A predefined visualization option, is included with this

model under View in the Model browser. Click on the monitor
shaped icon next to View1; this loads a predefined view in
the Model browser allowing you to view all four bolts in the Y-
Z plane. Two bolts have disc-shaped sections cut-off along its
length. These bolts are then reconnected using 1D beam
elements (CBEAM) and two rigid spiders (RBE2) per bolt. 1D
pretensioning can now be applied to these two bolts. 3D
pretensioning requires the creation of a surface at which
pretensioning forces can be applied.

Figure 16: Using the predefined visualization option View1.
A surface PT_Surf has been predefined to demonstrate 3D pretensioning on existing surfaces.

To additionally demonstrate 3D pretensioning by creating a new surface, the fourth bolt is left
unchanged.
Figure 17: Bolt Pretensioning for this tutorial model.
3. Click on Tools > Pretension Manager to access the Pretension Manager.

4. Click on Add 1D Bolts and select the two 1D beam elements in bolts 1 and 2 (Figure 18).
Tip: Care must be taken not to use CTRL+left mouse click while
zooming in and positioning the elements in the graphics area
for selection. Using CTRL+left mouse click can lead to the
model being rotated about an axis and thus disengaging from
the Y-Z plane of View1. It is recommended to only use
CTRL+right mouse click (dragging action) while working in
View1.

Figure 18: Selecting the predefined 1D elements for pretensioning.
5. Select both fields under the Load Type column in the Pretension Manager window (Click on the
first field and then while holding down the CTRL key, click on the second field). Click on the
downward facing arrow next to the second field and select Force from the drop-down menu.
6. In a similar fashion, enter 4500.0 for both bolts in the Load Magnitude column.
7. Click Apply. A pretensioning force of 4500.0 N is applied to both 1D bolts, as shown in Figure
19.
Figure 19: Pretensioning force is applied to 1D elements (PTFORCE=4500 N).
8. Click on Add 3D Bolts and select Select Existing Surface from the drop-down menu.
9. Click on the Wireframe elements skin only icon to view the predefined contact surface
PT_Surf on the third bolt.
Tip: If the predefined surface is not visible, then switch on (show)

the PT_Surf entry in the Model browser by clicking on the
icon next to it.

10. Click on the displayed predefined surface in the bolt, as shown in Figure 20 and click
proceed.
Figure 20: Selecting the predefined PT_Surf surface.
11. Select Force under the Load Type column and enter 4500.0 N for the Load Magnitude
column and click Apply.
A pretensioning force of 4500.0 N is applied normal to the PT_Surf surface, as shown in
Figure 21.

Figure 21: Applying a pretensioning force of 4500 N to the predefined surface PT_Surf on the third bolt.
12. Click on Add 3D Bolts and select Create New Surface from the drop-down menu.
13. Utilize the click and drag technique (while holding down the shift key) described previously to
select the top of the fourth bolt, as shown in Figure 22.
Figure 22: Creating a new surface for pretensioning.

14. Click on nodes in the panel below the graphics area and select all the nodes in the surface
perpendicular to the Y-Z plane, as shown in Figure 23.
The same click and drag technique can be used to select these nodes (draw a window
encompassing the line as the perpendicular surface is a line in the Y-Z plane).
Figure 23: Selecting the nodes necessary to create a pretensioning surface.
15. Click create > return to return to the Pretension Manager.

16. Select Force under the Load Type column and enter 4500.0 N for the Load Magnitude and
click Apply.

Figure 24: Pretension Manager with all four pretensioned bolts.
17. Click OK in the Pretension Manager to view all four bolts with their respective pretensioning
forces, as shown in Figure 25.
Figure 25: Reviewing the four pretensioned bolts.
Step 4: Creating a pretension loadstep and a subsequent analysis

loadstep
OptiStruct nonlinear quasi-static analysis loadsteps will be created for both pretensioning and the
subsequent analysis. The analysis is nonlinear due to the presence of contact elements and the
gasket loading/unloading paths. The CNTNLSUB bulk data entry is used to continue the
subsequent nonlinear analysis after pretensioning. Also, the pretensioning subcase is referenced
in the analysis subcase using STATSUB(PRETENS). The Load Step browser will be used to
created the loadsteps and assign respective data entries.

1. Click on the Shaded Elements and Mesh Lines icon next to the BLOCK and
CYLINDER_HEAD components in the Model browser to show the hidden components.
2. Click Tools > Load Step Browser to access the Load Step browser.
3. Right-click on Loadsteps in the Load Step browser and select New loadstep.
4. In the Loadstep name: field, enter Pretension and click Create.
Figure 26: Creating the Pretension subcase.
5. Select Nonlinear quasi-static from the drop-down menu next to Loadstep type: in the
Loadstep Type tab.
6. Switch to the Load References tab and click on NLPARM in the list of subcase entries.
7. Click on Nlparm in the Available nonlinear parameters: section and then click on the right
facing arrow to add it to the selected nonlinear parameter: section.
8. Similarly, click on SPC in the subcase entry list and add the Available SPC constraint to the
Selected SPC constraints: section.
9. Follow the instructions in Steps 6 or 7 to add PRETENS_1 to the list from the PRETENSION
subcase entry section.
10. Click OK after all three subcase entries are added to the Pretension loadstep.
11. Right-click on Loadsteps in the Load Step browser and select New loadstep.
12. In the Loadstep name: field, enter Pressure and click Create.
Figure 27: Creating the Pressure loadstep.
13. Select Nonlinear Quasi-static from the drop-down menu next to Loadstep type: in the
Loadstep Type tab.
14. Switch to the Load References tab and click on NLPARM in the list of subcase entries.
15. Click on Nlparm in the Available nonlinear parameters: section and then click on the right
facing arrow to add it to the selected nonlinear parameter: section.
16. Similarly, click on SPC in the subcase entry list and add the Available SPC constraint to the
Selected SPC constraints: section.

17. Follow the instructions in Steps 6 or 7 to add PRETENSION to the list from the
STATSUB(PRETENS) subcase entry section.
18. Again, follow the instructions in Steps 6 or 7 to add PRESSURES to the list from the LOAD
subcase entry section.
19. Click on the CNTNLSUB subcase entry and check the box next to CNTNLSUB, additionally
select YES from the pull-down menu next to CNTNLSUB.
20. Click OK after all five subcase entries are added to the Pressure loadstep.
21. Click Close to exit the Load Step browser.

name for the model, Pretension.fem, in the File name: field. The .fem filename extension is
the recommended extension for OptiStruct input decks.
4. Click Save.
The name and location of the Pretension.fem file displays in the input file: field.
Pretension.fem was selected. The Pretension.out file is a good place to look for error
messages that could help debug the input deck if any errors are present.
Displacements, Element stresses, Contact pressures, Gasket Sealing Status, Gasket thickness
direction closure and Gasket thickness direction pressures are calculated and can be plotted using
the Contour panel in HyperView.
Step 6: Viewing the results of the 1D and 3D bolt pretensioning analysis

HyperView.

4. Select the first pull-down menu below Result type: and select Displacement(v).
5. Click Apply, select Subcase 2 (Pressure) from the Results browser.

A contour plot of displacements is created, as shown in Figure 29. The cylinder head is hidden
to view the displacement plots for the head bolts.
Figure 29: Displacement contour for the Pressure subcase after pretensioning.
Checkpoint
In Figure 29, the displacement plot after running the pressure subcases can be seen. The
maximum displacement is around 0.089 mm and it occurs in the region near the pretensioned
bolt heads.
6. Select Gasket Thickness-direction Pressure in the Contour panel and click Apply.
A contour plot of gasket pressure in the thickness direction is created, as shown in Figure 30.
The other components are hidden to be able to better view the pressure variation on the
gasket.

Figure 30: Gasket pressure in the thickness direction for the Pressure subcase.
Checkpoint
The maximum pressure on the Gasket in the thickness direction is equal to 0.21 MPa.

OS-1392: Node-to-Surface versus Surface-to-Surface Contact
This tutorial demonstrates how to set up contact between two parts and the impact of using
choosing node-to-surface (N2S) versus surface-to-surface (S2S). In addition, this tutorial covers
how to review the internally created CGAPG elements in case of N2S, and the nodes in contact in
case of S2S.
Figure 1: Illustration of the model.
Summary
The model consists of two cubes in contact and enforced displacement on the top compressing
the structure.
 Launch HyperMesh and importing the model
 Define the surface for each part, which will be in contact with the other
 Define the interface, which links the two surfaces together
 Request contact related output
 Perform the N2S and S2S analyses
 Review and compare the results
 Check the contacts that have been analyzed

Prerequisites
1. The latest version of HyperMesh, HyperView and OptiStruct software installations. Some of
the presented features are available only in HyperMesh, HyperView, and OptiStruct version
14.0 and later.
2. The solver deck blocks_contact.fem is located in the optistruct.zip file. Refer to
HyperMesh

3. Click OK.
This loads the OptiStruct user profile. It includes the appropriate template, macro menu, and
The User Profiles dialog can also be accessed from the Preferences menu on the toolbar
4. Click the Import Solver Deck panel toolbar icon and browse to the location that contains
the model.
5. Select the blocks_contact.fem file you saved to your working directory from the
6. Click OK.
7. Click Import > Close.
The model is now loaded into HyperMesh.
Step 2: Creating Contact Surfaces

The imported model already contains the material, the property, the boundary conditions and the
loadstep. In this step, the contact surfaces and the interface are created.
2. Right-click in the Model browser and select Create > Contact Surface to create a contact
surface.
Figure 3: Creating a Contact Surface from the Model browser
3. For Name, enter bottom.

4. In the Model browser, right-click on the component bottom under Component and select
Isolate Only.
5. To add elements and their faces to the surface, select the bottom surface in the Contact
Surface panel of the Model browser and click on 0 Elements in the Entity state browser.
6. Click the Element button to select elements from the Panel. Switch the selector to Solid
faces, as this contact surface will be on solid elements.
7. Click Elements and select all elements from the bottom part of the structure.
8. Select three nodes on the surface that are in contact with the top part. Make sure the three
nodes are all part of one element.

9. Click return to finish.
10. Repeat steps 3 through 9 to create the top part.
Figure 4: Adding a Contact Surface
Step 3: Creating the Contact Interface

After defining the two contact surfaces you need to define that they are in contact and with which
properties. A contact interface needs to be defined.
2. For Name, enter top_to_bottom.
3. In the Model browser, select the newly created Contact to modify the properties of the
contact.
4. For TYPE, select SLIDE.
This will result in a frictionless contact.
5. To select the slave surface, click on the field next to Slave Entity IDs.
The slave surface should be the finer side, in this case the bottom (refer to the User's
Guide).
6. Select the top for Master Entity IDs.
7. For DISCRET, select N2S.
8. Retain the default values in the remaining fields, for now.
9. Click anywhere in the Model browser to apply these changes.

Figure 5: Defining the Contact interface in the Entity browser.
Step 4: Requesting Contact related output

In the final step of model preparation, you want to request contact related output, CONTF; which
causes Contact Force, Contact Deformation, Contact Status and Contact Traction to be output.
Also, CONTPRM,CONTGAP, CONTPRM,CONTGRID and GAPPRM,HMGAPST are used to review the
created contact elements.
1. From the main menu, select Setup > Create > Control Cards.
2. Select GLOBAL_OUTPUT_REQUEST and CONTF.
Figure 6: Setting up a Global output request.
3. In the next panel, select the settings to request contact related output, as shown below.
Figure 7: Requesting contact related output.
4. Click return to complete the card definition.

5. Repeat the steps above to create the CONTGAP and CONTGRID cards, as seen in Figure 8.
They are available under the CONTPRM control card.
6. Select UNSUPPORTED_CONTPRMS and enter 2.
7. Then create the following cards below.
CONTPRM,CONTGAP,YES (outputs the internally created CGAPG for N2S contact)
CONTPRM,CONTGRID,YES (outputs a set containing the grids in S2S contact)
8. Click return.
Figure 8: Defining CONTPRM cards CONTGAP and CONTGRID.
9. Click Next to locate the GAPPRM control card and click HMGAPST.
10. Set the VALUE to YES.
Outputs the open/closed status of the CGAPG elements.
Figure 9: Defining GAPPRM card HMGAPST.
Step 5: Launch OptiStruct for N2S

2. Click save as following the input file: field.
A Save As window opens.
3. Select the directory where you want to write the OptiStruct model file.

4. For File name, enter the model name Contact_N2S.fem. For OptiStruct input decks .fem is
the recommended extension.
5. Click Save.
The name and location of the Contact_N2S.fem file displays in the input file: field.
6. Set memory options: to memory default.
7. Set run options: to analysis.
8. Set export options: to all.
9. Click OptiStruct.
This launches the job.
If the job is successful, the new results files will appear in the directory from which
Contact_N2S.fem was selected. Look in the Contact_N2S.out file for error messages that
could help debug the input deck, if any errors are present.
Step 6: Launch OptiStruct for S2S

1. In the Model browser, select the top_to_bottom card under Group.
2. Set DISCRET to S2S.
3. Repeat Step 5 above, with the new file name Contact_S2S.fem.
Displacements, Element Stresses, Contact Force, Contact Deformation, Contact Status and
Contact Traction are calculated and can be plotted using the Contour panel in HyperView. Only
compare the Contact Traction between the N2S and the S2S run.
Step 7: Comparing the Contact Traction between N2S and S2S

HyperView.
HyperView is launched and the results are loaded for the S2S run.
2. A message window appears to verify that the model and result files are loading into
HyperView.
3. Click Close to close the message window, if available.
4. Select the page window layout icon to split the page into two windows.
5. Load the other model in the new window by clicking and selecting contact_N2S.h3d.
6. Click the Contour toolbar icon in one of the two windows.
7. For Result type, select Contact Traction/Normal(s).
8. Click Apply.

9. In the Model browser, unselect the top part of the structure.

Only the results on the contact surface are visible.
Figure 11: Isolating the bottom part of the structure in HyperView.
10. Right-click in the window that shows the contour and select Apply Style > Current Page >
All selected to view the same results for both models.
A contour plot of normal contact traction shows for both runs. The traction for the S2S run is
much more uniform than for N2S by comparing the maximum and minimum values.
Figure 12: Applying the setup in one window to the rest of the page.

Figure 13: Contour of the normal contact traction for S2S on the left and N2S on the right.
Step 8: Reviewing the internally created CGAPG elements for N2S

contact
After viewing the contact traction in HyperView, check the internally created contact elements for
the N2S.
1. Repeat Steps 1.1 through 1.4.
2. Select the Contact_N2S.fem file, located in the folder selected in Step 1.4.
3. Import the internally created CGAPG elements by importing the file
contact_N2S.contgap.fem.
4. Right-click on the component Gaps from CONTACT1 in the Model browser to review the gap
elements.
5. Select isolate only to visualize the elements better.
6. Click to turn on the element tags.

7. Click File > Run > Command File to create element sets to identify the open/closed status
of the elements at the end of the run.
8. Select the file contact_N2S.HM.gapstat.cmf.
Run a command file in HyperMesh to create sets containing open and closed gaps.
9. To see which gaps are closed or open at the end of the simulation, review the element sets
that were created. Review the set OS_gaps_sub_001_closed by selecting it in the Model
browser and clicking on the field next to Entity IDs in the Entity browser.
This shows that all gaps are closed, as it contains all elements. If there were some open gaps,
another set OS_gaps_sub_001_open would have been created, as well.

Figure 14: Reviewing the closed gaps at the end of the analysis.
Step 9: Reviewing the grids in contact for S2S contact

The contact for S2S contact is different from N2S in the sense that no CGAPG elements are
created internally. This means the process in Step 8 cannot be applied to S2S contacts. However,
you can review the master and slave grids that are being used in the S2S contact, to ensure that
the contact has been established in the correct manner.
1. Repeat Steps 1.1 through 1.4.
2. Select the Contact_S2S.fem file, located in the folder selected in Step 1.4.
3. Import the grid set that show the grids where S2S contact has been established by importing
the file contact_S2S.contgrid.fem.
4. Right-click on the component bottom in the Model browser and select isolate only to review
the grids.
5. Select Tools > Set Browser.
The Set browser opens.
6. In the Set browser, right-click on the set ^SlaveGrids_Contact_#1 and select Show.
Contact has been established on the entire surface as expected.

Figure 15: Reviewing the Slave nodes of the S2S contact.
7. Repeat Steps 8.3 through 8.6 for the component top and the set ^MasterGrids_Contact_#1.
Step 10: Reviewing the contact Status in HyperView for N2S and S2S
1. The contact status for both N2S and S2S can also be reviewed in HyperView, if the model
contained the contact result output request CONTF. To view this, repeat Step 7 while choosing
Contact Status/Normal(s) as the contour plot.
Figure 16: Reviewing the contact status in HyperView as a contour plot.

OS-1393: Basics of Contact Properties and Debugging
This tutorial demonstrates the effect of using contact stabilization, clearance, adjust and
smoothing.
Figure 1: Illustration of the model.
Summary
The model consists of two circular parts where the inner one is heated and the outer one cooled
down, leading to contact between the two. The effect of using several important contact settings
such as contact stabilization, clearance, adjust and smoothing on both the results and the
convergence behavior is considered.
 Launching HyperMesh and importing the model
 Create and assign the contact property PCONT
 Run the model
 Stabilization and clearance
 Adjusting and running smoothing
 Load and compare the results in HyperView
Prerequisites
14.0 and later.
2. The solver deck wheels_contact.fem is located in the optistruct.zip file. Refer to

HyperMesh
3. Click OK.
the model.
5. Select the wheels_contact.fem file you saved to your working directory from the
6. Click Import.

Step 2: Creating a PCONT property and assigning it
The imported model already contains the material, the property, the boundary conditions and the
loadstep, the contact surfaces and the Contact. In this step, a PCONT property is created.
2. Right-click in the Model browser, and select Create > Property to create a PCONT property.
3. For Name, enter cont_prop.
4. Open the Entity browser by selecting the newly created property in the Model browser.
5. In the Entity browser, change the Card Image to PCONT.
Figure 3: Changing the PCONT contact property through the Entity browser.
6. In the Model browser, select the interface cont_interf to assign the property to the interface.
7. In the Entity browser, select Property Id as the property and change the PID to
cont_prop.
Step 3: Launch OptiStruct for S2S

4. For File name, enter the model name Contact_S2S.fem. For OptiStruct input decks .fem is
5. Click Save.
The name and location of the Contact_S2S.fem file displays in the input file: field.

Contact.fem was selected. Look in the Contact_S2S.out file for error messages that could
help debug the input deck, if any errors are present.
Step 4: Launch OptiStruct with Contact Stabilization

1. Since the non-linearity of this model is only due to contact, a good way to overcome the
convergence issues is to add contact stabilization. This will especially be useful when part of
the structure is held in place by the contact, which is the case here.
2. Click Setup > Create > Control Cards.
3. Select PARAM and check the box next to EXPERTNL.
4. Select CNTSTB.
Also, contact stabilization can be activated through the bulk card CNTSTB and referencing it
from within the subcase. This gives you more options.
5. Repeat Step 3 above, with the new file name Contact_CNTSTB.fem.
Figure 4: Creating PARAM,EXPERTNL,CNTSTB.
Step 5: Launch OptiStruct with Clearance

Now you want to investigate the influence of clearance on the model.
1. In the Model browser, select the cont_prop property.
2. In the Entity browser, click on the field next to CLEARANCE and enter the value 0.1.
Clearance will internally set the gap between the surfaces to the real value chosen,
independently of the actual position of the grids, if grids are not moved to achieve this.

Figure 5: Changing the PCONT contact property through the entity browser.
3. Repeat Step 3 above, with the new file name Contact_Clearance.fem.
Step 6: Launch OptiStruct with Adjust

Now you want to investigate the influence of adjust on the model. First, remove the clearance
you defined in Step 5.
1. In the Model browser, select the property cont_prop.
2. In the Entity browser, click on the field next to CLEARANCE and remove the previously
inserted value of 0.1.
3. In the Model browser, select the interface cont_interf.
4. In the Entity browser, click on the field next to ADJUST and select AUTO.

Figure 6: Changing the parameters of the CONTACT through the Entity browser.
5. Repeat Step 5 above, with renaming the file Contact_Adjust.fem.
Step 7: Launch OptiStruct with surface Smoothing

1. In the Model browser, select the interface cont_interf.
2. In the Entity browser, click on the field next to ADJUST and set to blank.
3. For CONTACT_NUM_SMOOTH enter 1.
4. Click on the field next to SMSIDE and select BOTH and ALL.
Figure 7: Selecting the surface smoothing option on the CONTACT card.
5. Repeat Step 3 above, with the file name Contact_Smoothing.fem.

Displacements, Element Stresses, Contact Force, Contact Deformation, Contact Status and
Contact Traction are calculated and can be plotted using the Contour panel in HyperView. Only
compare the Contact Traction between the N2S and the S2S run.
Step 8: Comparing the Contact Traction between the four runs

1. Launch Hyperview.
2. Select the page window layout icon to split the page into four windows.
3. Click to load the first model in one of the window.
4. Select Contact_CNTSTB.h3d for model and results.
5. Click Apply.
6. Do the same in the other three windows for Contact_Clearance.h3d, Contact_Adjust.h3d
and Contact_Smoothing.h3d.
7. Click the Contour toolbar icon in one of the four windows.
8. For Result type:, select Contact Traction/Normal(s).
9. Click Apply.
10. In the Model browser, unselect the outer part of the structure.
Only the results on the contact surface will be visible
11. Right-click in the window that shows the contour and select Apply Style > Current Page >
All selected to view the same results for both models.
12. A contour plot of normal contact traction shows for both runs.
The traction for the runs with clearance and adjust are more uniform than they are for the
model with stabilization only. The surface smoothing leads to a more uniform contour. In
addition, the peaks are much lower for these three models. The reason why is, the traction is
much higher for adjust than it is for the clearance, and the adjust run is that for adjust, the
gap is closed initially, which leaves less room for stress free thermal expansion as for the
other runs.

Figure 9: Applying the setup in one window to the rest of the page
Figure 10: Normal contact traction contour for the four different runs.

Large Displacement Finite Element Analysis
OS-1500: Nonlinear Implicit Analysis of Bending of a Plate

The purpose of this tutorial is to demonstrate how to carry out nonlinear implicit analysis in
OptiStruct by simulating the bending of a plate under constant pressure.
Model Description
The figure below illustrates the structural model used for this tutorial: a long rectangular plate
which is supported at one end and distributed load is applied on the top surface. The dimensions
of the plate and material parameters can be obtained in the table below.

Units Length: mm; Time: s; Mass: Mgg; (Force: N; Stress: MPa)
Length 1000 mm
Width 200 mm
Thickness 4.0 mm
Material Steel, Elasto-plastic, using Johnson-Cook law
Initial density ( ): 7.90e-9 kg/mm3
Young's modulus (E): 200000 MPa
Poisson coefficient (ν): 0.29
Yield Stress ( 0): 100.0 MPa
Hardening Parameter 1.0MPa

(b):
Imposed pressure 0.02 MPa, applied normal to the plate
Simulation time [0 – 1.0 s]
The following exercises are included in this tutorial:

 Create plastic material and corresponding shell property
 Set up boundary conditions and imposed velocity
 Set up implicit analysis

Exercise

1. Launch HyperMesh Desktop. The User Profiles dialog appears.
2. Select OptiStruct and click OK. This loads the user profile.
3. Click File > Import > Solver Deck.
5. Select the Files icon . A Select OptiStruct File browser opens.

6. Select the plate.fem file you saved to your working directory from the optistruct.zip file.
8. The plate.fem OptiStruct input file is loaded into the current HyperMesh session.
9. Click Close to exit the tab.
Step 2: Define Unit System

2. Select DTI_UNITS, and set parameters, as shown below.
Step 3: Update the Material

1. In the Model browser, click on the material MAT1_1.
2. Check the box next to MATX and select MATX02 for the MATX_type field to define
additional material properties for Johnson-Cooke elastic-plastic material for geometric non-
linear analysis.
3. Input the values as shown below. See material parameters for details.

Step 4: Update the Property
1. In the Model browser, click on the property PSHELL_1.
2. Check the box next to PSHELLX (to define additional SHELL properties for geometric non-
linear analysis).
3. Input the values as shown below. See shell parameters for details.

Step 5: Create Boundary Condition
2. For Name, enter LC_SPC.
5. From the Analysis page, select constraints, toggle create.
6. Switch entity selector to nodes and select the nodes shown below.

7. Select the degrees of freedom dof1 and dof3. Deselect all others.
8. For load types, select SPC.
9. Click create to create the boundary constraints.
10. Next, select the bottom two nodes, as shown below.
11. Select the degrees of freedom dof1, dof2 and dof3. Deselect all others.
12. For load types, select SPC.
13. Click create to create the boundary constraints.
Step 6: Create Imposed Load

2. For Name, enter LC_PLOAD.
5. From the Analysis page, click pressures and toggle create.
6. Switch entity selector to elems and select all elements.
7. Click on the toggle next to magnitude= and switch pressure definition method to
constant vector.
8. For magnitude, enter -0.02.
9. For load types, make sure to select PLOAD as the load type.
10. Click create > return.
11. Create a load collector (using steps 6.1 to 6.3) named TH_IMPLOAD, with Card Image set to
TABLED1.
13. Click the Table icon next to Data and enter the values shown below in the pop-out
window.

14. Click Close. A curve is now created.
15. Create a new load collector named LC_IMPLOAD with Card Image set to NLOAD1.
17. In the Select Loadcol dialog, select LC_PLOAD.
18. For TID, click Unspecified > Loadcol.
19. In the Select Loadcol dialog, select TH_IMPLOAD.
Step 7: Define implicit analysis parameters

2. For Name, enter LC_NLPARM.
3. For Card Image, select NLPARM.
4. Select the CONV as P with a EPSP of 0.01.
5. Check the box next to NLPARMX. This defines the parameters for implicit nonlinear analysis
iteration strategy.
6. Input the values as shown below. See nonlinear analysis control parameters for details.

3. For DISPLACEMENT, ELFORCE, OLOAD, STRESS, and STRAIN, set Option to Yes.

Step 9: Create implicit analysis subcase (also referred to as a loadstep)
2. For Name, enter sub_nlgeom_implicit.
3. For Analysis type, select geometric non-linear from the drop-down menu.
5. In the Select Loadcol dialog, select LC_SPC from the list of load collectors and click OK.
6. For NLOAD, click Unspecified > Loadcol.
7. In the Select Loadcol dialog, select LC_IMPLOAD from the list of load collectors and click
OK.
9. In the Select Loadcol dialog, select LC_NLPARM from the list of load collectors and click OK.
10. For TTERM, enter a value of 1.0.

3. For File Name, enter plate.fem and click Save. The file extension .fem is necessary for
OptiStruct to recognize it as an input file.
5. Set the run options toggle to analysis.
If the job is successful, the new results files is located in the directory where HyperMesh was
invoked. The plate.out file is where you will find error messages that will help you debug
your input deck, if any errors are present.
The default files that will be written to your directory are:
plate.html HTML report of the analysis, giving a summary of the problem

plate.out ASCII based output file of the model check run before the
simulation begins and gives some basic information on the results
of the run.
plate.stat Summary of analysis process, providing CPU information for each

step during the process.
plate.h3d HyperView compressed binary results file.

1. Using HyperView, plot the Displacement and the von Mises stress contour at 1.0 s.

OS-1510: Follower Loads, Nonlinear Adaptive Criteria, and
Nonlinear Intermediate Results
This tutorial illustrates Follower Loads setup, and the usage of Nonlinear Adaptive Criteria
(NLADAPT) and how intermediate results can be requested for Nonlinear runs. You will see how
the activation of Follower Loads leads to a significant difference in model behavior and results,
and how inaccurate results may be output if the follower load mechanism is not taken into
account. You will look at activation of Follower Loads that are concentrated forces (Beam model)
and of Follower Loads that are pressures (Rubber Disk model).
Figure 1: Illustration of the models: Follower Loads: Concentrated Forces – Beam (left), Pressures – Rubber Disk Model
(Right).
Summary
Beam Model
The model is a curved steel beam constructed with CHEXA elements. A Force of 100 N is applied
to the top cross-section of the beam. The bottom of the beam is constrained by single point
constraints (SPC).
 Run the model without Follower Load activation
 Activate Follower Load (Concentrated force)
 Learn how to adjust nonlinear adaptive criteria (NLADAPT)
 Request intermediate nonlinear results using NLOUT.
 Review and compare results with and without follower loads. Also visualize the correct
animation of the deforming model as a result of NLOUT activation.

Rubber Disk Model
The model a rubber disk constructed with MATHE elements. A pressure load of 1 N/mm 2 is
applied to the rubber disk. The circumference of the disk is constrained via single point
constraints (SPC).
 Run the model without Follower Load activation
 Activate Follower Load (Pressure load) with Option=1, Option=2, and Option=3
 Request intermediate nonlinear results using NLOUT.
 Review and compare results with and without follower loads. Also visualize the correct
animation of the deforming model as a result of NLOUT activation.
Prerequisites
14.0.130/14.0.230 or later.
2. The solver decks beam_fllwer.fem and disk_fllwer.fem are located in the
Setting up the Beam model in HyperMesh
HyperMesh

3. Click OK.
The User Profiles dialog can also be accessed from the Preferences menu on the toolbar.
the model.
5. Select the beam_fllwer.fem file you saved to your working directory from the
6. Click Import.

Step 2: Running the beam model without Follower Load activation
The imported model already contains the material, the property, the boundary conditions,
activation of large displacement, and the loadstep. In this step, you will run the model directly to
generate results.
4. For File name, enter beam_fllwer.fem. The .fem filename extension is the recommended
extension for OptiStruct input decks.
5. Click Save.
The name and location of the beam_fllwer.fem file displays in the input file: field.
beam_fllwer.fem was selected. Look in the beam_fllwer.out file for error messages that
could help debug the input deck, if any errors are present.
Step 3: Activating Follower Loads for the beam model

Follower loads for concentrated forces do not depend on the area of the element face to whose
grids they are applied. Therefore, the results will remain the same for any activation option
chosen on either the FLLWER bulk data entry or the PARAM,FLLWER entry. Since you only have
one subcase, select the parameter PARAM,FLLWER to activate follower loading for this model.
1. In the Model browser, click PARAM. The list of parameters will show up in the Entity Editor
below.
2. Check the box next to FLLWER. A VALUE field displays below.
3. Click on the field next to VALUE and select 1 from the drop-down menu to activate Follower
Loads. As mentioned in the beginning of this step, the options 1, 2, and 3 have the same
effect for concentrated loads since element face areas are not involved. Using the parameter
instead of the Bulk Entry activates follower loading for all subcases in a model. If you want to
only activate follower loads for specific subcases, you can use FLLWER Bulk Data and Subcase
entries.

Step 4: Activating Nonlinear Adaptive Criteria (NLADAPT)
Parameters that allow you to define Nonlinear Adaptive Criteria are available via the NLADAPT
Bulk Data and Subcase entries. You can typically specify time-stepping and convergence criteria
for Nonlinear Analysis if you run into convergence issues. Refer to the NCUTS parameter in this
exercise. Similarly, you can define DTMIN, and DTMAX parameters, some of the other
parameters like NOPCL and NSTSL are intended for models with contacts.
1. Right-click in the Model browser, click Create > Load Collector from the drop-down menu.
2. Name the load collector NLADAPT.
3. In the corresponding Entity Editor, click on the field next to Card Image and select
NLADAPT.
4. Activate the check box next to NCUTS and in the VALUE field enter the integer 5 (which is
the default). This indicates to OptiStruct that the maximum number of cutbacks allowed to
reduce the time increment is 5. OptiStruct will error out if a greater number of cutbacks is
required for a particular time increment for iterative convergence.

5. Click on the Nonlinear Static Load Step to open it in the Entity Editor.
6. Click on the field next to NLADAPT and on the yellow Loadcol button.
7. Select the NLADAPT load collector in the Select Loadcol dialog and click OK.
Step 5: Activating Nonlinear Intermediate Results (NLOUT)

Parameters that allow you to activate Nonlinear Intermediate Results are available via the NLOUT
Bulk Data and Subcase entries. The number of intervals at which intermediate results are output
is controlled by the NINT parameter. The SVNONCNV parameter can be used to
activate/deactivate the output of results for non-convergent solutions. This is currently turned on
by default (set to YES).
1. Right-click in the Model browser, click Create and select Load Collector from the drop-down
menu.
2. Name the load collector NLOUT.

3. In the corresponding Entity Editor, click on the field next to Card Image and select NLOUT.
4. Activate the check box next to NINT and in the VALUE field enter the integer 10 (which is
the default). This indicates to OptiStruct that the maximum number of intervals at which
intermediate results are requested is 10. If the load increment from any load “n” to load
“n+1” is greater than 1/NINT (in this case, 1/10 is 0.1), then the results corresponding to
load level “n+1” are saved for output; otherwise, the results are not saved.
Note that this parameter has no control over the adaptive load size selection during the
incremental-iterative solution process. It only specifies the number of intervals when results
are saved for output during the solution process.
5. Click on the Nonlinear Static Load Step to open it in the Entity Editor.
6. Click on the field next to NLOUT and on the yellow Loadcol button.
7. Select the NLOUT load collector in the Select Loadcol dialog and click OK.

Step 6: Running the Beam model with Follower Loads activation
The model now consists of loads which have been identified as follower loads. Additionally, you
have learned how to activate adaptive criteria for nonlinear analysis, and request results at
intermediate increments.
1. Follow the instructions provided in Step 2 to save and launch OptiStruct.
2. For File name, enter beam_fllwer_ON.fem.
beam_fllwer_ON.fem was selected. Look in the beam_fllwer_ON.out file for error messages
that could help debug the input deck, if any errors are present.
Viewing and Post-processing the Results for the Beam Model
Displacements and Element Stresses are calculated by default and can be plotted using the
Contour panel in HyperView.
Step 7: Comparing the Displacement Results between models with and

without Follower Load activation
2. Select the page window layout icon to split the page into two windows.
3. In the first window, load the beam_fllwer.h3d file by clicking and navigating to your
working directory.
4. Similarly load the beam_fllwer_ON.h3d file in the second window.
5. Activate/Select the first window by clicking in it and then click the Contour toolbar icon .
6. For Result type, select Displacement (v).
7. Click Apply.
8. Activate/Select the second window by clicking in it and load the displacement results similarly.
However, since you have requested results for intermediate iterations via NLOUT, you will see
results for all intermediate iterations.
9. In the Results browser, click Load Factor, and select the final increment Load Factor =
1.000000E+00.

10. The Displacement contour results are now displayed as shown below. You can clearly see that
the activation of follower forces has modified the displacement profile significantly.
Setting up the Rubber Disk model in HyperMesh
HyperMesh
1. Similar to Step 1, select the disk_fllwer.fem file you saved to your working directory from
the optistruct.zip file.
2. Click Import.
Step 9: Creating Follower Load Bulk Data Entries for the three options
In the beam model in the first section of this exercise, follower loads for concentrated forces do
not depend on the area of the element face to whose grids they are applied. Therefore, the
results will remain the same for any activation option chosen on either the FLLWER bulk data
entry or the PARAM,FLLWER entry. Additionally, since you only had one subcase, select the
parameter PARAM,FLLWER to activate follower loading for this model.
In this current disk model, the loads are pressure loads which may depend on the area of the
element faces to whom they are applied. Additionally, you have multiple subcases to showcase
the effect of different FLLWER options. In the FLLWER bulk data entry in the OptiStruct help, you
will see:

OPT Options for the calculation of Follower Loads.
Default = 1 <-1, 0, 1, 2, or 3>
= -1, 0: Follower force calculation is not activated.
= 1: Follower effect is activated. For pressure load, both element surface area and
load direction are updated during the solution. For concentrated force, only the force
direction is updated.
= 2: Follower effect is activated. For pressure load, only element surface area is
updated (load direction is not updated) during the solution. For concentrated force,
only the force direction is involved; which is the same as OPT = 1.
= 3: Follower effect is activated. For pressure load, only load direction is updated
(element surface area is not updated). For concentrated force, only the force
direction is updated; which is the same as OPT = 1.
menu.
2. Name the load collector FLLWER_1.
3. In the corresponding Entity Editor, click on the field next to Card Image and select FLLWER.
4. Click on the field next to OPT and select 1 from the drop-down menu.
5. Similarly, create load collectors FLLWER_2 and FLLWER_3 and select OPT=2 and OPT=3
respectively for each entry.
Step 10: Referencing the FLLWER bulk entries in the Subcase section
The created FLLWER Bulk Data entries should now be selected in the Subcase section.
1. Click on the fllwer_1 Load Step to open it in the Entity Editor.
2. Check the box next to FLLWER in the Subcase Options section of the Entity Editor.
3. Click on the field next to ID and then on the yellow Loadcol button.
4. Choose the FLLWER_1 load collector in the Select Loadcol dialog and click OK.

5. Similarly, choose FLLWER_2 and FLLWER_3 load collectors for corresponding subcases
fllwer_2 and fllwer_3 respectively.
Step 11: Activating Nonlinear Intermediate Results (NLOUT)

Parameters that allow you to activate Nonlinear Intermediate Results are available via the NLOUT
Bulk Data and Subcase entries. The number of intervals at which intermediate results are output
is controlled by the NINT parameter. The SVNONCNV parameter can be used to
activate/deactivate the output of results for non-convergent solutions. This is currently turned on
by default (set to YES).
menu.
2. Name the load collector NLOUT.
3. In the corresponding Entity Editor, click on the field next to Card Image and select NLOUT.
4. Activate the check box next to NINT and in the VALUE field enter the integer 10 (which is
the default). This indicates to OptiStruct that the maximum number of intervals at which
intermediate results are requested is 10. If the load increment from any load “n” to load
“n+1” is greater than 1/NINT (in this case, 1/10 is 0.1), then the results corresponding to
load level “n+1” are saved for output; otherwise, the results are not saved.
Note that this parameter has no control over the adaptive load size selection during the
incremental-iterative solution process. It only specifies the number of intervals when results
are saved for output during the solution process.

5. Click on the fllwer_1 Load Step to open it in the Entity Editor.
6. Click on the field next to NLOUT and on the yellow Loadcol button.
7. Select the NLOUT load collector in the Select Loadcol dialog and click OK.
8. Similarly, select the NLOUT load collector for fllwer_2, fllwer_3, and NO_fllwer subcases.
Step 12: Running the Disk model with Follower Loads activation
The model now consists of loads which have been identified as follower loads. Additionally, you
have learned how to request results at intermediate increments.
1. Follow the instructions provided in Step 2 to save and launch OptiStruct.
2. For File name, enter disk_fllwer_ON.fem.
disk_fllwer_ON.fem was selected. Look in the disk_fllwer_ON.out file for error messages
that could help debug the input deck, if any errors are present.
Viewing and Post-processing the Results for the Disk Model

Displacements and Element Stresses are calculated by default and can be plotted using the
Contour panel in HyperView.
Step 13: Comparing the Displacement Results between models with and
without Follower Load activation
2. Select the page window layout icon to split the page into four windows.
3. In the first window, load the disk_fllwer_ON.h3d file by clicking and navigating to your
working directory.
4. Select Subcase 1 (fllwer_1) and Load Factor = 1.000000E+00 in the Results browser.
5. Similarly load the disk_fllwer_ON.h3d file again in the second window and select Subcase 2
(fllwer_2). Repeat this process until the four windows contain results from four different
subcases.
6. Activate/Select the first window by clicking in it and then click the Contour toolbar icon .
7. For Result type, select Displacement (v).
8. Click Apply.
9. Activate/Select the second window by clicking in it and load the displacement results similarly.
However, since you have requested results for intermediate iterations via NLOUT, you will see
results for all intermediate iterations. This is the reason you navigate the final load factor to
compare results.
10. The Displacement contour results are now displayed as in the figure below. You can clearly
see that the activation of follower forces has modified the displacement profile significantly.
Additionally, you can see that since subcase 3 (OPT=3) updates the load direction but not the
area, the force (Pressure*Area) distribution at the grid points is low for Subcase 3 and the
Displacement results reflect this when compared to OPT=1 and 2.


OS-1520: Finite Sliding of Rack and Pinion Gear Model
This tutorial outlines the procedure to perform finite sliding analysis on a rack and pinion gear
model. The circular gear is called the pinion and it engages teeth on the linear bar called the
rack.
Figure 1: Illustration of the model circular gear and rack
Tutorial prerequisites
1. The latest version of the Altair HyperMesh, Altair HyperView and Altair OptiStruct software
installations. Finite sliding of Rack and Pinion Gear model is available only in Altair HyperMesh
version-14.0.120, Altair HyperView version-14.0.120 and Altair OptiStruct version-14.0.230
and later.
2. The following file found in the optistruct.zip file is needed to perform this tutorial. Refer to
finite_sliding.hm
Why finite sliding and not small sliding analysis?

In small sliding analysis, not only is the relative sliding between master and slave relatively small
but the contact search is done only at the beginning of the simulation. While for finite sliding the
contact search is updated for every increment of the analysis. In this case, as you can see, the
circular gear has to be in contact with the entire rack over the course of the simulation, so
contact status needs to be updated for every increment to capture the entire motion and hence
finite sliding is necessary.

Step1: Selecting the OptiStruct User Profile and loading the model into
HyperMesh
Figure 2: Selecting the OptiStruct user profile.
3. Click OK.
This loads the OptiStruct User Profile. It includes the appropriate template, macro menu, and

Figure 3: Alternate method for accessing the "User Profiles" option from the Preferences menu.
4. Click the Open Model panel toolbar icon and browse to the location that contains the
model.
5. Select the finite_sliding.hm file you saved to your working directory from the
6. Click Open.
The model illustrated in Figure 1 is now loaded into HyperMesh.
Checkpoint
This tutorial helps you to define finite sliding contact between the circular gear and rack. The
gear is held fixed at the center in all dof while the rack is given displacement in x dof but
constrained in all other dof. All constraints and enforced displacements have already been
defined in model. Contact surfaces to define the slave and master surfaces are also pre-defined
in the model. Contact stabilization has been defined for the contact to help stabilize any rigid
body motion before contact gets established. A very tiny end-of-subcase stabilization also has
been specified to overcome any temporary instabilities that may sometimes occur at end-of-
analysis.
Step 2: Reviewing pre-defined model information

The imported model contains a large amount of pre-defined information which allows you to
focus on the finite sliding section in this tutorial. As explained in Step 1, all material and
properties are pre-defined for the circular gear and rack. The material properties of steel are
assigned to both components.
1. Right-click anywhere in the Model browser and select Expand All.
2. Right-click on STEEL and select Card Edit.

3. Make sure that the values on the MAT1 bulk data entry for the material properties of steel are
input, shown in Figure 4.
Young’s Modulus of Elasticity = 2.1 x 105 N/m2
Poisson’s Ratio = 0.3
4. Click return to complete the review.
Figure 4: Reviewing the material – Steel.
Tip
You can review, in a similar manner, the remaining pre-defined data entries, like properties and
load collectors. The procedure for load collector review is not as straight forward as shown above
in some cases; however, this has been thoroughly illustrated in various other tutorials for your
benefit.
Checkpoint
This concludes the review of the model section of the tutorial. You will now focus on reviewing
contact surfaces and generating finite sliding contact interface.
Step 3: Reviewing contact surfaces and generating finite sliding contact
Figure 5: Showing contact surface panel
1. Click Analysis > contactsurfs panel to review the already created contact surfaces.
2. Click solid faces > name and select rack.
3. Click review.

Figure 6: Review of contact surface for rack.
4. In a similar manner select gear and then click review.

5. Click return to get out of contactsurfs panel.
6. Next, go to interfaces panel and click create.
7. Click name = and enter the name rack_pinion for the interface.
8. Select type as CONTACT and then click create/edit.
9. Click add to choose the master and slave surfaces for the rack_pinion interface.
10. Change the entity type to csurfs for both master and slave.
Figure 7: Selecting master and slave surfaces.
11. For slave choose the rack contact surface and click update.
12. Similarly, for master choose the gear contact surface and click update.
13. To review the interface, click review, shown in Figure 8.
Figure 8: Reviewing interface
14. Click on card image and then click edit to edit the contact interface.
15. Set TYPE as SLIDE.
16. Set DISCRET as S2S.
17. Set TRACK as FINITE.
Surface-to-surface a finite sliding contact without friction have been defined, shown in Figure
9.

Figure 9: S2S, Finite Sliding Contact definition.
18. Click return to exit the interfaces panel. The finite sliding contact definition is now complete.
Step 4: Reviewing parameters, contact output definition and loadstep

definition
Large displacement formulation needs to be activated for finite sliding contact.
1. Click on Control card panel to review the parameter to turn on LGDISP.
2. Click next twice and then select PARAM.
3. Make sure PARAM, LGDISP, 1 is selected.
4. Click return and then go to previous page and select GLOBAL_OUTPUT_REQUEST.
5. Make sure CONTF is selected. This gives contact output results, like contact pressure, gap
penetration, sliding distance, etc.
6. Click return twice to exit the Control card panel.
7. Click the loadsteps panel to review the pre-defined loadstep.
8. The SPC and NLPARM loads have been defined and analysis should be of type nonlinear quasi-
static. The SPC load points to the fixed constraints on the circular gear, as well as enforced
displacement on the bottom of rack. The NLPARM load defines the nonlinear parameters.

name for the model, rack_pinion.fem, in the File name: field.
The .fem filename extension is the recommended extension for OptiStruct input decks.
4. Click Save.
Note the name and location of the rack_pinion.fem file displays in the input file: field.
This launches the job. If the job is successful, you should see new results files in the directory
from which rack_pinion.fem was selected. The rack_pinion.out file is a good place to look for

Displacements, Element stresses, Contact forces, contact deformation, etc. are calculated and
can be plotted using the Contour panel in HyperView.
Step 6: Viewing the results of the finite sliding analysis

1. Once you receive the message Process completed successfully in the command window, click
HyperView.
HyperView is launched and the results are loaded. A message window appears to inform of
the successful model and result files loading into HyperView.
4. Select the first drop-down menu below Result type: and select Element Stresses (2D &
3D)(t).
5. Select Load Factor = 3.369662E-01 and click Apply.

A contour plot of stresses is created, shown in Figure 11. The load factor here denotes the %
of load that has been applied. The figure below shows the stresses in rack and gear after
33.36% of load has been applied.
Figure 11: Stress contour at Load Factor = 3.3696 E-1

6. Similarly, you can change the load factor and observe the changes in stresses on the rack and
gear. As shown for load factor, if blow 0.874, the contact at this point of time is between a
very small area of the rack and gear tooth and hence stresses are higher.
Figure 12: Stress contour at Load Factor = 8.74E-1
Checkpoint
You can animate the results using the Set Transient Animation Mode in HyperView.
1. Select other Result type in the Contour panel and click Apply.

Fluid-Structure Interaction Analysis
OS-1600: Fluid-Structure Interaction Analysis of Piezoelectric

Harvester Assembly
The purpose of this tutorial is to demonstrate how to carry out Fluid-Structure Interaction
analysis i.e., with OptiStruct nonlinear transient analysis coupling within AcuSolve fluid dynamic
analysis.
In this tutorial, you explore the possibility of using piezoelectric based fluid flow energy
harvesters. These harvesters are self-excited and self-sustained in the sense that they can be
used in steady uniform flows. The configuration consists of a piezoelectric cantilever beam with a
cylindrical tip body (which is the structure model) which promotes sustainable, aero-elastic
structural vibrations induced by vortex shedding and galloping. The structural and aerodynamic
properties of the harvester alter the vibration amplitude and frequency of the piezoelectric beam
and the fluid flow. As you may know, the Piezoelectric energy harvesting using fluid flow involves
the mutual interaction of three distinct dynamic systems, namely the fluid, the structure and the
associated electrical circuit. Note that this tutorial is limited to study only fluid and the structure
domain.
Model Description
Figure 1: Schematic of the problem
The figure below illustrates the fluid structural model used for this tutorial: the dimensions of the
beam are shown in Figures 1 and 2.
The AcuSolve fluid model (slab_dcfsi.inp) and the OptiStruct structural beam model
(Slab.fem) are located in the fsi_models.zip file. Refer to Accessing the Model Files.

Figure 2: Beam with its various layers

 Set up Contact Surface, which is fluid-structure interaction surface.
 Set up Nonlinear parameters, TSTEP, NLOUT and FSI cards.
 Set up Nonlinear transient sub-case.
Exercise

3. Click File > Import > Model.
4. Select the Slab.fem file you saved to your working directory. Refer to Accessing the Model
Files.
5. Click Import.
Step 2: Create Contact Surface

2. For Name, enter FSI_Interaction_Surf.

5. For Elements, click on elements and pick all the faces of the beam, as shown below.
Tip: All sides of the beam except in the front, as shown below.
6. Click add to add the faces to the contact surface.

7. Click return to exit from this panel.
Step 3: Define Nonlinear parameters

2. For Name, enter NLPARM_Card.
5. Input the values, as shown below. See NLPARM Bulk Data Entry for more information.

Step 4: Define Transient Time Step Parameters
2. For Name, enter TSTEP_Card.
3. For Card Image, select TSTEP.
4. For TSTEP NUM, enter 1.
5. Click the icon and input the values, as shown below. See NLPARM Bulk Data Entry for more
information.
6. Click Close to finish.

Step 5: Define incremental result output for Nonlinear Analysis
2. For Name, enter NLOUT101.
4. For Card Image, select NLOUT from the drop-down menu.
Step 6: Define Fluid-Structure Interaction Parameters

2. For Name, enter FSI100.
4. For Card Image, select FSI from the drop-down menu.

3. For DISPLACEMENT, ELFORCE, OLOAD, STRESS, and STRAIN, set Option to Yes.
Step 8: Create Nonlinear Transient Analysis subcase

2. For Name, enter FSI.
4. For Analysis type, select Non-linear transient from the drop-down menu.
5. Input/Select the Load Collector, as shown below.

6. Reference the NLOUT bulk data entry as a SUBCASE_UNSUPPORTED entry as follows:
Step 9: Export the OptiStruct Input file

3. For File Name, enter Slab.fem and click Save. The file extension .fem is necessary for
OptiStruct to recognize it as an input file.

Step 10: Submit the job with HyperWorks Solver Run Manager
1. Launch the HyperWorks Solver Run Manager and select the Slab.fem file.
2. Click Run.
Step 11: Prepare and Submit the AcuSolve job with AcuSolve command
prompt
1. Open the AcuSolve input file (slab_dcfsi.inp) in a text editor and change the socket_host
parameter in the EXTERNAL_CODE block to your machines hostname and save the file.
2. Open the AcuSolve Cmd Prompt application and enter the command: acuRun-pb
slab_dcfsi -np 8 (shown below).
If the job is successful, you will see new results files in the directory where HyperMesh was
invoked. The Slab.out file is where you will find error messages that will help you debug your
input deck, if any errors are present.

cci.txt Contains information pertaining to model progression. Logs regarding
connection establishment, initial external code handshake and subsequent
time step data in conjunction with exchange/stagger.
slab.html HTML report of the analysis, giving a summary of the problem formulation
and the analysis results.
slab.out ASCII based output file of the model check run before the simulation
begins and gives some basic information on the results of the run.
slab.stat Summary of analysis process, providing CPU information for each step
during the process.
slab.h3d HyperView compressed binary results file.

1. Using HyperView, plot the Displacement contour at 1.0 s.

OS-1610: Thermal Fluid-Structure Interaction Analysis on a
Manifold
This example is an engine exhaust manifold with conjugate heat transfer and structural
deformation. The structure is gray cast iron, initially at 300 K. The manifold outer surface has a
convective heat transfer coefficient of h = 6 W/m2 K at 300 K. The four inlets to the manifold are
held at 500 K with air as the fluid at 5 m/s. AcuSolve passes heat fluxes to OptiStruct. OptiStruct
passes the temperatures to AcuSolve. Note that this tutorial is limited to study fluid and thermal
domain only.
Model Description
The figure below shows the Fluid structural model used for this tutorial:
AcuSolve Fluid model (FSI_AS_MANIFOLD.inp) and OptiStruct Structural beam model

(FSI_OS_MANIFOLD.fem) files are in the tfsi_models.zip file. Refer to Accessing the Model Files.

 Set up Contact Surface, which is Fluid Structure Interaction surface.
 Set up FSI card.
 Set up a Linear Thermal Transient sub-case.
Exercise

3. Click File > Import > Model.
4. Select the FSI_OS_MANIFOLD.fem file you saved to your working directory. Refer to Accessing
the Model Files.
5. Click Import.
Step 2: Create Contact Surface

2. For Name, enter FSI_Interaction_Surf.
5. For the Elements, click on elements and pick all the internal faces as shown in the below
figure.
Tip: To pick all the elements in the internal face, use the brake angle of 30 degrees.

6. Click add to add the faces to the contact surface.
7. Click return to exit from this panel.
8. Click Close to finish.
Step 3: Define Fluid Structure Interaction Parameters

2. For Name, enter FSI100.
4. For Card Image, select FSI from the drop-down menu.

2. Click GLOBAL_OUTPUT_REQUEST.
3. For THERMAL and FLUX, set Option to Yes.

Step 5: Create Transient Heat Transfer analysis subcase
2. For Name, enter TFSI.
4. For Analysis type, select Heat Transfer (transient) from the drop-down menu.
5. Input/Select the Load Collector, as shown below.
Step 6: Export the OptiStruct Input file

3. For File Name, enter FSI_OS_MANIFOLD.fem and click Save. The file extension .fem is
necessary for OptiStruct to recognize it as an input file.
Step 7: Submit the job with HyperWorks Solver Run Manager

1. Launch the HyperWorks Solver Run Manager and select the FSI_OS_MANIFOLD.fem file.
2. Click Run.

Step 8: Submit the AcuSolve job with AcuSolve command prompt
1. Open the AcuSolve input file (slab_dcfsi.inp) in a text editor and change the socket_host
parameter in the EXTERNAL_CODE block to your machines hostname and save the file.
2. Open the AcuSolve Cmd Prompt application and enter the command: acuRun-pb
FSI_AS_MANIFOLD -np 8 (shown below).
If the job is successful, you will see new results files in the directory where HyperMesh was
invoked. The FSI_OS_MANIFOLD.out file is where you will find error messages that will help
you debug your input deck, if any errors are present.

cci.txt Contains information pertaining to model progression. Logs

regarding connection establishment, initial external code
handshake and subsequent time step data in conjunction with
exchange/stagger.
FSI_OS_MANIFOLD.html HTML report of the analysis, giving a summary of the problem

FSI_OS_MANIFOLD.out ASCII based output file of the model check run before the
simulation begins and gives some basic information on the
results of the run.
FSI_OS_MANIFOLD.stat Summary of analysis process, providing CPU information for

each step during the process.
FSI_OS_MANIFOLD.h3d HyperView compressed binary results file.

1. Using HyperView, plot the Displacement contour at 1.0 s.

Multi-body Dynamics Analysis
OS-1900: Dynamic Analysis of a Three-body Model using

OptiStruct
In this tutorial, dynamic analysis on a simple three rigid bodies model is performed using
OptiStruct. The force of gravity acts along the global Y axis, and the system has one degree of
freedom.
This exercise includes the creation of PRBODY (rigid body definition), JOINT and boundary
conditions in HyperMesh. An existing finite element model is used in this tutorial problem.
- PRBODY
- JOINTS
- Boundary conditions (Gravity and MBSIM)
Rigid bodies model

Exercise

Step 2: Retrieve the HyperMesh Model File
1. Click the Open Model icon .

2. Select the 3bodies_dynamics.hm file you saved to your working directory from the
3. Click Open. The model has three components and a few free nodes that will be used to create
bodies and joints for the MBD model.
Step 3: Creating PRBodies

PRBODY is the Rigid Body Definition for Multi-body Simulation. PRBODY defines a rigid body out
of a list of finite element properties, elements and grid points.
Define the parts as PRBODY (Rigid Body definition)
1. From the Analysis page, enter the bodies panel.
2. Select the create subpanel.
3. Click body= and enter blue.
4. Click type= and select PRBODY.
5. Click props and select body1.
6. Click select.
7. Click create.
8. Repeat the above operation to define PRBODY for the component named body2 with the
name lime, and for body3 with the name orange.
9. Click return.
Step 4: Creating Joints

This step outlines defining all the necessary joints required for this model.
Create the component for the joints
1. In the Model browser, right-click the Component tree and select Create.
2. For Name, enter joints.

3. For Property and Material leave as <Unspecified>.
In this tutorial, two revolute joints, one ball joint, and one universal joint are created to constrain
the degrees of freedom (shown in the following figure), such that the remaining degree of
freedom will be just 1.
DOF = 3*6 – (5+5+4+3) = 1
Removes Removes Removes total
Type of Joint
translational dof rotational dof number of dof
Revolute 3 2 5
Universal 3 1 4
Ball (Spherical) 3 0 3

Joints in the model
Create the joints

1. From the menu, click Mesh > Create > 1D Elements > Joints to open the Joints panel.
First, the revolute joint at the lower right corner of body3 will be created.
2. Click the joint type: selector switch and select revolute.
3. Select node ID 12319 as the first terminal.

4. Select node ID 13158 as the second terminal.
Note: Nodes 12319 and 13158 are coincident. Coincident node

picking in options panel > graphics subpanel in HyperMesh
will help select these coincident nodes in the HyperMesh
screen.
5. Select node ID 12910 as a node for first orientation. The vector 12319 to 12910 defines the
axis of rotation of the revolute joint.
6. Click create.
Next, the revolute joint at the lower left corner of body1 will be created.

9. Select node ID 11706 as a node for first orientation.
10. Click create.
The vectors 11115 to 11706 define the axis of rotation of the revolute joint. A universal joint
between body3 and body2 will be created next.

11. Click the joint type: selection switch and select universal.
12. Select node ID 12330 as first terminal which belongs to body3.
13. Select node ID 7589 as second terminal which belongs to body2.
14. Select node ID 12921 as a node for first orientation.
15. Select node ID 11944 as a node for second orientation.
The vectors 12330 to 12921 define the first cross pin axis, and the vectors 7589 to 11944
define second cross pin axis.
16. Click create. A ball (spherical) joint between body1 and body2 will be created next.

Ball joint between body1 and body2
17. Click the joint type: selection switch and select ball.
18. Select node ID 11104 as first terminal which belongs to body1.
19. Select node ID 7578 as second terminal which belongs to body2.
20. Click create.
Step 5: Apply the boundary condition to the model

The gravity force that applies to the model and MBSIM bulk data card, which is to specify the
parameter for multi body simulation, is created in this step.
Create the gravity force
2. For Name, enter gravity.
3. Click Color and select any color.
4. Click Card Image and select GRAV.

5. Input the values, as illustrated below.
A new load collector, gravity is created.
Create an MBSIM card

2. For Name enter SIM.
4. Click Card Image and select MBSIM.

Step 6: Create an OptiStruct loadstep (also referred to as a subcase)
1. Click Setup > Create > LoadSteps to open the LoadSteps panel.
2. Set Analysis type to Multi-body dynamics.
3. For Name, enter Dynamic.
4. For MLOAD, click Unspecified > Loadcol.
5. In the Select Loadcol dialog, select gravity from the list of load collectors and click OK.
6. For MBSIM, click Unspecified > Loadcol.
7. In the Select Loadcol dialog, select SIM from the list of load collectors and click OK.
8. Click Close.

Submitting the Job

name for the model, 3bodies_dynamics_complete.fem, in the File name: field. The .fem
filename extension is the suggested extension for OptiStruct input decks.
4. Click Save.
The name and location of the 3bodies_dynamics_complete.fem file displays in the input
file: field.
8. Click OptiStruct. This launches an OptiStruct run in a separate command prompt (DOS or
UNIX).
3bodies_dynamics_complete.html HTML report of the analysis, giving a summary

of the problem formulation and the results from
the final iteration.
3bodies_dynamics_complete.out OptiStruct output file containing specific

information on the file set up, estimates for the
amount of RAM and disk space required for the
run, and compute time information. Review this
file for warnings and errors.
3bodies_dynamics_complete.mbd.log Log file containing the information on the joints

and markers, simulation etc., which are specific
to MBD analysis.
3bodies_dynamics_complete.mbd.xml Model file in .xml format – solver intermediate

input deck.
3bodies_dynamics_complete.h3d Binary results file.
3bodies_dynamics_complete.mbd.mrf Binary results file for plotting.
3bodies_dynamics_complete.stat Summary of analysis process, providing CPU

information for each step during analysis
process.

Viewing the Results in HyperView
This section describes how to view the results in HyperView which will be launched from within
the OptiStruct panel of HyperMesh.
Step 8: Review a Contour Plot of the Displacement

1. While in the OptiStruct panel of the Analysis page, click HyperView.
If a window appears with a warning message, click OK.
The path and file name for 3bodies_dynamics_complete.h3d appears in the fields to the
right of Load model and Load results. This is fine because the .h3d format contains both
model and results data.
2. The model and results are loaded in the current HyperView window.
4. Under Results type:, select Displacement(v).
5. Click Apply.
6. Verify the Animate Mode is set to Transient, .

8. The Animation Controls are in the panel next to the playback controls.
9. With the animation running, use the bottom slider bar to adjust the speed of the animation.
10. Click the Start/Pause Animation icon again to stop the animation.

OS-1910: Dynamic Analysis of a Slider Crank with a Flexible
Connecting Rod
The slider crank model shown in the figure below consists of a rigid crank, a flexible connecting
rod, and a rigid sliding block. The objective of this analysis is to determine the deformation and
stress of a flexible connecting rod under the high speed motion of the system.
This tutorial includes the creation of PRBODY (rigid body definition), PFBODY (flexible body
definition), and JOINT in HyperMesh 2017.
An existing finite element model is used in this tutorial.

 Setting up the problem in HyperMesh 2017
- PRBODY
- PFBODY
- JOINTS
- MBSIM (simulation parameter)
- INVELB (initial velocity)

Exercise

Step 2: Retrieve the HyperMesh Model File
1. Click on the Open Model icon . An Open Model browser window opens.
2. Select the slider_crank.hm file you saved to your working directory from the
3. Click Open. The model has five components and a few free nodes that will be used to create

To create PRBODY for component, support.
3. Click body= and enter support.
5. Click props and select support.
6. Click create.
To create PRBODY for component, crank.
7. Click body= and enter crank.
9. Click props and select crank.
10. Click nodes and select the node (ID 25231) at the center of RBE2 spider between
connecting rod and crank (see the following figure).

11. Click create.
To create PRBODY for component, block.
12. Click body= and enter block.
14. Click props and select block.
15. Click nodes and select the node (ID 25232) at the center of RBE2 spider between
connecting rod and block (see figure).
16. Click create.

This completes the definition of PRBODY.
Step 4: Creating PFBodies

PFBODY is the Flexible Body Definition for Multi-body Simulation. PFBODY defines a flexible body
out of a list of finite element properties, elements, and grid points.
Define PFBODY for the connecting rod
1. Click body= and enter rod.
2. Click type= and select PFBODY.
3. Click props and select rod.
4. Click elems and select two RBE2 elements that are inside a hole on the connecting rod.
Alternatively you could also use ‘elems by id’ and input IDs 18795 and 18796 for the two RBE2
elements.

5. Select Craig-Bampton as the CMS Method: and the number of modes: set to 10.
Step 5: Creating Joints

Here, defining all the necessary joints is required for this model. Five joints for the model are
required.
Create the component for the joints
In this tutorial three revolute joints, one fixed joint, and one translational joint are created to
constrain the degrees of freedom.
Type of Joint translational dof rotational dof number of dof
Revolute 3 2 5
Fixed 3 3 6
Translational 2 3 5

To create the joints:
1. Click Mesh > Create > 1D Elements > Joints to open the Joints panel.
First, the fixed joint between ground and support will be created.
2. Click the joint type: selection switch > fixed.
3. Select node ID 25313 as first terminal (see the following figure).
4. Select node ID 25543 as second terminal.

picking in options panel in HyperMesh will help select these
coincident nodes if nodes need to be selected in the screen.
5. Click create.
Next, the revolute joint between support and crank will be created.
6. Click the joint type: selection switch > revolute.
7. Select node ID 25472 as a first terminal (see the following figure).
8. Select node ID 15124 as a second terminal.
9. Select coordinates as first orientation and enter x= 0.0, y= 0.0, z= 1.0. The z-axis will be
the axis of rotation of revolute joint.

10. Click create.
A revolute joint between the crank and connecting rod will be created next.
14. Select the coordinates as the first orientation and enter x= 0.0, y= 0.0, z= 1.0. The z-axis
will be the axis of rotation of revolute joint.

15. Click create. A revolute joint between the connecting rod and sliding block will be created
next.
19. Select coordinates as first orientation and enter x= 0.0, y= 0.0, z= 1.0. The z-axis will be
the axis of rotation of revolute joint.
20. Click create. A translational joint between the sliding block and ground will be created next.
21. Click the joint type: selection switch > translational.
22. Select node ID 14519 as a first terminal (see the figure below).
24. Select coordinates as first orientation and enter x= 1.0, y= 0.0, z= 0.0.
X is the direction of translation.

Defining external inputs and simulation parameters (Steps 6 and 7)
The gravity force that applies to the model and MBSIM bulk data card, which is to specify the
parameter for multi body simulation, will be created in this step.
Step 6: Create DTI, UNITS

2. Click DTI_UNITS.
3. Define the unit system, as shown below.
4. Click return twice to return to the main menu.
Step 7: Define MBSIM and INVELB

2. For Name, enter SIM.
3. For Card Image, select MBSIM.

5. In Model browser, right-click and select Create > Load Collector.
6. For Name, enter Velocity.
8. For Card Image, select INVELB.
9. For BID, select block.
10. Click VX and enter -50.
Step 8: Create an OptiStruct loadstep (also referred to as a subcase)

2. Set the Analysis type to Multi-body dynamics.
3. For Name, enter dynamic.
6. For INVEL, click Unspecified > Loadcol.
7. In the Select Loadcol dialog, select Velocity from the list of load collectors and click OK.
8. Click Close.

Submitting the Job

name for the model, slider_crank_complete.fem, in the File name: field. The .fem file
name extension is suggested for OptiStruct input decks.
4. Click Save.
The name and location of the slider_crank_complete.fem file displays in the input file:
field.
8. Click OptiStruct. This launches an OptiStruct run in a separate (DOS or UNIX) shell.
slider_crank_complete_frames.html HTML report of the analysis, giving a summary of the

problem formulation and the results from the final
iteration.
slider_crank_complete.out OptiStruct output file containing specific information on

the file set up, estimates for the amount of RAM and
disk space required for the run, and compute time
slider_crank_complete.h3d Binary results file (Nodal results).
slider_crank_complete.stat Summary of analysis process, providing CPU

slider_crank_complete_mbd.abf Binary plotting file.
slider_crank_complete_mbd.h3d Binary results file (Modal results).
slider_crank_complete_mbd.log Log file from OS-Motion containing the information on

the joints and markers, simulation etc., which are
specific to MBD analysis.
slider_crank_complete_mbd.mrf Binary results file for plotting.
slider_crank_complete_mbd.xml Model file in .xml format – solver intermediate input

deck.

View the Results in HyperView
Step 10: Review a contour plot of the displacement and stress

Note that the path and filename for slider_crank_complete.h3d appears in the fields to the
The model and results are loaded in the current HyperView window.
3. Under Results type: select Displacement(v).
4. Click Apply.
5. Verify that the Animate Mode is set to Transient .
The HyperView playback controls

10. Go to the contour panel and select Element Stresses [2D & 3D] as Results type.
11. Stress type should be von Mises.
12. Click Apply.

OS-1920: Large Displacement Analysis of a Cantilever Beam
using OptiStruct
In this tutorial, multi-body dynamics analysis (simulation type: Transient Analysis) of a slender
cantilever beam will be performed using OptiStruct. An existing finite element model of a
cantilever beam will be imported into HyperMesh. The rest of the setup (creation of joint, loading,
etc.) is also done in HyperMesh. HyperView is used to post-process the large displacement results
of a cantilever beam model.
In this tutorial, you learn how to create a JOINT, a PFBODY, an MBMNTC and a multi-body
dynamics subcase.
The beam model consists of 10 different flexible bodies (PFBODY) and each body is to be
connected through a fixed joint and rigid element (RBE2).

Modeling RBE2
There are two RBE2’s defined at the boundary of each body (one for each body at this boundary).
The fixed joint will be created using coincident nodes which are independent nodes of each of the
RBE2s.
These exercises show how to:
 Load a model into HyperMesh
 Create a component for JOINT
 Create a fixed joint
 Create a PFBODY
 Create load collectors for MBMNTC and MBSIM
 Create an MBMNTC
 Create an MBSIM
 Create a multi-body dynamics subcase
 Load the model

Exercise
Step 1: Retrieve the structural model and define the OptiStruct template
1. Launch HyperMesh Desktop.
2. Set the User Profiles to OptiStruct and click OK.
3. Click File > Open > Model.
4. Select the cantilever_beam_MBD.hm file you saved to your working directory from the
5. Click Open.
Creating Joints (Steps 2 - 4)

Here, all the necessary joints required for this model are defined. Only fixed joints for this model
are needed.
Step 2: Create components for JOINT

This creates the new component named joints.
Step 3: Create a JOINT for the clamped boundary condition

The fix joint at the left corner of body_1 will be created to represent clamped boundary condition.
This fixed joint will be created using coincident nodes, so that coincident nodes need to be
created first at the left corner of body_1.
1. Click Geometry > Create > Nodes > XYZ to open the Create Nodes panel.
2. Move the cursor to the upper left corner of body_1 and click three times (see the following
figure). You will get the nodal coordinate (x=, y=, z=) of that node.
Location of coincident nodes
3. Click create.
4. Repeat the last two steps to create another coincident node at lower left corner of body_1.

5. Click return.
7. Click the joint type: selector switch and select fixed from the pop-up menu.
8. Click node under first terminal: and select one of the coincident nodes at upper left corner
node.
Note: To select the coincident nodes, the coincident picking option

has to be turned on, to do this:
- From the Preferences menu on the toolbar, select
Options.
- Select the graphics subpanel.
- Check the box for coincident picking.
- Click return to return to the joints panel.
9. Under second terminal:, click node and select the other coincident nodes at the same
location.
Fixed joint
10. Click create.

11. Repeat this process to create a fixed joint at lower left corner of body_1.
12. Click return.
Step 4: Create a fixed joint for each boundary of components

Fix joint will be created at the boundary of each component.
2. Click the joint type: selector switch and select fixed.
3. Zoom in to the boundary between Body_1 and Body_2.
4. Select one of the coincident nodes as first terminal (see the following figure).
5. Select the other coincident nodes as second terminal.
6. Click create.

Fixed joint
7. Repeat this process to create a fixed joint for the boundary of each body.
8. Click return.
Step 5: Creating PFBodies

PFBODY is the Flexible Body Definition for Multi-body Simulation. PFBODY defines a flexible body
out of a list of finite element properties, elements, and grid points.
You will have ten bodies apart from the ground body in your model.
Define the parts as PFBODY (Flexible Body definition)
1. From the Analysis page, click bodies.
3. Click body= and enter pfbdy_1.
5. Click props and check the box for body_1.
6. Click select.
7. Click elems and select by collector from the pop-up menu.
8. Check the box for the component rigid_1 and click select.
9. Use the toggle for number of modes: to switch from nmodes default to nmodes=.
10. Click nmodes= and enter 3.
11. Click create.
12. Switch over to the parameters subpanel using the radio buttons on the left-hand side of the
panel.
13. Use the damping: toggle to change from damping default to dval=.
14. Click dval= and enter 10.0.

15. Click update.
16. Repeat this process to create a PFBODY for each flexible body.
For example, for body_2:
body= pfbdy_2,
props= body_2,
elems = rigid_2, and so on.
Make sure that all PFBODY have a damping of 10.0 defined in parameters subpanel. For
pfbody_4 enter a value of 7 in the nmodes= field.
17. Click return.
Defining External Inputs and Simulation Parameters (Steps 6 - 8)
The moment applied at the end of the beam, the gravity force that applies to the model and
MBSIM bulk data card, which is to specify the parameter for multi body simulation, will be
created in this step.
Step 6: Create DTI, UNITS

2. Click DTI_UNITS.
3. Define the unit system, shown below.
4. Click return twice.
Step 7: Create load collector for MBSIM

2. For Name, enter mbmoment. Make sure Card Image is set to None.
4. For Name, enter sim.
5. For Card Image, select MBSIM from the list.
6. For TTYPE, select END.
7. In the TIME field, enter 0.5.
8. For STYPE, select DELTA.
9. In the DELTA field, enter 2.0e-04.
10. Change ITYPE to VSTIFF.

Step 8: Create an MBMNTC
First, load types for moment need to be changed to MBMNTC. moment is the default.
1. From the Analysis page, select load types.

2. Click moment= and select MBMNTC.
3. Click return. MBMNTC is the moment based on the curve so that the curve will be created
next.
4. Click XYPlots > Curve Editor to bring up the Curve editor window.
5. Click New.
6. For name =, enter mycurve.
7. Click proceed.
8. Select mycurve from the Curve List: located in upper left corner of the window.
9. Populate the X Y table, as shown here:
10. Click Update > Close.

11. Expand the Load Collector folder in the Model browser.
12. Right-click on mbmoment and click Make Current.
13. From the Analysis page, click moments.
14. Click nodes.
15. Select the 2 nodes at right tip of a beam, as shown in the following figure .
MBMNTC
16. Click the switch beside magnitude= and change to curve, components.
17. In the z comp= field, enter 1.0.

18. The x comp, y comp should remain at 0.
19. Click curve.
20. Select mycurve.
Step 9: Create an OptiStruct subcase

5. In the Select Loadcol dialog, select sim from the list of load collectors and click OK.
7. In the Select Loadcol dialog, select mbmoment from the list of load collectors and click OK.

name for the model, cantilever_beam_MBD.fem, in the File name: field. The .fem file name
extension is the suggested extension for OptiStruct input decks.
4. Click Save.
The name and location of the cantilever_beam_MBD.fem file displays in the input file: field.
8. Click OptiStruct. This launches an OptiStruct run in a separate shell (DOS or UNIX) which
appears.
If the optimization was successful, no error messages are reported to the shell. The
optimization is complete when the message Processing complete appears in the shell.
Step 11: View the Results in HyperView

This step describes how to view the results in HyperView.

View a contour plot of the displacement and stress
Note that the path and file name for cantilever_beam_MBD.h3d appears in the fields to the
The model and results are loaded in the current HyperView window.
3. For Result type: select Displacement(v).
4. Click Apply.
5. Verify that the Animate Mode is set to Transient.
10. For Result type:, select Element Stresses (2D & 3D) (t).
11. Click Apply.


OS-1930: Generating a Flexible Body for use in Altair
MotionSolve
An existing finite element model is used in this tutorial to demonstrate how HyperMesh may be
used to set up a model to generate a flexible body for use in Altair MotionSolve. The model is
then run in OptiStruct. The figure below illustrates the structural model used for this tutorial.

 Retrieving the .hm file

Exercise
Step 1: Retrieving the HyperMesh file and define the OptiStruct

template
2. Select OptiStruct in the User Profiles dialog and click OK.
4. Select the susp_sla.hm file you saved to your working directory from the optistruct.zip
5. Click Open. The susp_sla.hm database is loaded into the current HyperMesh session,
Step 2: Create load collectors that will be used to conduct the flexible
body reduction
In this step, two collectors will be created; one for the ASET that defines the connecting degrees
of freedom of the flexible body and the other for the method and parameters for the component
mode synthesis.
2. For Name, enter ASET.
4. Set Card Image to None. This load collector is used to define connecting degrees of freedom
of the flexible body to the multi-body system.
6. For Name, enter CMS.
7. For Card Image, select CMSMETH from the list. This creates the load collector used to
define the component mode synthesis method and parameters. The card image can now be
edited.
8. The Craig-Bampton (CB) method is selected by default.
Either UB_FREQ (upper bound on frequency) or NMODES (number of modes) must be
defined.
9. Under NMODES, enter 10.
Step 3: Modify the load types of constraint to ASET

1. From the Analysis page, enter the load types panel.
2. Click constraint = and select ASET.
3. Click return.

Step 4: Create the ASETs required in the analysis
1. In the Model browser, right-click on ASET and click Make Current to set the current Load
Collector.
3. Select the following degrees of freedom: dof1, dof2, and dof3.
Deselect any degree of freedom by right-clicking a checked (selected) box.

4. Click nodes.
Select the nodes that sit in the middle of the multi-node rigid on the primary attachment point
of the control arm to the chassis.
5. Click create.
6. Select dof2 and dof3 and verify that the nodes button remains active.
Select the node and the last attachment point of the control arm.
7. Click create.
8. Create the third constraint by selecting dof3 and selecting the top node in the rigid which
would fasten the bottom of the shock assembly to the control arm. This can be seen in the
next figure.
9. Click create.
Constraints applied to control arm model
10. Create the fourth constraint by selecting dof1, dof2, and dof3 and choosing the top node in
the rigid on the boss to the right.

2. Activate the GLOBAL_CASE_CONTROL card.
3. Check the box preceding CMSMETH.
4. Click CMSMETH and select the CMS load collector.
5. Click return to return to the Control Cards panel.
Step 6: Define the analysis type, unit system, create a title, and create
the output control for the component mode synthesis
1. Click on DTI_UNITS in the list of Control Cards to define the units system for the flex body
output. The units should be defined consistent with the material properties of the material
defined for this model. This way, you will not need to take care of the units of Multi-body
Dynamics Analysis.
Note: To check the material properties of your model:
In the Model browser, right-click on MAT1_1 and select Card

Edit. You will be able to view the Elastic modulus (2.1e+05),
Poisson’s Ratio (0.3) and the Density of the material (7.9e-
09).
For this model, the material used is Steel. Since the values of
the material properties provided are consistent with
Megagram, Newton, Millimeter, Second, the sequence: MGG
N MM S is selected for this control card.
2. Click return.
3. From the Control Cards panel, click GLOBAL_OUTPUT_REQUEST > STRESS.
4. Check the box preceding STRESS.
5. Select the options shown below.
6. Click return.
7. Click next and then click OUTPUT and set the options shown in figure below.

8. Click return.
9. Click TITLE and enter a title for this analysis.

The OptiStruct panel accomplishes two things: it saves the current model with its settings to
create the input file OptiStruct will use, and it allows you to select the type of analysis.
2. Set the export options: toggle at the bottom of the panel to all.
3. After input file: click save as.
4. For File name:, enter susp_sla.fem. The file extension .fem is necessary for OptiStruct to
recognize an input file.
6. Leave the memory options: toggle set to memory default.
invoked. The susp_sla.out file is a good place to look for error messages that will help you
debug your input deck if any errors are present.
susp_sla.h3d H3D file that contains the flexible body data for use in Altair
MotionSolve.
susp_sla.out ASCII-based output file of the model check run performed before
the simulation begins which gives some basic information on the
results of the run.
susp_sla.stat Detailed breakdown on the CPU time used for each significant
stage in the analysis.

OS-1940: MBD Rigid Contact
 Model Contacts using HyperMesh 2017
Contact constraints are very common in the mechanisms/general machinery domain. MotionSolve
uses the penalty-based Poisson contact force model for calculating the magnitude and direction
of the contact and friction forces. For more information on this, refer to the MotionSolve help.
The Curved Pentagon Positive Return Cam system is used to define the contacts. In this system
the curved pentagon rolls inside the circle and translates the slider.
Rigid body model
Exercise
3. Click File > Open > Model. An Open file browser window opens.
4. Select the for_contact_tutorial.hm file you saved to your working directory from the
5. Click Open. The model has five components and a few free nodes that will be used to create

There will be five bodies apart from the ground body in our model via: the stand, the slider, the
driver, the pentagon and the circle. Pre-defined free nodes will be used to define the bodies and
joints.
3. Click body= and enter stand.
5. Click props and select Stand1.
6. Click props and select by id option and enter 2, 19391, and 19402.
7. Click create.
8. Use the table to repeat the above operation to define PRBODY for the remaining components.
body= type= props free nodes
Slider PRBODY Slider2 4, 19399

Driver PRBODY Driver3 19392, 19395
Pentagon PRBODY Pentagon4 4246, 19396
Circle PRBODY Circle5 414, 19400
Ground GROUND - 19401
Note: To define the ground body the selection of props is

not required.
9. Click return.

Creating Joints (Steps 3 and 4)
Here, all the necessary joints required for this model will be defined. Five joints for the model are
required, as shown in the table below.
Type of Joint Body 1 Body 2
Fixed Stand Ground
Revolute Stand Driver
Translational Stand Slider
Revolute Driver Pentagon
Fixed Slider Circle
Step 3: Create the component for the joints

In this tutorial step, two revolute joints, two fixed joints, and one translational joint are
created to constrain the degrees of freedom (shown in the following figure), such that the
remaining degree of freedom will be just 2.
DOF = 5*6 – (5+5+6+6+5+1) = 2
Revolute 3 2 5
Fixed 3 3 6
Translational 2 3 5
Motion (rev) 3 2 1

Joint locations in the model
Step 4: Create the joints

First, the fixed joint between the stand and ground will be created.
2. Click the joint type: selector switch and select fixed.
Note: The first and second terminals are corresponding to the

bodies that are connected by the joint. Nodes 19401 and
19402 are coincident. Coincident node picking is in options
panel > graphics subpanel in HyperMesh will help select
these coincident nodes in the HyperMesh screen.
5. Click create.
Next the fixed joint between the slider and the circle is created.

8. Click create.
To create the revolute joints in the model (b/w stand-driver and driver-pentagon bodies),
refer to the image below and follow the steps.
Defining a revolute joint

10. Select the node ID 19391 as the first terminal.
11. Select the node ID 19392 as the second terminal.
12. Select the vector option and for the first orientation, select y-axis.
13. Click create.
17. Select the vector option and for the first orientation, select y-axis.
18. Click create. To create the translational joint in the model (b/w slider-stand), refer to the
image below and follow the steps.
Defining a translational joint
19. Click the joint type: selector switch and select translational.
22. Select the vector option and for the first orientation, select x-axis.
23. Click create.

Step 5: Defining a Contact in the model
Use pre-defined element sets to add a Contact to the model.
Note: These element sets are defined from the Analysis page, entity sets
by choosing a set of elements. The set of elements on the face of
the pentagon body is named master and the sets elements on the
face of the circle body is named slave.
1. From the Analysis page, enter the interfaces panel.

2. Click the create radio button.
3. Click name= and enter Contact.
4. Click type= and select MBCNTR.
5. Click create.
6. Click the add radio button.

7. Select sets option for both master: and slave:.
8. Click on the sets for the master: and select the entity set named mas and click update.
9. Click on the sets for the slave: select the entity set named Sla, and click update.
Interfaces panel – contact
10. Click the card image radio button and click edit.
11. Select POISSON for CNFTYPE and enter the values, as shown in the image below:
12. Click return twice to close the Interface panel.

The motion which drives the mechanism, the gravity force that applies to the model and MBSIM
bulk data card, which is to specify the parameter for multi body simulation, will be created in this
step.
Step 6: Define the motion constraint

2. Click nodes and select the option by id and enter node id 19392.
3. Uncheck all fields; except for dof5 and enter a value of 1 (refer to the image below).
Constraints panel - motion
4. Click load types = and select MOTNG(V).

5. Click create to create the constraint.
Note: You can find a new load collector (auto1)

added to the model after completing this step.
The motion is assigned to this load collector
and will be used as reference in the OptiStruct
subcase.
Step 7: Create the gravity force

4. For Card Image, select GRAV.

Step 8: Create an MBSIM card


5. In the Select Loadcol dialog, select Gravity from the list of load collectors and click OK.
8. For MOTION, click Unspecified > Loadcol.
9. In the Select Loadcol dialog, select auto1 from the list of load collectors and click OK.


name for the model, for_contact_tutorial.fem, in the File name: field. The .fem filename
4. Click Save.
The name and location of the for_contact_tutorial.fem file displays in the input file: field.
8. Click OptiStruct. This launches an OptiStruct run in a separate command prompt (DOS or
UNIX).
for_contact_tutorial.html HTML report of the analysis, giving a summary of the

problem formulation and the results from the final
iteration.
for_contact_tutorial.out OptiStruct output file containing specific information on

the file set up, estimates for the amount of RAM and
disk space required for the run, and compute time
for_contact_tutorial.log Log file containing the information on the joints and

markers, simulation etc., which are specific to MBD
analysis.
for_contact_tutorial.xml Model file in .xml format – solver intermediate input

deck.
for_contact_tutorial.h3d Binary results file.
for_contact_tutorial.mrf Binary results file for plotting.
for_contact_tutorial.stat Summary of analysis process, providing CPU

Note: There are a few more files written to the directory with
the name for_contact_tutorial_mbd.

This step describes how to view the results in HyperView which will be launched from within the
OptiStruct panel of HyperMesh.
HyperView provides a complete post-processing and visualization environment for finite element

Note: That the path and file name for

for_contact_tutorials.h3d appears in the fields to the
right of Load model and Load results. This is fine because the
.h3d format contains both model and results data.

3. For Results type:, select Displacement(v).
4. Click Apply.

OS-1950: Curve to Curve Constraint
 Model a CVCV (curve-to-curve) joint using HyperMesh 2017
A CVCV (curve-to-curve) joint is a higher pair constraint. The constraint consists of a planar
curve on one body rolling and sliding on a planar curve on a second body. The curves are
required to be co-planar. This constraint can act as a substitute to contact modeling in many
cases where the contact occurs in a plane. One such case is the Curved Pentagon Positive Return
Cam system in which the curved pentagon rolls inside the circle and translates the slider. Instead
of modeling the contact between the pentagon and the circle, a CVCV constraint between their
profiles will be specified.
Rigid body model
In this tutorial, a Curved Pentagon Positive Return Cam system with the help of a CVCV
constraint is modeled.
Exercise

4. Select the for_cvcv_tutorial.hm file you saved to your working directory from the
5. Click Open. The model has five components and a few free nodes that should be used to
create bodies and joints for the MBD model.

There will be five bodies apart from the ground body in the model via: the stand, the slider, the
driver, the pentagon and the circle. Pre-defined free nodes will be used to define the bodies and
joints.
3. Click body= and enter stand.
5. Click props below type= and select Stand1.
6. Click free nodes and select by id option and enter 2, 19392, and 19402.
7. Click create.
8. Use the table to repeat the above operation to define PRBODY for the remaining components.
body= type= props free nodes
Slider PRBODY Slider2 4, 19398, 19400
Driver PRBODY Driver3 19391, 19395
Pentagon PRBODY Pentagon4 19396
Circle PRBODY Circle5 19397, 19399
Ground GROUND - 19401
Note: To define the ground body the selection of props is

not required.
9. Click return.
Creating Joints (Steps 3 - 5)
Here, you will define all the necessary joints including the CVCV joint. Five joints for the model
are needed. The first joint is the fixed joint between the stand and ground body. The second joint
is a revolute joint between the stand and driver, the third joint is the translational joint that
connects the slider to the stand, the fourth joint is the revolute joint between the driver and the
pentagon, and the fifth joint is the fixed joint between the slider and the circle.

A new component named joints is created.
In this step, two revolute joints, two fixed joints, and one translational joint are created to
constrain the degrees of freedom (shown in the following figure), such that the remaining
degree of freedom will be just 2.
DOF = 5*6 – (5+5+6+6+5+1) = 2
Revolute 3 2 5
Fixed 3 3 6
Translational 2 3 5
Motion (rev) 3 2 1
Joint locations in the model

First, the fixed joint between the stand and ground will be created.
2. Click the joint type: selection switch and select fixed.


picking is in options panel > graphics subpanel in
HyperMesh will help select these coincident nodes in the
HyperMesh screen.
5. Click create.
Next, the fixed joint between the slider and the circle is created.
8. Click create.
To create the revolute joints between (stand-driver and driver-pentagon) in the model, refer
to the image below and follow the steps.
Defining a revolute joint

12. Select the vector option and select y-axis for the first orientation.
13. Click create to create the joint.
16. Select the vector option and select y-axis for the first orientation.
To create the translational joint between (slider-stand) in the model, refer to the image below
and follow the steps.
Defining a translational joint
18. Click the joint type: selector switch, and select translational.

21. Select the vector option and select x-axis for the first orientation.
Step 5: Defining a CVCV joint

Pre-defined curves will be used in order to add a CVCV joint.
Note: These curves are defined from the Analysis page, entity sets
by choosing a set of nodes. The curve on the pentagon body
is named master and the curve on the circle body is named
slave.
1. Click the joint type: selector switch and select cvcv.

4. Click on set = for the first curve, select master.
5. Click on set = for the second curve, select slave.
6. Click create.
Joints panel – CVCV joint
step.
Step 6: Define the motion constraint

2. Click nodes twice and select the option by id and enter node id 19392.
3. Check the field next to dof5 and enter a value of 1.0 (refer to image below).

Constraints panel - motion
4. Click load types = and select MOTNG(V).

5. Click create to create the constraint.
Note: You can find a new load collector (auto1) added to the
model after completing this step. The motion is assigned to
this load collector and will be used to reference in the
OptiStruct subcase.




5. In the Select Loadcol dialog, select gravity from the list of load collectors and click OK.
6. For MBSIM, select SIM from the list of load collectors and click OK.
7. For MOTION, select auto1 from the list of load collectors and click OK.

name for the model, for_cvcv_tutorial.fem, in the File name: field. The .fem filename
4. Click Save.
The name and location of the for_cvcv_tutorial.fem file displays in the input file: field.
appears.
for_cvcv_tutorial.html HTML report of the analysis, giving a summary of the

problem formulation and the results from the final iteration.
for_cvcv_tutorial.out OptiStruct output file containing specific information on the

file set up, estimates for the amount of RAM and disk space
required for the run, and compute time information. Review
this file for warnings and errors.
for_cvcv_tutorial.log Log file containing the information on the joints and

markers, simulation etc., which are specific to MBD
analysis.
for_cvcv_tutorial.xml Model file in .xml format – solver intermediate input deck.
for_cvcv_tutorial.h3d Binary results file.
for_cvcv_tutorial.mrf Binary results file for plotting.
for_cvcv_tutorial.stat Summary of analysis process, providing CPU information for



View the animation
Note: That the path and file name for for_cvcv_tutorial.h3d

appears in the fields to the right of Load model and Load
results. This is fine because the .h3d format contains both

4. Click Apply.

OS-1960: Defining Point to Deformable Curve Joint in
HyperMesh and Performing Analysis using OptiStruct
In this tutorial, a multi-body dynamics analysis (simulation type: Transient Analysis) of a hook on
a flexible cable are performed using OptiStruct. An existing finite element model is imported into
HyperMesh. The rest of the setup (creation of joint, loading, etc.) is done in HyperMesh.
HyperView is used to post-process the large deformations of the flexible cable model.
Hook rolling on a cable
In this tutorial, you learn how to create JOINTS (Fixed, PTDCV), a PFBODY, a PRBODY, an
MBDCRV, and a multi-body dynamics subcase.
Model in HyperMesh

The flexible cable consists of 50 different CBAR elements (PFBODY) and the end of this flexible
body is connected to ground (GROUND) using fixed joints.
The Hook (PRBODY) is an external graphic and is connected to the flexible cable by the PTDCV
joint.
This exercise will show how to:
 Load a model into HyperMesh
 Create a PRBODY
 Create a PFBODY
 Create an MBDCRV
 Create a component for JOINT
 Create fixed joints
 Create a PTDCV joint
 Adding a displacement motion to the model
 Create load collectors for GRAV and MBSIM
 Create a multi-body dynamics subcase
Exercise
Step 1: Define the OptiStruct User Profile and retrieve the finite element
model
1. Launch HyperMesh Desktop and select OptiStruct in the User Profiles dialog.
3. Select the flex_cable.hm file you saved to your working directory from the optistruct.zip
4. Click Open. The flex_cable.hm database is loaded into the current HyperMesh session,
Create a PRBODY/GROUND and PFBODY (Steps 2 - 5)
Step 2: Create the rigid body (PRBODY)

3. Click body= and enter Hook.
5. Click props under properties: and check the box for Hook.
6. Click select.

7. Under free nodes:, click nodes and select the option by id and enter node ID 14399.
8. Click create.
Step 3: Create flex body (PFBODY)

1. Click body= and enter Cable.
3. Click props under properties: and check the box for Cable.
4. Click select.
5. Under free nodes:, click nodes and select the option by id and enter node IDs 1, 2.
6. For CMS Method:, verify that Craig-Bampton (CB) is selected.
7. For frequency upper bound: verify that upper bound default is selected.
8. For number of modes:, select nmodes= and enter the value 15.
Step 4: Create ground body (GROUND)

1. Click body= and enter Ground.
2. Click type= and select GROUND.
3. Under free nodes:, click nodes and select the option by id and enter node IDs 14397,
14398.
Note: To define the ground body, the selection of props is not

required.
Step 5: Define the deformable curve

2. For Name, enter deform_curve.
3. Click Card Image and select MBDCRV from the drop-down menu and click Yes to confirm.
4. Confirm Set Type is set to ordered.
5. For Entity IDs, click Nodes and click on node list selector in the panel under the graphics
area.
6. Click by path from the extended selection menu.

7. Select the nodes at two ends of the flexible cable made up by CBAR elements. See that all the
nodes are automatically selected on the cable.
8. Click proceed.

Here, you will define all the necessary joints including the PTDCV joint. Three joints for the model
are needed. Two fixed joints between the Cable ends to the Ground and one PTDCRV between
the Hook and the Cable.
3. Click Color and select any color. A new component named joints is created.

First, the fixed joint between one end of the Cable and Ground will be created.
2. Click the joint type: selection switch and select fixed.
Note: Nodes 1 and 14397 are coincident. Coincident node picking

is in options panel > graphics subpanel in HyperMesh will
help select these coincident nodes in the HyperMesh screen.
5. Click create.
Next, the fixed joint between the other end of the Cable and Ground is created.

8. Click create.
Step 8: Create the PTDCV Joint

1. Click the joint type: selection switch and select ptdcv.
3. Click on set= and select deform_curve entity set defined as MBDCRV.
4. Click create.
5. Click return.
Define External Inputs and Simulation Parameters (Steps 9 and 10)
step.

5. Enter CID = Unspecified, G = 9801.0, N1 = 0.0, N2 = -1.0, N3 = 0.0.


4. For Card Image, select MBSIM from the list.
5. Input the values, shown in the image below.

4. For MLOAD, select gravity from the list of load collectors and click OK.
5. For MBSIM, select SIM from the list of load collectors and click OK.

name for the model, flex_cable.fem, in the File name: field. The .fem filename extension is
the suggested extension for OptiStruct input decks.
4. Click Save.
The name and location of the flex_cable.fem file displays in the input file: field.
appears.
flex_cable.html HTML report of the analysis, giving a summary of the problem formulation
and the results from the final iteration.
flex_cable.out OptiStruct output file containing specific information on the file set up,
estimates for the amount of RAM and disk space required for the run, and
compute time information. Review this file for warnings and errors.
flex_cable.log Log file containing the information on the joints and markers, simulation
etc., which are specific to MBD analysis.
flex_cable.xml Model file in .xml format – solver intermediate input deck.
flex_cable.h3d Binary results file.
flex_cable.mrf Binary results file for plotting.
flex_cable.stat Summary of analysis process, providing CPU information for each step

View the animation
Note: That the path and file name for flex_cable.h3d appears in
the fields to the right of Load model and Load results. This is
fine because the .h3d format contains both model and results
data.

4. Click Apply.

Topology Optimization
OS-2000: Design Concept for a Structural C-clip

The topology optimization technique yields a new design and optimal material distribution.
Topology optimization allows designers to start with a design that already has the advantage of
optimal material distribution and is ready for design fine tuning with shape or size optimization.
In this tutorial, topology optimization is performed on a model to create a new topology for the
structure, removing any unnecessary material. The resulting structure is lighter and satisfies all
design constraints.
The optimization problem for this tutorial is stated as:
Objective: Minimize volume fraction.
Constraints: Translation in the y-axis for node A < 0.07mm.
Translation in the y-axis at node B > -0.07mm.
Design The density of each element in the design space.

variables:
In this tutorial, you will learn to:

 Setup the model in HyperMesh
 Analyze the baseline model
 Setup the optimization
 Post-process the optimization results

Exercise
Set Up the Model in HyperMesh
Step 1: Launch HyperMesh Desktop and Set the User Profile

1. Launch HyperMesh Desktop through the start menu. The User Profiles dialog appears.
Step 2: Open the cclip.hm File

1. From the File menu on the toolbar, select Open > Model.
2. Select the cclip.hm file you saved to your working directory from the optistruct.zip file.
3. Click Open. The cclip.hm database is loaded into the current HyperMesh session, replacing
any existing data. The database only contains geometric data and the mesh.
Step 3: Create Materials and Properties; Assign to Components

Since components need to reference a material, the materials collectors should be created first.
2. Enter the Name as Steel.
3. Select MAT1 as Card Image.
4. For E, enter the value 2.1E5.
5. For Nu, enter the value 0.3.
6. For RHO, enter the value 7.9E-9.
8. For Name, enter prop_shell.
9. Select PSHELL as the Card Image.
11. In the Select Material dialog, select Steel as the material and click OK to complete the
material selection.
12. Activate the thickness field for the shell component by clicking T. This allows the field to be
edited. Accept the default of 1.0.
13. Expand the Component folder to see the list of components.
14. Select the component comp_shell.
15. In the Entity Editor, for Property, click Unspecified > Property.

16. In the Select Property dialog, select prop_shell from the list of properties and click OK to
complete the property selection.
Step 4: Create Load Collectors

Next, you will create two load collectors (Constraints and Forces) and assign each a color. Follow
these steps for each load collector.
2. Enter the Name as Constraints.
3. Leave the Card Image field set to None.
4. Click Color, and select a color from the palette.
5. Using the same method, create the second load collector, named Forces.

For the three nodes that show constraints in the following figure, you need to create the SPC
constraints and assign them to the Constraints load collector, as outlined in the following steps.
1. From the Model browser, expand Load Collector, right-click on Constraints, and click Make
Current.

3. Select nodes and corresponding dofs, and click create to create constraints, as shown below.

Mesh showing the boundary conditions applied on the c-clip.
4. Click return.
Step 6: Create Forces

In this step, you will load the structure with two opposing forces of 100.0 N at the opposite tips
of the opening of the c-clip.
1. From the Model browser, expanded Load Collector, right-click on Forces, and click Make
Current.
2. From Analysis page, click forces.
3. To create the force at the top of the opening, click on the node at the top of the opening (A)
of the c-clip as in the figure below.

Opposing forces created at the opening of the c-clip.
4. Click magnitude=, enter 100.0, and press ENTER.

5. Set the switch below to y-axis.
6. Click create. An arrow, pointing up, appears at the node on the screen.
7. Similarly, to create the force at the bottom of the opening, click on the node at the bottom of
the opening (B) of the c-clip.
8. Click magnitude=, enter -100.0, and press ENTER.
9. Verify that the y-axis is selected.
10. Click create. An arrow, pointing down, appears at the node on the screen.
11. To provide a separation between the arrows, select uniform size=, enter 7, and press
ENTER.
12. Click return to go back to the Analysis page.
Step 7: Create Load Cases

The last step in establishing boundary conditions is the creation of a loadstep.
1. From the Analysis page, click loadsteps.
2. Click name=, enter opposing forces, and press ENTER.
3. Set type to linear static.
4. Check the box preceding SPC. An entry field appears to the right of SPC.

5. Click on the entry field and select Constraints from the list of load collectors.
6. Check the box preceding LOAD and select Forces from the list of load collectors.
7. Click create.
Analyze the Baseline Model

A linear static analysis of this C-clip is performed prior to the definition of the optimization
process. An analysis identifies the responses of the structure before optimization to ensure that
constraints defined for the optimization are reasonable.
2. Click save as.
name for the model, cclip.fem, in the File name: field. For OptiStruct input decks .fem is
4. Click Save.
The name and location of the cclip.fem file displays in the input file: field.
8. Set the options: field to blank.
Upon successful completion of the analysis, the message ANALYSIS COMPLETED will appear
HyperWorks Solver View dialog.
10. Click Close in the HyperWorks Solver View dialog.
Step 9: View Displacement Contour

1. From the OptiStruct panel, click HyperView. HyperView launches the cclip.mvw file which
loads the model and the results files.
2. From the Results menu, click Plot and then click Contour.
3. Select Displacement as the Result type and set the menu below Displacement to Y.
4. Click Apply.

This shows the contour of Y displacements.
5. Verify if the values are equivalent to those in the image above.

6. From the Page Control toolbar, click the page delete icon to delete the HyperView page, as
seen in the figure below.
7. Back in HyperMesh, click return to exit the panel.
Set Up the Optimization
The finite element model, consisting of shell elements, element properties, material properties,
and loads and boundary conditions has been defined. Now a topology optimization will be
performed with the goal of minimizing the amount of material to be used. Typically, removing the
material in an existing volume with the same loads and boundary conditions makes the model
less stiff and more prone to deformation. Therefore, you need to track the displacements (which
represent the stiffness of the structure) and constrain the optimization process such that the
least material necessary is used and overall stiffness is also achieved.
The forces in the structure are applied on the outer nodes of the opening of the clip, making
those two nodes critical locations in the mesh where the maximum displacement is likely to
occur. In this tutorial, you will apply a displacement constraint on the nodes so that they would
not displace more than 0.07 in the y-axis.
Step 10: Create the Topology Design Variables

1. From the Analysis page, click optimization.
2. Select topology.
3. Make sure the create subpanel is selected.
4. Click desvar=, enter d_shell, and press ENTER.

5. Click props and select prop_shell from the list of props; click
select.
6. Set type: as PSHELL.
7. Verify that the base thickness is 0.0.
A value of 0.0 implies that the thickness at a specific element can go to zero, and therefore
becomes a void.
8. Click create.
9. Click return.
Step 11: Create a Volume Response

1. Enter the Responses panel.
2. Click response= and enter volfrac.
3. Click the switch below response type switch and select volumefrac from the pop-up menu.
4. Click create.
Step 12: Create a Displacement Response

To create a displacement as a response, you need to supply a meaningful name for the response,
set the response type to displacement, select the node for the response, and select the type of
displacement (dof).
1. Click responses.
2. Click response= and enter upperdis.
3. Change the response type: to static displacement.
4. Click the node labeled A (upper opening of the c-clip), as shown in the figure to select it.
5. Select dof2 for the node.

6. Click create.
7. Click response= and enter lowerdis.
8. The response type: should be static displacement.

9. Click the node labeled B (lower opening of the c-clip), as shown in the figure to select it.
10. Select dof2 and create the response.

11. Click return to go back to the Optimization panel.
Step 13: Create Constraints on Displacement Responses

In this step, the upper and lower bound constraint criteria for this analysis will be set.
1. Select the Dconstraints panel.
2. Click constraint= and enter c_upper.
3. Check the box for upper bound only.
4. Click upper bound= and enter 0.07.
5. Select response= and set it to upperdis.
6. Click loadsteps.
7. Check the box next to opposing forces.
8. Click select.
9. Click create.
10. Click constraint= and enter c_lower.
11. Check the box for lower bound only.
12. Click lower bound= and enter -0.07.
13. Select response= and set it to lowerdis.
14. Click loadsteps.
15. Check the box next to opposing forces.
16. Click create.

Step 14: Define the Objective Function
1. Click objective.
2. The switch on the left should be set to min.
3. Click response= and select volfrac.
4. Click create.
5. Click return twice to exit the Optimization panel.
Step 15: Run the Optimization Problem

2. Click next twice.
3. Click SCREEN and return.
This will make OptiStruct output the optimization iterations to the output window.
5. Click save as, enter cclip_complete.fem as the file name, and click Save.
6. Click the run options: switch and select optimization.
7. Click OptiStruct to run the optimization.
The message following message appears in the window at the completion of the job:
OPTIMIZATION HAS CONVERGED.
FEASIBLE DESIGN (ALL CONSTRAINTS SATISFIED).
OptiStruct also reports error messages if any exist. The file cclip_complete.out can be
opened in a text editor to find details regarding any errors. This file is written to the same
directory as the .fem file.
8. Click Close to close the HyperWorks Solver View dialog.
The default files that get written to your run directory include:
cclip_complete.res HyperMesh binary results file.
cclip_complete.h3d HyperView binary results file.
cclip_complete.HM.comp.cmf HyperMesh command file used to organize elements into

components based on their density result values. This file
is only used with OptiStruct topology optimization runs.
cclip_complete.out OptiStruct output file containing specific information on

the file setup, the setup of the optimization problem,
for the run, information for all optimization iterations, and
compute time information. Review this file for warnings
and errors that are flagged from processing the
cclip_complete.fem file.

cclip_complete.sh Shape file for the final iteration. It contains the material
density, void size parameters and void orientation angle
for each element in the analysis. This file may be used to
restart a run.
cclip_complete.hgdata HyperGraph file containing data for the objective function,

percent constraint violations, and constraint for each
iteration.
cclip_complete.oss OSSmooth file with a default density threshold of 0.3. You

may edit the parameters in the file to obtain the desired
results.
cclip_complete_hist.mvw Contains the iteration history of the objective, constraints,

and the design variables. It can be used to plot curves in
HyperGraph, HyperView, and MotionView.
cclip_complete.stat Contains information about the CPU time used for the
complete run and also the break-up of the CPU time for
reading the input deck, assembly, analysis, convergence,
etc.
Post-process the Optimization Results
OptiStruct provides element density information for all iterations, and also gives displacement
and von Mises stress results (linear static analysis) for the starting and last iterations. This
section describes how to view those results in HyperView.
Step 16: View an Iso Value Plot of Element Densities

This plot provides the information about the element density. Iso Value retains all of the
elements at and above a certain density threshold. Pick the density threshold providing the
structure that suits your needs.
1. From the OptiStruct panel, click HyperView. This will launch HyperView inside the
HyperMesh Desktop and open the session file cclip_complete.mvw which contains two pages
with the results from two files:
Page 2 - cclip_complete_des.h3d: Optimization history results (element density).
Page 3 - cclip_complete_s1.h3d: Subcase 1 results; initial and final (displacement stress).
2. On page 2, click in the area of the Results browser circled below.

3. Select Design under the load case section and the last iteration listed.
4. From Results menu, click Plot > Iso.
5. In the panel area at the bottom of the GUI, select Element Densities as the Result type.
6. Click Top view orientation to set the correct view.
7. Click Apply.
8. Set the Current Value: to 0.3.
Iso value plot of element densities.
9. Move the slider below Current value: to change the density threshold.
You will see the iso value in the graphics window update interactively when you scroll to a
new value. Use this tool to get a better look at the material layout and the load paths from
OptiStruct.

Step 17: Compare Static Contour of Original to the Optimized Material
Layout
1. In HyperView, click the Next Page arrow toolbar icon to go to page 3. This will bring up
the cclip_complete_s1.h3d file, which contains the static subcase results for the first and
last iteration steps.
2. Divide this page into two vertical windows using the Page Layout toolbar icon .
3. Click Top view orientation to set the correct view.
4. From the Results menu, select Plot > Contour.
5. Select Displacement as the Result type, and set the menu below Displacement to Y.
6. Click Apply.
8. On the Deformed shape panel, change the scale value to 100, the undeformed shape to
edges, and click Apply.
9. From the Edit menu, click Copy > Window, and then click on the empty window.
10. Again, from the Edit menu, click Paste > Window.
11. Switch the animation mode to Linear .
12. With the second window selected, select Iteration 28.
13. From the Edit menu, click Copy > Page.

14. Again, from the Edit menu, click Paste > Page. This will create a third page on this report.
15. Now click the first window and click the Contour icon .
16. Change the Result type to Element Stresses (2D & 3D) (t).
17. For Averaging method:, select Simple and click Apply.
18. Click with the right button on the first window; select Apply Style, then Current Page, and
select Contour.

These stress results can be used only as reference to help understanding how far from the
limits the design is.
Remember that topologic optimization will show you a concept shape and the stress results
should be validated during the next design phases.

OS-2005: Design Concept for a Structural C-clip with Minimum
Member Size Control
Performing topology optimizations early in the conceptual design stage results in the generation
of a good baseline design and contributes to a shorter design cycle. One challenge with post-
processing topology optimization results is that the results may have several intermediate density
elements or checkerboard patterns which can be interpreted either as solid members or as a
void. If these semi-dense elements are interpreted as thin members, the final design is harder to
manufacture.
OptiStruct offers the minimum member size control method which provides some control over
member size in the final topology designs by defining the least dimension required in the final
design. It helps achieve a discrete solution by eliminating the intermediate density elements and
checkerboard density pattern, resulting in a discrete and better-reinforced structure, which is
easier to interpret and also easier to manufacture.
Exercise
This optimization problem applies the technique of minimum member size control on the
elements of the model to achieve a discrete solution.
The following exercise is an OptiStruct topology optimization and covers the following processes:
 Import the .fem file into HyperMesh
 Setup the minimum member size control problem using HyperMesh
 Post-processing the results in HyperView
Step 1: Launch the HyperMesh Desktop, Load the User Profile, and
Retrieve a File
2. Choose OptiStruct in the User Profiles dialog and click OK.
3. Click the Import Solver Deck icon . The Import tab appears.
4. Set the File type: to OptiStruct.
5. Select the cclip_complete.fem file you saved to your working directory from the
The location of the file displays in the File: field.
6. Click Import to import the model file.
Step 2: Apply Minimum Member Size Control Parameter

Minimum member size control will be applied to achieve a discrete solution.
1. Click inside the graphics area and press F4 to bring up the Distance panel.
2. Click the two nodes radio button.
3. N1 is highlighted, indicating that it is active. Select any node on the screen.

4. N2 is highlighted, indicating that it is active. Select another node on the same element.
5. Repeat steps 3 and 4 a few times using different elements to obtain an average element size.
The average element size for this model is about 2.5. It is recommended that the MINDIM
value be three times larger than this average element size unless the element's mesh is
aligned; in which case it can be two times larger.
8. Click topology.
9. Activate the parameters radio button.
10. Click review.
11. Select shells (1).
12. Click the toggle next to minmemb off to activate mindim= and set the value to 5.
13. Click update. A minimum member size control has been applied on this topology optimization
problem.
14. Click return twice to go back to Analysis page.
Step 3: Run the Optimization

2. Click save as, enter cclip_complete_min_member.fem as the file name, and click Save.
5. At the end of processing, click Close to close the HyperWorks Solver View dialog.
The result files load automatically into HyperMesh and HyperView on completion of the run, so
you can proceed directly to the post-processing step.
Step 4: Post-process the Results using HyperView

1. From the OptiStruct panel, click HyperView. This launches HyperView within HyperMesh
Desktop and opens the session file load cclip_complete_min_member.mvw that contains two
pages with the results from two files:
Page 2 - cclip_complete_min_member_des.h3d: Optimization history results (element
density).
Page 3 - cclip_complete_min_member_s1.h3d: Subcase 1 results; initial and final
(displacement, stress).
2. Select Design under the load case column and the last iteration to review the optimized
iteration result.

3. From the Results menu, click Plot > Iso.
4. Select Element Densities (s) as the Result type.
5. Click Apply.
6. Set Current value: to 0.3.
Iso value plot of element densities.
7. Compare this image to the one you achieved in the previous optimization without the
application of minimum member size control, OS-2000.
The iso value plot displayed is similar to the one previously. Notice the smaller members in
the original iso surface plot are replaced by a more discrete rib pattern. This design is easier
to manufacture.

OS-2010: Design Concept for an Automotive Control Arm
This tutorial uses OptiStruct's topology optimization functionality to create a design concept for
an automotive control arm required to meet performance specifications. The finite element mesh
containing designable (blue) and non-designable regions (yellow) is shown in the figure below.
Part specifications constrain the resultant displacement of the point where loading is applied for
three load cases to 0.05mm, 0.02mm, and 0.04mm, respectively. The optimal design would use
as little material as possible.
Finite element mesh containing designable (blue) and non-designable (yellow) material.
A finite element model representing the designable and non-designable material (shown in
figure) is imported into HyperMesh. Appropriate properties, boundary conditions, loads, and
optimization parameters are defined and the OptiStruct software determines the optimal material
distribution. The results (the material layout) are viewed as contours of a normalized density
value ranging from 0.0 to 1.0 in the design space. Isosurfaces are also used to view the density
results. Areas that need reinforcement will tend towards a density of 1.0.
Objective: Minimize volume.
Constraints: SUBCASE 1 - The resultant displacement of the point where

loading is applied must be less than 0.05mm.
SUBCASE 2 - The resultant displacement of the point where

SUBCASE 3 - The resultant displacement of the point where

Design Element density (and corresponding stiffness of the element) of

variables: each element in the design space.

 Setting up the FE model in HyperMesh
 Setting up the optimization in HyperMesh

Exercise
Setting Up the FE Model in HyperMesh
Step 1: Launch the HyperMesh Desktop, Set the User Profile and Retrieve
the File
2. Choose the OptiStruct in the User Profiles dialog and click OK. This loads the user profile. It
4. Select the carm.hm file you saved to your working directory from the optistruct.zip file.
5. Click Open.
Step 2: Create Materials and Properties and Assign to Proper

Components
3. For Name, enter Steel.
4. For Card Image, select MAT1 as the material type.
5. For E, enter the value 2.0E5.
6. For Nu, enter the value 0.3.
8. For Name, enter design_prop.
9. For Card Image, select PSOLID as the property type.
material selection.
13. For Name, enter nondesign_prop.
14. For Card Image, select PSOLID as the property type.
material selection.
17. Open the Component folder to update the component collectors with the newly created
properties.

18. Click the nondesign component to display it in the Entity Editor.
20. In the Select Property dialog, select nondesign_prop from the list of options and click OK to
21. Repeat steps 17 through 20 to assign design_prop to the design component.
Step 3: Create Load Collectors

Next, you will create four load collectors (SPC, Brake, Corner and Pothole) and assign each a
color. Follow these steps for each load collector.
2. For Name, enter SPC.
5. Similarly, create load collectors named Brake, Corner, and Pothole.
Step 4: Apply Constraints

Next, creating constraints and assigning them to the SPC load collector, is outlined in the
following steps.
1. From the Model browser, expand Load Collector, right-click on SPC, and click Make
Current.
3. Make sure the create subpanel is selected using the radio buttons on the left-hand side of the
panel.
4. Make sure that SPC is selected for load types.
5. Select the node at one end of the bushing (see the figure below) by clicking on it in the
graphics window.
6. Constrain dof1, dof2, and dof3; make sure dofs 1, 2, and 3 are checked and dofs 4, 5, and
6 are unchecked.
Dofs with a check will be constrained, while dofs without a check will be free.
7. Click create.
A constraint is created. A constraint symbol (triangle) appears in the graphics window at the
selected node. The number 123 is written beside the constraint symbol, indicating that dof1,
dof2 and dof3 are constrained.

Constraining dof1, dof2 and dof3 at one end of the bushing.
8. Select the node at the other end of the bushing (see the following figure) by clicking on it in
the graphics window.
9. Constrain dof2 and dof3; make sure only dofs 2 and 3 are checked.
10. Click create.
A constraint is created. A constraint symbol (triangle) appears in the graphics window at the
selected node. The number 23 is written beside the constraint symbol, indicating that dof2
and dof3 are constrained.
Constraining dof2 and dof3 at the other end of the bushing.
11. Click nodes and select by id from the extended entity selection window.
12. Enter the value 3239 and press ENTER.
13. This selects node ID 3239 (see the next figure), which corresponds to the shock absorber
mounting location.
14. Constrain only dof3.
15. Click create. A constraint is created. A constraint symbol (triangle) appears in the graphics
window at the selected node. The number 3 is written beside the constraint symbol, indicating
that dof3 is constrained.

Constraining dof3 on node ID 3239.
Step 5: Apply Forces for Brake, Corner, and Pothole Loadcases

1. From the Model browser, expand Load Collector, right-click Brake, and click Make Current.
2. From Analysis page, click forces.
4. Type the node number 2699 and press ENTER. This selects the node where the force is being
applied.
5. Click magnitude=, enter 1000.0 and press ENTER.
6. Set the switch below to x-axis.
7. Click create. An arrow, pointing the x direction, appears at the node on the screen.
8. For better visualization of the arrows, select uniform size=, enter 100, and press ENTER.
9. From the Model browser, expand Load Collectors, right-click Corner, and click Make
Current.
11. Enter the node number 2699 and press ENTER.
13. Set the switch below to y-axis.
14. Click create. An arrow, pointing in the Y direction, appears at the node on the screen.
15. From the Model browser, expanded Load Collector, right-click Pothole, and click Make
Current.

17. Enter the node number 2699 and press ENTER.
19. Set the switch below to z-axis.
20. Click create. An arrow, pointing in the Z direction, appears at the node on the screen.
Three separate forces in load collectors: brake, corner, and pothole with the component "design" turned off using the
display panel.
Step 6: Create Brake, Corner and Pothole Loadcases

The last step in establishing boundary conditions is the creation of a subcase.
2. Click name=, enter Brake, and press ENTER.
3. Set type as linear static.
5. Click on the entry field and select SPC from the list of load collectors.
6. Check the box preceding Load and select Brake from the list of load collectors.
7. Click create.
8. Similarly create the load cases Corner [by selecting the load collectors Corner and SPC] and
Pothole [by selecting the load collectors Pothole and SPC].

Setting Up the Optimization in HyperMesh
Step 7: Define the Topology Design Variables

2. Enter the topology panel.
panel.
4. Click DESVAR=, enter design_prop, and press ENTER.
5. Click props , select design_prop from the list of props, and click
select.
6. Set type: as PSOLID.
7. Click create. A topology design space definition, design_prop, has been created. All
elements organized in this design property collector are now included in the design space.
8. Click return.
Step 8: Create a Volume and Displacement Response

1. Enter the responses panel.
2. Click response = and enter vol.
3. Click on the switch below response type and select volume from the pop-up menu.
4. Ensure the regional selection is set to total (this is the default).
5. Click create. A response, vol, is defined for the total volume of the model.
6. Click response = and enter disp1.
7. Click on the switch below response type and select static displacement from the pop-up
menu.
9. Enter 2699 and press ENTER.
The node where the three forces are applied is selected.
10. Select total disp from the radio options.
This is the vector sum of the x, y, and z translations.
11. Click create. A response, disp1, is defined for the total displacement of node 2699.
Step 9: Define the Objective

1. Enter the objective panel.

3. Click response= and select vol.
4. Click create.
5. Click return to exit the Optimization panel.

In this step, the upper and lower bound constraint criteria for this analysis are set.
1. Enter the dconstraints panel.
2. Click constraint= and enter constr1.
5. Select response= and set it to disp1.
6. Click loadsteps.
7. Check the box next to Brake.
8. Click select.
9. Click create.
15. Check the box next to Corner.
16. Click create.
22. Check the box next to Pothole.
23. Click create.
Step 11: Check the Optimization Problem

A check run may be performed in which OptiStruct will estimate the amount of RAM and disk
space required to run the model. During the check run, OptiStruct will also scan the deck
checking that all the necessary information required to perform an analysis or optimization is
present and also that this information is not conflicting.

2. Click save as.
name for the model, carm_check.fem, in the File name: field. The extension.fem is for
OptiStruct input decks.
4. Click Save.
The name and location of the carm_check.fem file displays in the input file: field.
6. Click the run options: switch and select check.
8. Click OptiStruct. This launches the OptiStruct check run.
When the processing is complete, view the file carm_check.out. This is the OptiStruct output
file containing specific information on the file setup, optimization problem setup, RAM and
disk space requirement for the run. Review this file for possible warnings and errors.
Is the optimization problem set up correctly? See Optimization Problem Parameters section of
the carm_check.out file.
The objective function? See Optimization Problem Parameters section of the carm_check.out
file.
The constraints? See Optimization Problem Parameters section of the carm_check.out file.
What is the recommended amount of RAM for an In-Core solution? See Memory Estimation
Information section of the carm_check.out file.
Is there enough disk space to run the optimization? See Disk Space Estimation Information
section of the carm_check.out file.

2. Click save as, enter carm_complete.fem as the file name, and click Save.
The following message appears in the window at the completion of the job:
OPTIMIZATION HAS CONVERGED.
FEASIBLE DESIGN (ALL CONSTRAINTS SATISFIED).
OptiStruct also reports error messages if any exist. The file carm_complete.out can be

5. At the end of process, close the HyperWorks Solver View dialog.
carm_complete.hgdata HyperGraph file containing data for the objective function,
percent constraint violations, and constraint for each iteration.
carm_complete.his_data The OptiStruct history file containing iteration number, objective

function values and percent of constraint violation for each
iteration.
carm_complete.HM.comp.cmf HyperMesh command file used to organize elements into

components based on their density result values. This file is only
used with OptiStruct topology optimization runs.
carm_complete.HM.ent.cmf HyperMesh command file used to organize elements into entity

sets based on their density result values. This file is only used
with OptiStruct topology optimization runs.
carm_complete.html HTML report of the optimization, giving a summary of the

carm_complete.oss OSSmooth file with a default density threshold of 0.3. You may
edit the parameters in the file to obtain the desired results.
carm_complete.out OptiStruct output file containing specific information on the file

setup, the setup of the optimization problem, estimates for the
for all optimization iterations, and compute time information.
Review this file for warnings and errors that are flagged from
processing the cclip_complete.fem file.
carm_complete.res HyperMesh binary results file.
carm_complete.sh Shape file for the final iteration. It contains the material density,
void size parameters and void orientation angle for each
element in the analysis. The .sh file may be used to restart a
run and, if necessary, run OSSmooth files for topology
optimization.
cclip_complete.stat Summary of analysis process, providing CPU information for

Post-processing the Results in HyperView
Element density results are output to the carm_complete_des.h3d file from OptiStruct for all
iterations. In addition, Displacement and Stress results are output for each subcase for the first
and last iterations by default into carm_complete_s#.h3d files, where # specifies the sub case
ID. This section describes how to view those results in HyperView.

Step 13: View the Deformed Structure
1. When the message OPTIMIZATION HAS CONVERGED is received in the command window,
click HyperView.
HyperView is launched with the HyperWorks Desktop and the results are loaded. A message
window appears to inform about the successful loading of the model and result files into
HyperView. Notice that all three .h3d files get loaded, each in a different page of HyperView.
It is helpful to view the deformed shape of a model to determine if the boundary conditions
are defined correctly, and also to find out if the model is deforming as expected. The analysis
results are available in pages 2, 3, and 4. The first page contains the optimization results.
3. Click the Next Page toolbar icon to move to the second page.
The second page has the results from the carm_complete_s1.h3d file. The name of the page
is displayed as Subcase 1 – Brake to indicate that the results correspond to subcase 1.
4. Select Linear as the animation mode .
6. Select the first drop-down menu below Result type: and select Displacement [v].
7. Select the second drop-down menu and select Mag.
10. Set Result type: to Displacement (v), Scale: to model units, and Type: to Uniform.
11. Enter 10 for value:. This means that the maximum displacement will be 10 Model units and
all other displacements will be proportional.
12. Below the Undeformed shape: section, click on the drop-down menu next to Show and
select Wireframe.
13. Click Apply. A deformed plot of your model with displacement contour should be visible,
overlaid on the original undeformed mesh.
14. Click Start/Pause Animation to animate the model . A deformed animation for the first
subcase (brake) should be displayed.
In what direction is the load applied for the first subcase?
Which nodes have degrees of freedom constrained?
15. Select Iteration 18 in the Results browser.

The contour now shows the displacement results for Subcase 1 (brake) and iteration 18 which
corresponds to the end of the optimization iterations.
16. Stop the animation .
17. Click Next Page toolbar icon to move to the third page.
The third page which has results loaded from carm_complete_s12.h3d file is displayed. The
name of the page is displayed as Subcase 2 – corner to indicate that the results correspond to
subcase 2.
18. Repeat this process to display the displacement contours and deformed shape of the model
for the second subcase.
In what direction is the load applied for the second subcase?
Which nodes have degrees of freedom constrained?
19. Similarly, review the displacements and deformation for subcase 3 (pothole).
Step 14: Review Contour Plot of the Density Results

The optimization iteration results (Element Densities) are loaded in the first page.
1. Click the Previous Page icon until the name of the page is displayed as Design History,
indicating that the results correspond to optimization iterations.
Note the Result type: is Element Densities [s]; this should be the only results type in the
“file_name”_des.h3d file.
The second drop-down menu shows Density.
3. In the Averaging method: file, select Simple.
4. Click Apply to display the density contour.
Note the contour is all blue this is because your results are on the first design step or
Iteration 0.
5. Select Iteration 18 in the Results browser.
Each element of the model is assigned a legend color, indicating the density of each element
for the selected iteration.
Have most of your elements converged to a density close to 1 or 0?
If there are many elements with intermediate densities, the DISCRETE parameter may need
to be adjusted. The DISCRETE parameter (set in the opti control panel on the optimization
panel) can be used to push elements with intermediate densities towards 1 or 0 so that a
more discrete structure is given.
In this model, refining the mesh should provide a more discrete solution; however, for the
purposes of this tutorial, the current mesh and results are sufficient.
Regions that need reinforcement tend towards a density of 1.0. Areas that do not need
reinforcement tend towards a density of 0.0.
Is the max= field showing 1.0e+00?

In this case, it is.
If it is not, the optimization has not progressed far enough. Allow more iterations and/or
decrease the OBJTOL parameter (also set in the Opti control panel).
If adjusting the discrete parameter, refining the mesh, and/or decreasing the objective
tolerance does not yield a more discrete solution (none of the elements progress to a density
value of 1.0), review the set up of the optimization problem. Some of the defined constraints
may not be attainable for the given objective function (or vice versa).
Step 15: View an Iso Value Plot on Top of the Element Densities Contour
1. From the Results menu, click Plot > Iso.
2. From the panel area (lower portion of the GUI), select Element Densities as the Result
type.
3. Click Apply.
You will see the iso value in the graphics window update interactively when you scroll to a
new value. Use this tool to get a better look at the material layout and the load paths from
OptiStruct.

OS-2020: Increasing Natural Frequencies of an Automotive
Splash Shield with Ribs
A preliminary design of stiffeners in the form of ribs for an automotive splash shield will be
generated in this tutorial. The objective is to increase the natural frequency of the first normal
mode using topology to identify locations for ribs in the designable region (shown in red).
Finite element mesh containing designable (red) and non-designable (blue) material.
Objective: Maximize frequency of mode number 1.
Constraint: Upper bound constraint of 40% for the designable volume.
Design variables: Density of each element in the design space.

 Setting up the normal modes analysis in HyperMesh
 Post-processing the initial results in HyperView
 Setting up the optimization in HyperMesh
 Post-processing the optimization results in HyperView
 Setting up the final normal modes analysis in HyperMesh
 Post-processing the final results in HyperView
 Comparing the final results with initial results
sshield_opti.fem Original ASCII O

Exercise
Setting Up the Normal Modes Analysis in HyperMesh
Step 1: Launch the HyperMesh Desktop, Load the User Profile, and
Retrieve a File
3. From the File menu on the toolbar, select Import > Solver Deck. An Import tab is added to
your tab menu.
4. Click the Select Files icon .

5. Select the sshield_opti.fem file you saved to your working directory from the
6. Click Import. The sshield_opti.fem OptiStruct input file is loaded into the current
HyperMesh session.
7. Click Close to exit the Import tab menu.
Step 2: Create an EIGRL Load Collector

4. For Card Image, leave the field set to None.
6. For Name, enter EIGRL.
8. For Card Image, select EIGRL. The Entity Editor updates to show the fields for the EIGRL
card. Click in the entry field, and enter the value.
10. For ND, enter the value 2.
A load collector was just created, which defines data needed to perform real eigenvalue
analysis (vibration or buckling) and specified the solver to calculate the first two modes
between a frequency range of 0 and 3000 Hz.
Step 3: Create Constraints at the Bolt Locations

1. From the Model browser, expand Load Collector, right-click constraints, and click Make
Current. The load collector name changes to bold to signify that it is now the current load
collector.

panel.
6. Enter the value 1075 (beside id=) and press ENTER.
7. Enter the value 1076 and press ENTER.
8. Constrain all dofs.
9. Click create.
Two constraints are created. Constraint symbols (triangles) appear in the graphics window at
the selected nodes. The number 123456 is written beside the constraint symbol, indicating
that all dofs are constrained.
Step 4: Create a Loadstep (also referred to as a subcase)

2. Click name = and enter frequencies.
3. Click the type switch and select normal modes from the pop-up menu.
5. Click on the entry field and select constraints from the list of load collectors.
6. Check the box preceding METHOD(STRUCT). An entry field appears to the right of
METHOD.
7. Click on the entry field (=) and select EIGRL from the list of load collectors.
8. Click create. An OptiStruct loadstep has been created which references the constraints in the
load collector spc and the eigenvalue extraction data in the load collector EIGRL.

name for the model, sshield_analysis.fem, in the File name: field. The .fem file name
4. Click Save.
The name and location of the sshield_analysis.fem file displays in the input file: field.


8. Let the options: field be blank.
model file was written. The sshield_analysis.out file is a good place to look for error
sshield_analysis.html HTML report of the analysis, giving a summary of the problem
sshield_analysis.out OptiStruct output file containing specific information on the file

set up, the set up of the optimization problem, estimates for the
for all optimization iterations, and compute time information.
sshield_analysis.res HyperMesh binary results file.
sshield_analysis.stat Summary of analysis process, providing CPU information for each

sshield_analysis.h3d HyperView results file.
sshield_analysis.mvw HyperView session file.
sshield_analysis_frames.html HTML file used to post-process the .h3d with HyperView Player
using a browser. It is linked with the _menu.html file.
sshield_analysis_menu.html HTML file to post-process the .h3d with HyperView Player using a
browser.
Post-processing the Initial Results in HyperView
Eigenvector results are output from OptiStruct for a normal modes analysis by default. This
section describes how to view the results in HyperView.
Step 6: View the First Mode Shapes in HyperView

1. While still in the OptiStruct panel, click HyperView. This launches HyperView in page 2 of the
HyperWorks Desktop and loads the session file sshield_analysis.mvw that is linked with the
sshield_analysis.h3d file.
A Message Log pop-up will inform about the result files loaded into HyperView.
2. Click Close to exit the Message Log window.
3. Set the animation type to Modal .

4. Click the drop-down menu, as shown in the following image of the Results browser. The
window appears showing the calculated first two natural frequencies between 0 and 3000Hz.
5. Click Mode 1 to select those mode results.

7. Make or verify the following settings in the Deformed panel.
Result Type: Eigen mode (v)
Scale: Model Units
Type: Uniform
Value: 10
8. Click Apply.
9. Click the Animation Controls toolbar icon.
10. Move the Max Frame Rate: slider between 60 and 1 to increase or decrease the animation
speed.
You can also change the default values for Angular Increment: to refine your animation.
11. Click the Play/Pause Animation icon to start the animation. An animation of the mode
shape should be seen for the first frequency.
12. Click the Play/Pause Animation icon again to stop the animation.
13. On the Page Control toolbar, click the Page Delete icon to delete the HyperView page as
seen in the figure below.
Setting Up the Optimization in HyperMesh
Step 7: Create Design Variables for Topology Optimization

1. Once back in HyperMesh, click return to exit the OptiStruct panel.

5. Click desvar = and enter shield.
6. Click props.
7. Check the box next to design and click select.
8. Set the type toggle to PSHELL.
9. Click base thickness = and change the value to 0.300.
10. Click create.
A topology design space definition, shield, has been created. All elements referring to the
design property collector (elements organized into the "design" component collector) are now
included in the topology design space. The thickness of these shells can vary between 0.3
(base thickness defined above) and the maximum thickness defined by the T (thickness) field
on the PSHELL card.
The object of this exercise is to determine where to locate ribs in the designable region.
Therefore, a non-zero base thickness is defined, which is the original thickness of the shells.
The maximum thickness, which is defined by the T field on the PSHELL card, should be the
allowable depth of the rib.
Currently, the T field on the PSHELL card is still set to 0.3 (the original shell thickness). You
will change this to 1.0 so that the ribs of a maximum height of 0.7 units can be obtained by
the topology optimization.
12. In the Model browser, open the Property folder and select the design property.
13. In the Entity Editor, replace 0.300 in the T field with 1.000.
Step 8: Create Responses

A detailed description of the available responses can be found in the OptiStruct User's Guide,
under Responses.
Two responses will be defined here: the first frequency will be the objective function and a
volume fraction response that will be used as a constraint.
1. Select the responses panel.
2. Click response = and enter freq1.
3. Click on the switch below response type and select frequency from the pop-up menu.
4. Click Mode Number: and enter 1 (this is the default value).
5. Click create. A response, freq1, is defined for the frequency of the first mode extracted.
6. Click response = and enter volfrac.
7. Click on the switch below response type and select volumefrac from the pop-up menu.
8. Set the total/regional toggle to total.
9. Click create. A response, volfrac, is defined for the volume fraction of the design space.
10. Click return to go to the Optimization Setup panel.

In this step, the objective is to maximize the response, 'freq1', which was defined in the previous
section.
1. Enter the objective panel from within the Optimization panel.
2. Click on the switch in the upper left corner of the panel, and select max from the pop-up
menu.
3. Click response= and select freq1 from the list of responses.
4. Click loadstep and select the frequencies loadstep previously defined.
5. Click create.
Step 10: Define the Constraints

A response defined as the objective cannot be constrained. In this case, you cannot constrain the
response freq1.
An upper bound constraint is to be defined for the response volfrac.
1. Enter the dconstraints panel from the Optimization panel.
2. Click constraint= and enter volume_constr.
3. Check the box to the left of upper bound =.
4. Click upper bound = and enter the value 0.40.
5. Click response = and select volfrac from the response list.
6. Click create.
A constraint is defined on the response volfrac. The constraint is an upper bound with a
value of 0.40. The constraint applies to all subcases as the volumefrac response is a global
response. In this step you are allowing the topology optimization to use additional volume
with which it can come with ribsvconstr.
7. Click return to return to the Optimization panel.
Step 11: Run the OptiStruct Analysis

name for the model, sshield_optimization.fem, in the File name: field. The .fem
extension is used for OptiStruct input decks.
4. Click Save.

sshield_optimiz
HyperGraph file containing data for the objective function, percent constraint
ation.hgdata
violations and constraint for each iteration.
sshield_optimiz The OptiStruct history file containing iteration number, objective function
ation.his_data values, and percent of constraint violation for each iteration.
sshield_optimiz HyperMesh command file used to organize elements into components based
ation.HM.comp.c on their density result values. This file is only used with OptiStruct topology
mf optimization runs.
sshield_optimiz HyperMesh command file used to organize elements into entity sets based on
ation.HM.ent.cm their density result values. This file is only used with OptiStruct topology
f optimization runs.
sshield_optimiz HTML report of the optimization, giving a summary of the problem formulation
ation.html and the results from the final iteration.
sshield_optimiz OSSmooth file with a default density threshold of 0.3. You may edit the
ation.oss parameters in the file to obtain the desired results.
sshield_optimiz OptiStruct output file containing specific information on the file setup, the
ation.out setup of your optimization problem, estimates for the amount of RAM and disk
space required for the run, information for all optimization iterations, and
compute time information. Review this file for warnings and errors.
sshield_optimiz Shape file for the final iteration. It contains the material density, void size
ation.sh parameters and void orientation angle for each element in the analysis. The
.sh file may be used to restart a run and, if necessary, to run OSSmooth files
for topology optimization.
sshield_optimiz Summary of analysis process, providing CPU information for each step during
ation.stat analysis process.
sshield_optimiz HyperView session file.

ation.mvw
sshield_optimiz HTML file used to post-process the .h3d with HyperView Player using a
ation_frames.ht
browser. It is linked with the _menu.html file.
ml
sshield_optimiz HTML file used to post-process the .h3d with HyperView Player using a
ation_menu.html
browser.
sshield_optimiz HyperView binary results file that contains: Density results from topology
ation_des.H3D optimizations, Shape results from topography or shape optimizations and
Thickness results from size and topology optimizations.
sshield_optimiz HyperView binary results file that contains: Displacement results from linear
ation_s1.H3D static analysis, Element strain energy results from normal mode analysis
and Stress results from linear static analysis, etc.
The name and location of the sshield_optimization.fem file displays in the input file: field.


model file was written. The sshield_optimization.out file is a good place to look for error
Post-processing the Optimization Results in HyperView
With topology optimization of shell elements, Element Density and Element Thickness results are
output from OptiStruct for all iterations. In addition, Eigenvector results are output for the first
and last iterations by default. This section describes how to view those results in HyperView.
Step 12: View a Static Plot of the Density Results

1. While in the OptiStruct panel, click HyperView. This launches HyperView with the
HyperWorks Desktop and loads the session file sshield_optimization.mvw that is linked with
the sshield_optimization_des.h3d and the sshield_optimization_s1.h3d files.
A Message Log window opens, indicating the location of the .h3d file.
3. Enter the Contour panel by clicking the Contour toolbar icon .
4. Set the Result type: to Element Thickness(s).
5. Click Apply.
6. From the Results browser, select the last iteration.
Each element of the model is assigned a legend color, indicating the thickness of each
element for the selected iteration.
Have most of your elements converged to a thickness close to 1 or 0?

If there are many elements with intermediate densities (represented by intermediate
thickness), the discrete parameter may need to be adjusted. The DISCRETE parameter (set in
the Opti control panel on the Optimization panel) can be used to push elements with
intermediate densities towards 1 or 0 so that a more discrete structure is given.
Is the max = field showing 1.0e+00?
In this case, it is. If it is not, the optimization has not progressed far enough. Allow more
iterations and/or decrease the OBJTOL parameter (set in the Opti control panel).
If adjusting the DISCRETE parameter, incorporating a checkerboard control, refining the
mesh, and/or decreasing the objective tolerance does not yield a more discrete solution (none
of the elements progress to a density value of 1.0), you may want to review the set up of the
optimization problem. Some of the defined constraints may not be attainable for the given
objective function (or visa-versa).
Where would you place your ribs?
Contour plot of element densities at iteration 6 with all components except the designable component turned off. (top
view)
7. On the Page Control toolbar, click the Page Delete icon to delete the HyperView page.

Setting Up the Final Normal Modes Analysis in HyperMesh
Based on the topology results obtained above, a number of ribs were added to the model. The
new design sshield_newdesign.fem, which includes these ribs can be found in the
Step 13: Delete the Current Model

1. Once back in HyperMesh, click return to exit the OptiStruct panel.
2. Click the New Model icon to clear the session.

3. Click Yes.
Deleting the current model clears the current HyperMesh database. Information stored in .hm
files on your disk is not affected.
Step 14: Import the OptiStruct Input File sshield_newdesign.fem

1. From the File menu, select Import > Solver Deck. An Import tab is added to your tab
menu.
2. Select the Files icon .

3. Select the sshield_newdesign.fem file you saved to your working directory from the
4. Click Import.
The sshield_newdesign.fem OptiStruct input file is loaded into the current HyperMesh
session. The ribs which were added are in the ribs component collector.
5. Click Close.

Step 15: Run OptiStruct Analysis
name for the model, sshield_newdesign.fem, in the File name: field.
4. Click Save.
The name and location of the sshield_newdesign.fem file displays in the input file: field.
8. Leave the options: field blank.
Post-processing the Final Results in HyperView
Step 16: View the Mode Shapes

1. While in the OptiStruct panel, click HyperView. This launches HyperView in the HyperMesh
Desktop and loads the file sshield_newdesign.mvw that is linked with the file
sshield_newdesign.h3d.
A Message Log window opens, indicating the location of the .h3d file.
3. Set the animation mode to Modal .
4. In the Results browser, select Mode 1.
6. Make or verify the following settings in the Deformed panel.
Result Type: Eigen mode (v)
Scale: Model Units
Type: Uniform
Value: 10
7. Click Apply.
8. Click Pause/Play Animation to start the animation . An animation of the mode shape
should be seen for the first frequency.
9. Click Pause/Play Animation again to stop the animation.

Comparing the Initial and Final Results
What is the percentage increase in frequency for your first mode (sshield_analysis.fem vs.
sshield_newdesign)?
You have seen that the frequency of the structure for the first mode has increased from 43.63 Hz
to 84.88 Hz.
How much mass has been added to the part (check the mass of your ribs in the mass calc panel
in the Tool page)?
What is the percentage increase in mass?

OS-2030: Control Arm Topology Optimization with Draw
Direction Constraints
In this tutorial a topology optimization using draw direction constraints on a control arm is
performed. The finite element mesh containing designable (brown) and non-designable regions
(blue) is shown in Figure 1.
Figure 1. Control arm schematic.

 Setting up topology design variables and the draw direction constraints in HyperMesh
 Setting up the optimization problem in HyperMesh

Exercise
Setting Up Topology Design Variables and the Draw Direction

Constraints in HyperMesh
Step 1: Launch the HyperMesh Desktop and Load the User Profile
Step 2: Retrieve the controlarm.hm file

1. From the File menu on the toolbar, select Open. An Open file browser window opens.
2. Select the controlarm.hm file you saved to your working directory from the optistruct.zip
3. Click Open. The controlarm.hm database is loaded into the current HyperMesh session.
Step 3: Create Design Variables for Topology Optimization with Draw

Direction Constraints
The draw direction constraints allow the casting feasibility of the design so that the topology
determined will allow the die to slide in a given direction. These constraints are defined using the
DTPL card. Two DRAW options are available. The option 'SINGLE' assumes that a single die will
be used. The option 'SPLIT' assumes that two dies splitting apart in the given draw direction will
be used to cast the part.
2. Select the topology panel.
3. Make sure the create radio button is selected on the left hand side of the panel.
4. Enter a name in desvar = dv1.
5. Click props and select Design.
6. Click select.
7. Set the type: toggle to PSOLID.
8. Click create.
9. Click the draw radio button, and toggle the draw type: to single.
The option 'SINGLE' assumes that a single die will be used and it slides in the given drawing
direction. The anchor node and the first node define the drawing direction.
10. Click anchor node.
11. Enter the value 3029 and press ENTER. This selects node ID 3029.
12. Click first node.

13. Enter the value 4716 and press ENTER. This selects node ID 4716.
14. Under obstacle, double-click props, select Non-design and click select.
This selects the non-designable parts as obstacles for the casting process on the same DTPL
card. This preserves the casting feasibility of the final structure.
15. Click update.
Setting Up the Optimization Problem in HyperMesh
Step 4: Create the Optimization Responses

2. In the response = field, enter Volfrac.
3. Select the switch below response type: and set it to volumefrac.
4. Click create.
5. In the response = field, enter Compl.
Just eight characters can be used here. Since the name is used, a label is needed for the
response.
6. Set the response type: to weighted comp (use the arrows to access the second page, if
not shown).
7. Click loadsteps, check the boxes next to both loadcases, and click return.
8. Click create.
Step 5: Apply Design Constraints on Volume Fraction Response

1. Click dconstraints to define the constraints.
2. Enter Constr in the constraint = field.
Only eight characters can be used here. Since the name is used, a label is needed for the
response.
3. Select upper bound = by clicking in the box preceding it.
4. Click in the text box and enter the value 0.3.
5. Click response = and select Volfrac.
6. Click create. The volume fraction constraint is now created.
Step 6: Set Minimize Compliance as Objective

1. Click objective to define the objective function.
2. Click the min/max switch in the upper left corner and select min.

3. Click response and select Compl.
4. Click create.
This completes your optimization problem setup.
Step 7: Save the Database

1. From the File menu on the toolbar, select Save as > Model.
2. Change the file name to controlarm_opt.hm and click Save.

If the job is successful, new result files will be seen in the directory where HyperMesh was
invoked. The controlarm_opt.out file is a good place to look for error messages that will
help to debug the input deck if any errors are present.
controlarm_opt.hgdata HyperGraph file containing data for the objective function,

percent constraint violations and constraint for each
iteration.
controlarm_opt.HM.comp.cmf HyperMesh command file used to organize elements into

components based on their density result values. This file
is only used with OptiStruct topology optimization runs.
controlarm_opt.HM.ent.cmf HyperMesh command file used to organize elements into

entity sets based on their density result values. This file is
only used with OptiStruct topology optimization runs.
controlarm_opt.hist The OptiStruct iteration history file containing the

iteration history of the objective function and of the most
violated constraint. Can be used for a xy plot of the
iteration history.
controlarm_opt.oss OSSmooth file with a default density threshold of 0.3. You

results.

controlarm_opt.out OptiStruct output file containing specific information on
the file setup, the set up of your optimization problem,
for the run, information for all optimization iterations, and
compute time information. It is highly recommended to
review this file for warnings and errors that are flagged
from processing the Controlarm_opt.fem file.
controlarm_opt.html Automatic .html report generation which can be viewed

in Netscape or MS Internet Explorer using the HyperView
Player plug-in.
controlarm_opt.sh Shape file for the final iteration containing the material
density, void size parameters, and void orientation angle
for each element in the analysis. The .sh file may be used
to restart a run and, if necessary, run OSSmooth files for
topology optimization.
controlarm_opt.mvw HyperView session file.
controlarm_opt_hist.mvw HyperView session file with the history plots.
controlarm_opt_frames.html HTML file used to post-process the .h3d with HyperView

Player using a browser. It is linked with the _menu.html
file.
controlarm_opt_menu.html HTML file used to post-process the .h3d with HyperView

Player using a browser.
controlarm_opt_des.H3D HyperView binary results file that contains: Density

results from topology optimizations, Shape results from
topography or shape optimizations and Thickness results
from size and topology optimizations.
controlarm_opt_s1.H3D HyperView binary results file that contains:

controlarm_opt_s2.H3D Displacement results from linear static analysis,
Element strain energy results from normal mode
analysis and Stress results from linear static analysis,
etc.
controlarm_opt.res HyperMesh Binary result file.
Post-processing the Results using HyperView
OptiStruct provides the Element density information for all of the iterations. OptiStruct will also
show Displacement and von Mises stress results of a linear static analysis for iteration 0 and
iteration 38. This section describes how to view those results in HyperView. First, the HyperMesh
binary results file needs to be loaded.

Step 9: Contour Plot of Element Densities
1. From the OptiStruct panel, click HyperView.
2. Click Close to close the message GUI.
3. Select the last iteration in the Results browser.
5. Under Result type:, select Element densities (s) from the first menu and Density for the
second menu.
6. Set the Averaging method: to Simple.
7. Click Apply.
The resulting contours represent the displacement field resulting from the applied loads and
boundary conditions.
sake of this tutorial, the current mesh and results are sufficient.
Step 10: Iso Plot of the Densities

The iso surface feature can be a very useful tool for post-processing density results from
OptiStruct. For models with solid design regions, this feature becomes a vital tool for analyzing
density results.
1. Click the Iso Value icon .
2. Set the Result type: to Element Densities (s).
3. Make sure the last iteration is still selected in the Results browser.
4. Click Apply.
5. Enter a value of 0.3 in the Current value: field.
6. Make sure that Show values: is set to Above.
7. Also check the boxes next to Features and Transparent.
8. You can also move the slider bar to change current value of Element densities.

Isosurface plot of element densities.
Step 11: Plot a Contour of Displacements and Stresses

1. Click the Next Page arrow to proceed to the results of Load Case 1 on page 3.
2. Set the animation mode to Linear Static .
4. Set the Result type: to Displacements (v).
5. Click Apply. This will give a displacement plot for Iteration 0.
6. Set the iteration to the last iteration in the Model browser.
A displacement plot for the last Iteration # should be visible.

Displacement contour for the first loadstep at the last iteration.
The stress results are also available for the respective iterations.
7. Similarly, results for Load Case 2 can be viewed on page 4 using Next Page.
Displacement contour for the second loadstep at the last iteration.

OS-2040: Spot Weld Reduction using CWELD and 1D Topology
Optimization
This tutorial demonstrates how to perform 1D topology optimization. The model is a simple
welded hat section. The welding is modeled using CWELD elements.
The hut.hm file can be found in the optistruct.zip file and copied to your working directory.
The objective is to minimize the weighted compliance through all three load cases. The volume
fraction of the weld component is limited to 0.3. The design space is the spot weld component.

 Define the design space
 Setting up the optimization problem
 Post-processing the results

Exercise
Step 1: Load the Model in the HyperMesh Desktop

1. Start HyperMesh Desktop.
4. Select the hut.hm file you saved to your working directory from the optistruct.zip file.
5. Click Open. The hut.hm database is loaded into the current HyperMesh session, replacing any
existing data.
Step 2: Define the Design Space

1. Go to the Analysis page.
2. Click optimization. This brings up the optimization module.
3. Click topology.
4. Set the radio button to create.
5. Enter desvar = tpl.
6. Set the type to PWELD.
7. Click props.
8. Select the box PWELD_500.
9. Click return.
10. Click create. This defines the design space.
11. Click return.
Step 3: Define the Responses

1. Click responses.
2. From the drop-down menu below response type:, select volumefrac from the list of
responses that are available for optimization in OptiStruct.
3. Click on the toggle next to total and select by entity. The yellow selection box is now
available.
4. Switch the yellow box to the props box.
5. Click props.
6. Select the tick box PWELD_500.
7. Click select.
8. Enter response = volfrac.

9. Click create. This defines the volume fraction response.
10. Enter response= wcomp.
11. Select the drop-down menu below response type: to open a window listing all responses
available for optimization in OptiStruct.
12. Click weighted comp to select it as the response type and return to the response panel.
(Click the arrow icon to go to the second page, if necessary.)

14. Turn on all three check boxes for the subcases.
15. Change the weighting factors for SUBCASE200 and SUBCASE300 to 100.0. This increases
the influence of the two bending load cases vs. the torsion load case SUBCASE1, which is kept
at 1.0.
16. Click return.
17. Click create. This defines the weighted compliance response.
18. Click return.
Step 4: Define the Constraint and Objective

1. Click dconstraints.
2. Select response = volfrac.
3. Select the check box upper bound = and enter 0.3.
4. Enter constraint = volfrac.
5. Click create. This defines the volume fraction constraint.
6. Click return.
7. Click objective.
8. Select response = wcomp.
9. Select min as the objective.
10. Click create. This defines the weighted compliance objective.
11. Click return. This concludes the definition of the optimization problem. Some optimization
parameters should be modified to achieve a good result.
12. Click opti control.
13. Select the check box DISCRT1D = and enter 20.0. This increases the penalty factor in the
density method only for the 1D elements to achieve a discrete result.
14. Select the check box OBJTOL = and enter 1.e-5. This reduces the objective tolerance that is
checked for convergence.

Step 5: Perform the OptiStruct Run
1. Click OptiStruct to enter the panel to run OptiStruct.
name for the model, hut_opt.fem, in the File name: field. The .fem file extension is
suggested for OptiStruct input decks.
4. Click Save.
The name and location of the hut_opt.fem file displays in the input file: field.
5. Select export options: all.
6. Select run options: optimization.
7. Select memory options: memory default. The input file name should be hut_opt.fem.
This will export the input deck and start the execution of OptiStruct in the solver GUI window.
Step 6: Visualize the New Spot Weld Configuration

To post-process the results, the weld elements will be sorted by density into different
components.
1. From the File menu on the toolbar, select Run > Command File.
2. Find the output hut_opt.HM.comp.cmf from your OptiStruct run.
3. Click Open. As a result, four of the welds are in the DENS 0.9-1.0 component; all others are
in the DENS 0.0-0.1 component.
4. To do a re-analysis with the new weld configuration, undisplay the components with low
density (DENS 0.0-0.1 to DENS 0.8-0.9) and rerun the analysis with export options: set to
displayed in the OptiStruct panel.
Final configuration.

OS-2050: Pattern Repetition using Topology Optimization
This tutorial demonstrates how to perform topology optimization using pattern repetition. The
model is a rectangular plate with a concentrated force on one edge and two constraints on the
opposite edge. Two other rectangular plates with a scaled size of 0.6 and 0.3 from the original
plate, with forces and boundary conditions applied in different directions, are also modeled to
highlight the difference between the topology results with and without pattern repetitions.
The objective is to minimize the compliance for the single subcase. The volume fraction of the
design space is limited to 0.3. The design spaces are the three plates.
The following exercises are covered:

 Retrieving the OptiStruct input file
 Setting up the optimization problem without pattern repetition
 Post-processing the results without pattern repetition
 Adding pattern repetition cards
 Post-processing new results with pattern repetition
The following file can be found in the optistruct.zip file and copied to your working directory.
no_repeat.fem Original ASCII OptiStruct input deck.

Exercise
Retrieving the OptiStruct Input File
Step 1: Launch the HyperMesh Desktop, Set the User Profile, and Import
the File
your tab menu.
4. Click the Select file icon to locate and open the no_repeat.fem file you saved to your
working directory from the optistruct.zip file. Refer to Accessing the Model Files.
5. Click Import. The no_repeat.fem OptiStruct input file is loaded into the current HyperMesh
session.
6. Click Close.
Setting Up the Optimization Problem Without Pattern Repetition
Step 2: Create the Topology Design Variable

1. From the Analysis page, enter the optimization panel.
2. Click topology to enter the panel.
panel.
4. Click desvar = and enter dv1.
5. Click props and select the property labeled first by checking the box beside it.
6. Click select.
7. Set the type: selector to PSHELL.
8. Click create.
9. Select the parameters subpanel using the radio buttons on the left-hand side of the panel.
10. Toggle minmemb off to mindim=.
11. Click mindim= and enter 2.0.
12. Click update.
13. Repeat steps 3 through 12 for the components labeled second and third with the desvar
names dv2 and dv3, respectively. This defines the design space.
14. Click return.

Step 3: Create the Volume Fraction and Compliance Response
3. Set the switch below response type: to volumefrac.
4. Verify that the toggle in the center of the panel is set to total.
5. Click create. This creates the volume fraction response.
6. Click response = and enter comp.
7. Set the selector under response type: to compliance.
8. Verify that the toggle in the center of the panel is set to total.
9. Click create. This creates the compliance response.
10. Click return.
Step 4: Create a Constraint on Volume Fraction Response

2. Click constraint = and enter volfrac.
3. Click response = and select volfrac.
4. Check the box next to upper bound =.
6. Click create. This creates a volume fraction constraint.
7. Click return.

1. Enter the objective panel. The switch on the left should be set to min.
2. Click response = and select comp.
3. Click loadstep and select sub.
4. Click create. This creates the compliance response as the objective.
This completes the definition of the topology optimization problem without pattern repetition.

1. Click OptiStruct to enter the panel to run OptiStruct.
name for the model, no_repeat_opt.fem, in the File name: field. The .fem extension is
4. Click Save.
The name and location of the no_repeat_opt.fem file displays in the input file: field.

Post-processing the Results Without Pattern Repetition
Step 7: Review an Iso Value Plot of Element Densities

1. Click HyperView in the OptiStruct panel. This launches HyperView in a new page with the
HyperMesh Desktop and loads the session file no_repeat_opt.mvw that is linked with the
no_repeat_opt_des.h3d file.
2. Click Close in the Message Log window that appears.
3. Click the Iso Value toolbar icon.

4. Under Result type:, select Element Densities(s) from the drop-down list.
5. Click to choose the last iteration from the Simulation list.

6. Click Apply.
7. Set Current value: to 0.4 using the slider bar in the same panel.
8. Set Show values: to Above.
9. Check the boxes beside Features and Transparent under Clipped geometry:.
An isosurface plot is displayed in the graphics window. (Note the display of each plate). Those
elements of the model with a density greater than the value of 0.4 are shown in color, the
rest are transparent.

10. Use the page delete button contained within the page control toolbar to delete the HyperView
page.
Adding Pattern Repetition Cards
Step 8: Set up Pattern Repetition

The pattern repetition cards can now be defined in HyperMesh. Once back in HyperMesh, set up
the pattern repetition.
1. From the Tool page, select the numbers panel.
3. Enter all of the following values after id=, separating them with commas:
1329
66
6
46
507
447
487
928
892
948
4. Press ENTER.
5. Click the green on button. This displays the selected node numbers.
6. Click return to exit the Numbers panel.
7. From the View menu, select the Mask browser tab menu, if it not already displayed.

8. From the Mask tab menu, select 1 under the Isolate column to display only component
collectors.

11. Select the pattern repetition subpanel using the radio buttons on the left side of the panel.
12. Double-click the desvar= and select dv1.
13. Make sure the switch is pointing to master.
14. Toggle from system to coordinates.
15. Click first and select node ID 6.
16. The blue border moves over second after the first has been selected; now choose the second
node ID 46.
17. Select the third node ID 1329.
18. Click anchor and select the node ID 66.
19. Click update on the right side to create a master DTPL card.
20. Click desvar= and select dv2.
21. Click the switch and select slave.
22. Make sure master= is pointing to dv1.
23. Set the following values: sx= 0.6, sy= 0.6, sz= 1.0.
24. Click first and select the node ID 447.
25. For second and select the node ID 487.
26. For third and select the node ID 1329.
27. For anchor and select the node ID 507.
28. Click update on the right side to create the slave DTPL card.
29. Click desvar= and select dv3.
30. Click the switch and change to slave.
31. Make sure master= is pointing to dv1.
32. Set the following values: sx= 0.3, sy= 0.3, sz= 1.0.
33. Click first and select the node ID 892.

34. For second and select the node ID 928.
35. For third and select the node ID 1329.
36. For anchor and select the node ID 948.
37. Click update on the right side to create the slave DTPL card.
The above modification identifies the first DTPL card with ID 1 (on the first component) as the
master. The DTPL’s of ID 2 (second component) and ID 3 (third component) are slaves and
dependent on DTPL of ID1. The second component is scaled 0.6 in both the x- and y-axis,
while the third component is scaled 0.3 in both the x- and y-axis with respect to the first
component.
To view the card image for the DTPL card, right-click on any of the design variables in the
Results browser and select Card Edit. The card image for dv2 is shown below.

1. From the Analysis page, click OptiStruct to run the solver.
name for the model, repeat_opt.fem, in the File name: field.
4. Click Save.
The name and location of the repeat_opt.fem file displays in the input file: field.

Post-processing New Results with Pattern Repetition
Step 10: Review an Iso Value Plot of Element Densities

1. From the OptiStruct panel, click HyperView. This launches HyperView in a new page within
the HyperMesh Desktop and loads the session file repeat_opt.mvw that is linked with the
repeat_opt_des.h3d file.
A Message Log window will appear, indicating the location of the .h3d file.
3. Click the Iso toolbar icon .

5. Select the last design under Simulation.
6. Click Apply.
7. Set current value: to 0.38 using the slider bar in the same panel.
8. Set Show: to Above.
9. Check the boxes for Features and Transparent under Clipped geometry:.
An iso surface plot is displayed in the graphics window. Those parts of the model with a
density greater than the value of 0.38 are shown in color, and the rest are transparent.
10. From the File menu, click Exit to quit HyperView.

OS-2060: Symmetry and Draw Direction Applied
Simultaneously in Topology Optimization
This tutorial demonstrates how to perform a topology optimization on an automotive control arm
with the simultaneous application of symmetry and draw direction constraints.
This tutorial uses the same optimization problem considered in Design Concept for an Automotive
Control Arm (OS-2010), except that a refined mesh will be used in order to better capture the
effect of applying symmetric and draw manufacturing constraints simultaneously. The finite
element mesh of the structural model containing the designable (blue) and the non-designable
(red) regions, along with the loads and constraints applied, is shown in the following figure.
The optimization problem is stated as:
SUBCASE 1: The resultant displacement of the point where loading is

applied must be less than 0.05 mm.

Constraints: applied must be less than 0.02 mm.

applied must be less than 0.04 mm.
Design Element density.

variables:
This tutorial covers the following exercises:

 Defining the symmetry and draw direction control parameters for optimization

Exercise
Step 1: Launch HyperMesh, Set the User Profile, and Import a File
2. Choose OptiStruct in the User Profiles dialog and click OK. This loads the user profile. It
The User Profiles GUI can also be accessed from the Preferences menu on the toolbar.
3. Click the Import Solver Deck icon and select the carm_draw_symm.fem file you saved to
your working directory from the optistruct.zip file. Refer to Accessing the Model Files.
4. Click Import.
Defining the Symmetry and Draw Direction Control Parameters for

Optimization
Step 2: Define the Symmetry and Draw Direction Manufacturing

Constraints
1. From Analysis page, enter the optimization panel.
3. Click review and select the desvar solid.
4. Select the parameters subpanel and define a minimum member size = 16.0 mm.
This forces the diameter or thickness of any structural member to be higher than 16 mm; if
this is not user-set, OptiStruct automatically selects a minimum member size based on the
average mesh size (if a manufacturing constraint is selected).
5. Click update to confirm the minimum member size set up.
6. Select the draw subpanel to set up the draw direction.
7. Set the selector under draw type: to single.
8. Select the anchor node and the first node as shown below. Together, these two nodes
define a vector in the positive Z direction. This defines that the die draw direction is along the
positive Z direction.

9. Select obstacle: as the nondesign property.
10. Select the pattern grouping subpanel to define the symmetry constraint and toggle the
pattern type: to 1-pln sym.
The symmetry constraints in topology optimization lead to symmetric designs for solid
models, regardless of the initial mesh, boundary conditions or loads. In this case, the 1-pln
sym option enforces symmetry across a defined plane. A symmetric mesh is not required, as
OptiStruct creates variables that are nearly identical across the plane(s) of symmetry. The
plane of symmetry is defined by specifying the anchor and the first nodes. The plane of
symmetry will then be perpendicular to the vector from the anchor node to the first node, and
pass through the anchor node.
11. Click anchor node, input the node id= 1, and press ENTER.
This selects the node with the ID of 1.
12. Click first node, input the node id= 2 and press ENTER. This selects the node with the ID of
2.
13. Click update to update the design variables.
Together, these two nodes define a vector in the negative Z direction. Hence, the symmetry
plane is defined as the plane perpendicular to the Z-axis (which is the same as the Y-Z
plane), and passing through the anchor node.
This completes the definition of the symmetry constraint.

This tutorial problem takes nearly one hour to run.
2. Click save as, enter carm_draw_symm_complete.fem as the file name, and click Save.
5. Make sure the memory options: toggle is set to 2000.

8. Close the HyperWorks Solver View dialog when Processing complete appears.
OptiStruct reports error messages (if any exist). The file carm_draw_symm_complete.out can
be opened in a text editor to find details regarding any errors. This file is written to the same
Post-processing Results with HyperView
Step 4: Review Contour Plot of the Density Results

Element density results are output to the carm_draw_symm_complete_des.h3d file from
OptiStruct for all iterations. In addition, displacement and stress results are output by default
into carm_draw_symm_compelte_s#.h3d files for each subcase for the first and last iterations;
where # specified the subcase ID. This section describes how to view those results in HyperView.
1. Click the HyperView button in the panel to view the results.
HyperView is launched and the results are loaded. A message window appears to inform
about the successful loading of the model and result files into HyperView. Notice that all three
.h3d files get loaded, each in a different page of HyperView.
It is helpful to view the deformed shape of a model to determine if the boundary conditions
are defined correctly, and also to find out if the model is deforming as expected. The analysis
results are available in pages 2, 3, and 4. The optimization iteration results (Element
Densities) are loaded in the first page.
3. Click the Previous Page icon until the name of the page is displayed as Design History,
indicating that the results correspond to optimization iterations.
4. Enter the Contour panel by clicking the icon on the toolbar.
Note the Result type: is Element Densities [s]; this should be the only results type in the
“file_name”_des.h3d file. The second drop-down list shows Density.
5. In the Averaging method: field, select Simple.
Note the contour is all blue because your results are on the first design step or Iteration 0.
7. Select the last iteration listed in the Results browser.

Step 5: View an Iso Value Plot on Top of the Element Densities Contour
1. From Graphics menu, click Iso, and select Element Densities as the Result type.
3. Click Apply.
An iso value plot is displayed in the graphics window. The parts of the model with densities
greater than the specified value of 0.2 are shown in the figure below.

Iso value plot of element densities
Have most of your elements converged to a density close to 1 or 0?

If there are many elements with intermediate densities, the DISCRETE parameter may need
to be adjusted. The DISCRETE parameter (set in the opti control panel on the optimization
panel) can be used to push elements with intermediate densities toward 1 or 0, so that a
more discrete structure is given.
purposes of this tutorial, the current mesh and results are sufficient.
Is the max= field showing 1.0e+00?
In this case, it is.
If it is not, the optimization has not progressed far enough. Allow more iterations and/or
decrease the OBJTOL parameter (also set in the opti control panel).
If adjusting the discrete parameter, refining the mesh, and/or decreasing the objective
tolerance does not yield a more discrete solution (none of the elements progress to a density
value of 1.0), review the set up of the optimization problem. Some of the defined constraints
may not be attainable for the given objective function (or vice versa).
The iso value appears in the graphics window update interactively when scrolling to a new
value. Use this tool to get a better look at the material layout and the load paths from
OptiStruct.
5. From the File menu, select Exit to quit HyperView.
Review
Has the volume been minimized for the given constraints?

Have the displacement constraints been met?

OS-2070: Topology Optimization of a Reduced Model using
DMIG
In this tutorial, an existing finite element model of a simple cantilever beam is used to
demonstrate how to reduce the finite element model using static reduction and also how to
perform topology optimization on that reduced model. The full cantilever beam model without
static reduction is shown here.
Cantilever beam model.
The optimization problem may be stated as:
Objective: Minimize compliance.
Constraints: Upper bound constraint of 40% for the designable volume.
Design variables: The density for each element in the design space.
Topology optimization results for the full cantilever beam model.

The part to be reduced out of the model through the static reduction model reduction technique
is referred to as a superelement. In OptiStruct, ASET or ASET1 bulk data entries are required to
indicate the boundary degrees of freedom of a superelement, meaning the set of degrees-of-
freedom where the component (being replaced by direct matrix input) connects to the modeled
structure. Both the accuracy and the cost of static reduction increase as the number of ASET
entries is increased. For example, by using static reduction, the size of the matrix to solve will
become smaller, but if the reduced matrix (DMIG) is very dense, then the solution time will
become larger than the solution time for the full model where the matrix may be sparse. Hence,
the selection of ASET entries is very important in performing an efficient analysis using DMIG.
In order to prevent the reduced matrix from being too dense, ASET entries are chosen carefully
(see the next figure) instead of creating ASET entries for all of the boundary nodes between the
design and non design spaces. Due to the small size of the problem used for this tutorial, the
selection of ASET entries may not affect the solution time.
ASET for the cantilever beam model.

 Generate a superelement
 Include the superelement in the model
 Set up the optimization in a model with a superelement
 Post-process the optimized results in HyperView

Exercise
Step 1: Launch HyperMesh and Set the User Profile

2. A User Profiles dialog will appear, select OptiStruct.
Step 2: Retrieve the cantilever_full.hm File
1. Click the Open Model icon and load the cantilever_full.hm file you saved to your
working directory from the optistruct.zip file. Refer to Accessing the Model Files.
Complete model.
Generate a Superelement
Step 3: Create ASETs (specifying boundary degrees of freedom of the

superelement assembly)
2. For Name, enter Asets.
4. From the Analysis page, select constraints.
6. Select the boundary nodes (as shown in the image before step 1) by clicking in the graphics
window.
7. Make sure dofs 1 through 6 are checked.
Dofs with a check will be assigned to the ASET.

8. Click Load Type= and select ASET.
9. Click create.
Step 4: Delete Elements Which will be Retained in the Subsequent

Optimization
The reduced stiffness matrix and load vector will be generated for only those elements that will
be reduced out (superelement). Therefore, a new model needs to be created containing just the
superelement part and the loads and boundary conditions applied directly to that part.
1. Press F2 to open the Delete panel.
2. Click the entity selection switch and select elems from the pop-up menu.
3. Click elems and select by window from the pop-up menu.
4. Move the mouse over to the graphics area and draw a window around the elements, as shown
in the figure below.
Elements to be deleted.
5. Click delete entity.

Step 5: Define a Parameter to Write out Reduced Matrices to an External

File
The PARAM,EXTOUT bulk data entry is required to activate the matrix save process. Without this
parameter, the run will proceed as normal. This parameter has two options: DMIGPCH, which will
save the matrices in an ASCII format to a .pch file and DMIGBIN, which will save the matrices in
a binary format to a .dmg file. DMIGPCH is used for this tutorial.
1. On the Analysis page, select the control cards panel.
2. Click next twice to be able to select PARAM, check the box next to EXTOUT.
3. Select DMIGPCH.
4. Click return to exit PARAM.
5. Click return to get back to the main menu.

Step 6: Save the DMIG Database
1. Click File > Save As > Model, set the directory in which to save the file and, in File name:,
enter cantilever_dmig.hm.
2. Click Save.

cantilever_dmig.fem in the File name: field.
4. Click Save.
The name and location of the cantilever_dmig.fem file displays in the input file: field.
If the analysis is successful, no error messages are reported to the shell. The analysis is
complete when the message Processing completed successfully appears in the shell. The
new results files can be seen in the directory where the OptiStruct model file was written. The
cantilever_dmig.out file is a good place to look for error messages that will help to debug
cantilever_dmig.out OptiStruct output file containing specific information on the

file set up, the set up of your optimization problem,
estimates for the amount of RAM and disk space required for
the run, information for each optimization iteration, and
compute time information. Review this file for warnings and
errors.
cantilever_dmig_AX.pch Reduced matrices (DMIG) file.
cantilever_dmig.stat Summary of analysis process, providing CPU information for

The matrices are written to the .pch file with the same format as the DMIG bulk data entry.
They are defined by a single header entry and one or more column entries. By default, the
name of the stiffness matrix is KAAX, the mass is MAAX, and the load is PAX. Since mass
matrix is not used in this tutorial, it is not written to .pch file.
The I/O Option entry, DMIGNAME, provides you with control over the name of the matrices.

Step 8: Clear the HyperMesh Database
1. From the File menu, click New.
This will clear the existing HyperMesh database.
Include the Superelement in the Model
Step 9: Re-retrieve the cantilever_full.hm file

1. Click File > Open > Models.
2. Browse to locate the file cantilever_full.hm.
The cantilever_full.hm database is loaded into the current HyperMesh session, replacing
any existing data.
Step 10: Delete the Superelement Part Reduced out Using DMIG
Since the matrices for the superelement part will be replaced by DMIG, the bulk data entries for
the nodes and elements, as well as all loads and boundary conditions that are in the
superelement, should be deleted.
1. Press F2 to open the Delete panel.
2. Click the entity selection switch and select elems from the pop-up menu.
3. Click elems and select by window from the pop-up menu.
4. Move the mouse over to the graphics area and draw a window around the elements, as shown
The elements to be deleted.

All of the loads and boundary conditions associated with those elements will be deleted
automatically.

Step 11: Set up the Topology Optimization with DMIG
1. On the Analysis page, select the control cards panel.
2. Click INCLUDE_BULK.
3. Enter the file name cantilever_dmig_AX.pch.
The reduced matrices (DMIG) will be included in OptiStruct input deck. Here you are
assuming that the topology optimization will be run in the same folder as the
cantilever_dmig_AX.pch file. If you plan to run it in a different folder, then define the full
path of this file.
4. Click return to exit INCLUDE_BULK.
5. Select K2GG.
6. Enter KAAX in the K2GG= field. This specifies that the reduced stiffness matrix with the name
KAAX has to be used (stored in the cantilever_ dmig_AX.pch file).
7. Click return to exit K2GG subpanel.
8. Select the P2G subpanel.
9. Enter PAX in the P2G= field.
10. Click return to exit P2G.
Set up the Optimization in a Model with a Superelement
Step 12: Define Design Variables for Topology Optimization

1. On the Analysis page, select the optimization panel.
2. Go to the topology panel.
4. Click desvar = and enter topo.
5. Click props.
6. Check the box next to design.
7. Click select.
8. Set the type toggle to PSHELL.
9. Click create.
10. Click parameters.
11. Toggle minmemb off to mindim = and enter 1.2.
12. Click update.
13. Click return to go back to the optimization page.

Step 13: Create Volume Fraction and Compliance Responses
1. Select responses.
2. Enter Volfrac in the response = field.
3. Set the switch below response type to volumefrac.
4. Click create.
5. Enter Compl in the response = field.
6. Turn the response type selector to compliance.
Just eight characters can be used here, since the name is used, a label is needed for the
response.
7. Click create.
8. Click return to go back to the optimization panel.
Step 14: Create Constraints on Volume Fraction

1. Click dconstraints to define the constraints.
2. Enter VFrac in the constraint = field. Only eight characters can be used here. Since the
name is used, a label is needed for the response.
3. Click response = and select Volfrac.
4. Select upper bound = by clicking in the box preceding it.
5. Click in the text box and enter the value 0.4.
6. Click create. The volume fraction constraint is now created.
Step 15: Define Minimize Compliance as Objective

1. Click objective to define the objective function.
2. Set the switch in the upper left corner to min.
3. Click response and select Compl.
4. Click loadstep.
5. Select the loadstep step.
6. Click create.
7. Click return twice. This completes your optimization problem setup.

1. Click File > Save As > Model.
2. Set the directory in which to save the file and, in File name:, enter cantilever_opti.hm.
3. Click Save.

cantilever_opti.fem in the File name: field.
4. Click Save.
The name and location of the cantilever_opti.fem file displays in the input file: field.
model file was written. The cantilever_opti.out file is a good place to look for error
cantilever_opti.hgdata HyperGraph file containing data for the objective

function, percent constraint violations, and constraint
values for each iteration.
cantilever_opti.HM.comp.cmf HyperMesh command file used to organize elements

into components based on their density result values.
cantilever_opti.HM.ent.cmf HyperMesh command file used to organize elements

into entity sets based on their density result values.
cantilever_opti.html HTML report of the optimization giving a summary of

the problem formulation and the results from the final
iteration.
cantilever_opti.oss OSSmooth file with a default density threshold of 0.3.

You may edit the parameters in the file to obtain the
desired results.
cantilever_opti.out OptiStruct output file containing specific information on

the file set up, the set up of the optimization problem,
estimates for the amount of RAM and disk space
required for the run, information for all optimization
iterations, and compute time information. Review this
cantilever_opti.res HyperMesh binary results file.
cantilever_opti_des.h3d HyperView binary results file to post-process element

density for topology optimization.

cantilever_opti_s1.h3d HyperView binary results file to post-process anything
from displacement to stress results.
cantilever_opti.sh Shape file for the final iteration. It contains the

material density, void size parameters, and void
orientation angle for each element in the analysis. The
.sh file may be used to restart a run and, if necessary,
run OSSmooth files for topology optimization.
cantilever_opti.stat Summary of analysis process providing CPU

Post-process the Optimized Results in HyperView
Element density and element thickness results are output from OptiStruct for all iterations. In
addition, displacement and stress results are output for the first and last iteration by default. This
Step 18: Contour Plot of Element Densities

3. Under Result type:, select Element densities (s) from the drop-down list and review the
Density component.
4. In the Averaging method: field, select Simple.
5. Click Apply.
The resulting contours represent the element densities field resulting from the applied loads
and boundary conditions.

Step 19: Add an Iso Surface Plot of the Densities
The iso surface feature can be a very useful tool for post-processing density results from
OptiStruct. For models with solid design regions, this feature becomes a vital tool for analyzing
density results.

2. Set the Result type: to Element densities (s).
3. Make sure that Show is set to Above.
4. Click Apply.
5. Also check the boxes next to Features and Transparent.
6. The current value can be changed to see more material. Enter a value of 0.3 in the Current
value: field.
You can also move the slider bar to change current value of Element densities.
The isosurface post-processing feature in HyperView is an excellent tool for viewing the
density results from OptiStruct.
Click and move the slider bar (currently pointing to a value representing 0.3) for your density
to change the isosurface.
The isosurface is available in the graphics window interactively update when you change it to
a new value. Use this tool to get a better look at the material layout and the load paths from
OptiStruct.

OS-2080: Topology Optimization of a Hook with Stress
Constraints
In this tutorial, a topology optimization is performed on a bracket-hook modeled with shell
elements. The structural model with loads and constraints applied is shown in the figure below.
The objective is to minimize the volume of the material used in the model subject to certain
stress constraints. Topology optimization is performed to find the optimal material placement and
reduce the volume. This optimization normalizes each element according to its density and lets
you remove elements that have low density.
FEA model
The structural model is loaded into HyperMesh Desktop. The constraints, loads, subcases and
material properties are already defined in the model. The topology design variables and the
optimization problem setup will be defined using HyperMesh, and OptiStruct is used to determine
the optimal material layout. The results can then be reviewed in HyperView.
Objective function: Minimize mass.
Constraints: Minimum Member Size = 1.0
Von Mises stress < 1000
Design Variables: The density of each element in the design space.
The exercises covered in this tutorial include:

 Setting up the optimization problem in HyperMesh

Exercise
Step 1: Launch HyperMesh and Set the User Profile


1. Select the Import Solver Deck icon . An Import tab is added to your tab menu.
2. Make sure the File type: is set to Optistruct.
3. Click the Select file icon to locate and open the hook.fem file you saved to your working
directory from the optistruct.zip file. Refer to Accessing the Model Files.
4. Click Open.
Setting up the Optimization Problem in HyperMesh
Step 3: Set the View

1. In the Model browser, right-click on Component.
2. Click Isolate Only.
3. Click to fit the model to the screen. This displays only the components in the graphics
area.
Step 4: Create the Design Variables for Topology Optimization

1. From the Analysis page, select the optimization panel.
2. Click the topology panel.
3. Select the create radio button.
4. Click props and select the check boxes by the Design and Base properties.
5. Click select.
6. Enter the name shells in the desvar= field.
7. Set the type: to PSHELL.
8. Click create.
9. Select the parameters subpanel.
10. Toggle minmemb off to mindim=.
11. For mindim=, enter 1.0.

12. Under stress constraint, toggle from none to stress=.
13. For stress=, enter 1000.
14. Click update.
A topology design variable (DESVAR) is created.

This sets the optimization to optimize the shell elements in the Design and Base components to
create structural members with minimum member size of 1.0 unit in width with thicknesses that
vary between zero and the thickness of the shell. The optimization will use 1000 as the maximum
stress for any element within the design region when validating the design.
Step 5: Create the Responses

A detailed description is available in the OptiStruct User's Guide, under Responses.
1. Select the optimization panel.
2. Click responses to go to the Responses panel.
3. Click response = and enter mass.
4. Click the response type switch and select mass from the pop-up menu.
5. Click create. A response, mass, is defined for the total volume of the model.
Step 6: Define the Constraints

In this step, there is no need for additional constraints, since setting a stress target in the design
variable serves as a constraint that limits the amount of material used in the optimized model.

In this step, the objective is to minimize the mass response defined in Step 5.
1. Select the objective panel.
2. Click the switch in the upper left corner of the panel and select min from the pop-up menu.
3. Click response = and select mass from the response list.

4. Click create. The objective function is now defined.
5. Click return twice to return to the main panel.
Step 8: Save the HyperMesh Database

1. Click the Save .hm File icon . A Save file browser window opens.
2. Select the directory where you want to save the database and enter the name for the
database, hook_opt.hm, in the File name: field.
3. Click save.
Step 9: Submit the Job to OptiStruct

name for the model, hook_opt.fem, in the File name: field. .fem is the suggested extension
for OptiStruct input decks.
4. Click Save.
The name and location of the hook_opt.fem file displays in the input file: field.
5. Make sure the memory options: toggle is set to memory default.
7. Make sure the export options: toggle is set to all.
model file was written. The hook_opt.out file is a good place to look for error messages that
Step 10: View an Isosurface Plot of the Density Results

1. Click Results in the HyperWorks Solver View window that displays the progress of the
optimization run.
2. The results of the Optimization run and the corresponding Linear Static subcases are loaded
into HyperView.
3. Click the Contour plot icon .
4. For Result type:, select Element Densities (s) and click Apply.

5. In the Results browser, select Design and Iteration 26 (or your final iteration number from
the drop-down menu).

7. Select the Result type: Element densities (s).
8. In the Results browser, set the Design Iteration to the last one, and click Apply.

9. Change the value of the Current value: field (in the Iso panel) to see the results with
varying density values.
The isosurface post-processing feature is an excellent tool to use for viewing the density results from OptiStruct
(Current value=0.4528).
You will see the isosurface in the graphics window interactively update when you change it to
a new value. Use this tool to get a better look at the material layout and the load paths from
OptiStruct.
Step 11: View the Element Stress Results

1. Click the Next Page toolbar icon to move to the page which displays results from the
Linear Static Analysis of Subcase 1.
The next page, which has results loaded from hook_opt_s19.h3d is displayed; this contains
the linear static results for the 1st subcase.
3. Select the first pull-down menu below Result type: and select Element
stresses(2D&3D)(t).
4. Select the second pull down menu and select vonMises.
5. In the Results browser, set the displayed Iteration to the last one.
6. Click Apply.

7. Similarly, you can review the results from the other subcases.
von Mises Stress results shown
Notice that there are some local regions where the stresses are still high; this is because
topology stress constraints should be interpreted as global stress control or global stress
target.
The functionality has some ways to filter out the artificial or local stresses caused by point
loading or boundary conditions, but those artificial stresses will not be completely removed
unless the geometry is changed by shape optimization.
Note: There might still be high local stress regions which can be
improved more effectively with local shape and size
optimization.

OS-2090: Topology Optimization with Extrusion Constraints
The extrusion constraints method allows you to perform an optimization problem with extrusion
constraints to obtain a constant cross section along a given path, particularly in the case of parts
manufactured through an extrusion process. By using extrusion manufacturing constraints in
topology optimization, constant cross-section designs can be obtained for solid models –
regardless of the initial mesh, boundary conditions, or loads.
This tutorial show the steps involved in defining topology optimization over a curved beam,
simulating a rail, over which a vehicle is moving. Both ends of the beam are supported. A point
load is applied over the length of the rail in seven independent load cases, simulating the
movement of the vehicle. The rail should be manufactured through extrusion. The steps taken to
define the topology design space, the extrusion-manufacturing constraints and the optimization
parameters (responses, objective and constraints) using HyperMesh are shown.
In this tutorial, you will perform topology optimization on a curved beam so that the extruded rail
will be stiffer and have less material. The optimization problem is stated as:
Objective: Minimize weighted compliance
Constraints: Volume fraction < 0.3
Design The density of each element in the design space

variables:
The DTPL (Design Variable for Topology Optimization) card is used for this optimization.
The finite element mesh of the curved beam is shown in the following.
Finite element mesh of the curved beam showing loads and boundary conditions

 Setting up Extrusion Constraints in HyperMesh
 Setting up the optimization problem
 Post-processing the optimization results with extrusion constraints

Exercise
Step 1: Launch HyperMesh, Set the User Profile, and Retrieve a File
2. Click the Import Solver Deck icon . An Import tab is added to the tab menu.
3. Select the rail_complete.fem file you saved to your working directory from the
Setting Up Extrusion Constraints in HyperMesh
Step 2: Create the Topology Design Variables

panel.
4. Click desvar=, enter design_solid, and press ENTER.
5. Click props , select new_solid from the list of props, and click
select.
6. Set type: as PSOLID.
7. Click Create. A topology design space definition, design_solid, has been created. All
elements organized in this design property collector are now included in the design space.
Step 3: Define Extrusion Problem and Extrusion Path

1. From the Tool page, enter the numbers panel.
2. Click nodes and select by id.
3. Enter numbers 71559,70001 and press ENTER, check the display box, then click on.
The numbers 71559 and 70001 should be displayed on the screen.
4. Click return.
5. From the Analysis page, enter optimization panel.
6. Click topology.
7. Make sure the extrusion subpanel is selected using the radio buttons on the left-hand side of
the panel.
8. Double-click desvar = and select design_solid.

9. Switch the toggle to no twist.
Extrusion constraints can be applied to domains characterized by non-twisted cross-sections
or twisted cross-sections by using the NOTWIST or TWIST parameters, respectively.
10. Select the primary path by selecting node list and clicking by path.
It is necessary to define a ‘discrete’ extrusion path by entering a series of grids. The curve
between these grids is then interpolated using parametric splines. The minimum amount of
grids depends on the complexity of the extrusion path. Only two grids are required for a linear
path, but it is recommended that at least 5-10 grids be used for more complex curves.
11. First, select node 71559 and then select node 70001.
12. Click update.
Extrusion path definition
A line of nodes starting from 71559 and ending with node 70001 should be highlighted,
indicating the extrusion path.
It is not required to select as many nodes to define the curve. This is an exercise to show that
the nodes by path option can also be used.
Setting Up the Optimization Problem
Step 4: Create the Volume Fraction and Weighted Compliance Response

3. Click on the switch below response type and select volumefrac from the pop-up menu.
5. Click create. A response, volfrac, is defined for the total volume of the model.
6. Click response = and enter wcomp1.

7. Click on the switch below response type and select weighted comp from the pop-up menu.
8. Click loadsteps and select step1, step2, step3, step4, step5, step6, and step7 from the
extended entity selection menu that appears.
9. Click return.
10. Click create. A response, wcomp1, is defined for the weighted compliance.
Step 5: Create Constraints on Volume Fraction Response

In this step, setting the upper and lower bound constraint criteria for this analysis is
demonstrated.
Constraint set up

5. Select response= and set it to volfrac.
6. Click create.

3. Click response= and select wcomp1.
4. Click create.
5. Click return to exit the optimization panel.
Step 7: Submit the Job to OptiStruct

name for the model, rail_complete_extrusion.fem, in the File name: field. .fem is the
suggested extension for OptiStruct input decks.

4. Click Save.
The name and location of the rail_complete_extrusion.fem file displays in the input file:
field.
5. Make sure the memory options: toggle and set upper limit in Mb = to 2000 Mb.
7. Make sure the export options: toggle is set to all.
model file was written. The rail_complete_extrusion.out file is a good place to look for
error messages that will help to debug the input deck if any errors are present. Solving time
for this extrusion constraint problem takes about 2 hours.
Post-processing the Optimization Results with Extrusion Constraints
Step 8: Load Results File and Post-process

1. Click HyperView to launch a new HyperView window with the results from the optimization.
2. In the Subcase Selection section of the Results browser, change Iteration 0 which
shows your results at the beginning of the optimization to the last iteration, as shown below,
which has the final analysis results for this optimization.
3. Go to the Iso icon and set the Result type: to Element Densities.
4. Click Apply.
5. Set Current Value: to 0.3.
6. Click Apply.
Isosurface plot of a curved beam rail layout of the topology optimization with extrusion constraints
As expected, the result with manufacturing extrusion constraints permits a constant cross
section for the entire length of the model.

Step 9: View a Section Cut of the Extrusion Component
The Section Cut panel allows you to cut planar sections through a model. This is useful when you
want to see details inside of a model.
1. Go to the Section Cut panel on the View toolbar on the left side of the graphics area next
to the Results browser.
2. Click Add to add a new section cut.
3. For Define plane:, select Y Axis.
4. Click Base to active it, and click on any corner at the center of the model.
5. Click Apply.
6. Move the slider bar below Y Axis to scroll though the model.
7. Under Display options:, use the slider bar next to Width to change the Cross section
width.
Contour plot of a section cut on x-z plane of the curved beam.
As expected, the result with manufacturing extrusion constraints shows constant cross section
through the length of the model.

OS-2095: Frequency Response Optimization of a Rectangular
Plate
This tutorial demonstrates the capability of frequency response optimization using OptiStruct.
Initially, an existing finite element (FE) model of a flat plate is retrieved and modal frequency
response analysis is performed to derive the peak magnitude. A dynamic response optimization is
then performed on the same plate to obtain a new design.
The new design gives an optimized material layout with a minimized peak response. Post-
processing tools will be used in HyperView to visualize iso-plots, magnitude, and phase of the
complex displacement results.
Plate model
Objective: Minimize volume
Constraints: Max FRF Disp. < 600 mm
Design The density for each element in the design space

variables:
The following exercises are covered:

 Setting up a modal frequency response analysis in HyperMesh
 Post-processing FRF results
 Setting up a topology optimization
 Post-processing the topologic results

Exercise
Step 1: Launch the HyperMesh Desktop, Set the User Profile and Import
a File
2. A User Profiles GUI will appear, select OptiStruct.
The User Profiles GUI can also be accessed from the Preferences menu on the toolbar.
4. Click the Import Solver Deck icon .
5. Click the File icon and select the frf_response_input.fem file you saved to your working
6. Click Import. The frf_response_input.fem OptiStruct input file is loaded into the current
HyperMesh session.
7. Click Close to exist the Import panel.
Setting Up a Modal Frequency Response Analysis in HyperMesh
Step 2: Create the SPC and Unit Load Collectors

In this section, the model is constrained at one edge. A unit vertical load will be applied acting
upwards in the positive z-direction at a point on a free edge corner of the plate. First, create the
two load collectors spcs and unit-load.
1. Click the Model tab to active the Model browser.

8. Click Color and select a different color from the color palette.

1. In the Model browser, expand Load Collector, right-click on spcs, and click Make Current.
2. From the Tool page, select the numbers panel.

3. Click nodes and select by id from the extended entity selection menu.
4. Enter the following numbers one by one: 1, 2, 3, and 4.
5. Click on.
6. Click return.
7. From the Analysis page, enter the constraints panel.
panel.
10. Select the nodes with the following IDs: 1 and 2.
11. Constrain All Dofs.

13. Again, select nodes and select node by id, node 4.
14. Uncheck all dofs except dof3 and click create.

1. From the Model browser, right-click on unit-load, and click Make Current.
2. From the Analysis page, enter the constraints panel.
5. Select node number 3 on the plate by clicking on it (see figure).
6. Un-check all dof except dof3, and click the = to the right of dof3 and enter a value of 20.
7. Click on the load types field and select DAREA.
8. Click create.
9. Click return.
FE plate model with dofs

2. Click Name and enter tabled1.

4. For Card Image, select TABLED1 from the list.
5. Click TABLED1_NUM = and input a value of 2.
6. Click to open the TABLED1_NUM = dialog.

7. Click in the input field below y(1), and enter a value of 1.0.
8. Click in the input field below x(2), and enter a value of 1000.0.
9. Click in the input field below y(2), and enter a value of 1.0. Notice x(1) was not changed
from 0.0.
10. Click Close to close the dialog.

This provides a frequency range of 0.0 to 1000.0 with a constant load over this range.

2. Click Name and enter rload2.
4. For Card Image, select RLOAD2 from the list.
5. Click EXCITEID to activate the option, click Loadcol.
6. In the Select Loadcol dialog, select the collector unit-load from the list of collectors and click
OK.
7. Click TB to activate the option, click Loadcol.
8. In the Select Loadcol dialog, select collector tabled1 and click OK.
9. For TYPE, set LOAD. This defines the input as a force.

2. Click Name and enter freq5.
4. For Card Image, select FREQi from the list.

5. Check the FREQ5 checkbox and enter NUMBER_OF_FREQ5= as 1 and
FREQ5_MAX_NUMBER_OF_FR= as 3.
6. Click to open the NUMBER OF FREQ = dialog.

7. Click F1 and input a value of 1.0.
8. Click F2 and input a value of 1000.
9. Click FR(0) and input a value of 1.
10. Click FR(1) and input a value of 0.8.
11. Click FR(2) and input a value of 0.2.
12. Click Close to close the dialog.

This defines a set of frequencies for the modal method of frequency response analysis by
specification of a frequency range and fractions of the natural frequencies within that range,
as shown in the following image.

Step 8: Create a LoadCollector EIGRL to Use as the Modal Method
2. Click Name and enter eigrl.
4. For Card Image, select EIGRL from the list.
5. Click ND and enter a value of 17 in the field below it.
This specifies the eigenvalue extraction of the first 17 frequencies using the Lanczos method.
Step 9: Create an OptiStruct Loadstep (also referred to as a subcase)

2. Click name = and enter subcase1.
3. Click the type: switch and choose freq.resp (modal) from the pop-up menu.
4. Check the box preceding SPC.
5. Click on the entry field and select spcs from the list of load collectors.
6. Check the box preceding METHOD (STRUCT).
7. Click on the entry field and select eigrl from the list of load collectors.
8. Check the box preceding DLOAD.
9. Click on the entry field and select rload2 from the list of load collectors.
10. Check the box preceding FREQ.
11. Click on the entry field and select freq5 from the list of load collectors.
12. Click create.

spc, the unit load in the load collector rload2; with a set of frequencies defined in load
collector freq5 and modal method defined in the load collector eigrl.
It is recommended to do a modal analysis before any FRF simulation. Here, this step is
suppressed to focus on Frequency Response Analysis setup.
13. Click edit and check the box next to RESVEC.
14. Set TYPE to APPLOAD with OPTION set to YES.

Step 10: Create a Set of Nodes for Output of Results
1. From the Analysis page, enter the entity sets panel.
2. Click name = and enter SETA. Set the Card Image to SET_GRID.
3. Set the set type: switch to non-ordered.
4. Click the entity: switch and choose nodes from the pop-up menu.
5. Make sure that the yellow selection type box is set to nodes and select the node 3.
This is the node where the load was applied.
6. Click create.
A message appears stating that the entity set has been created.
With FRF simulation, the amount of data generated can easily create big results files. It is a
good practice to work with sets where you can specify only the points of interest. This reduces
the CPU time and the amount of data to be saved.
7. Click return.
Step 11: Create a Set of Outputs and Include Damping for Frequency
Response Analysis
1. On the Analysis page, click the control cards panel and enter the
GLOBAL_OUTPUT_REQUEST panel.
2. Check DISPLACEMENTS. A new set of options appears in the work area screen.
3. Click the field box for FORM(1) and select PHASE from the pop-up menu.
4. Click the field box for OPTION(1) and select SID from the pop-up menu.
A new field appears in yellow.
5. Double-click the yellow SID(1) box and select SETA from the pop-up selection on the bottom
left corner.
set 1.
6. Click return to exit the GLOBAL_OUTPUT_REQUEST menu.

7. Select the FORMAT subpanel. A new window appears in the work area screen.
8. Click number_of_formats = and input a value of 2.
9. On the extended menu in the work area, click the FORMAT_V1 field box and select OPTI
from the pop-up menu for the second time.
10. Click return to exit the FORMAT menu.
11. Click next to move to another page.

12. Select the PARAM subpanel, and check the box next to G. A new window appears in the work
area screen.
13. Click below G_V1, and input a value of 0.05 into the field box.
This specifies that the system will have a constant damping coefficient equal to 2.5% of the
Critical Damping Ratio.
15. Select the OUTPUT subpanel. A new window appears in the work area.
16. Verify KEYWORD is set to HGFREQ.
17. Click on the box beneath FREQ and select LAST from the pop-up selection.
18. Leave number_of_outputs set equal to 1.
19. Click return to exit the OUTPUT subpanel.
20. Click return to exit the control cards menu.
21. Click File > Save > Model to save the model.
22. Enter frf_response_input.hm for the model name and click Save.

2. Click save as following the input file: field, select the directory where you would like to write
the model file and enter the name for the model, frf_response_analysis.fem, in the File
name: field.
3. Click Save.
The name and location of the frf_response_analysis.fem file displays in the input file:
field.
8. Click OptiStruct. This launches the OptiStruct analysis job.
model file was written. The frf_response_analysis.out file is a good place to look for error

Post-processing FRF Results
Step 13: Viewing the Peak Displacement of the Baseline Model in

HyperGraph
This section describes how to view displacement results (.mvw file) in HyperGraph and also how
to understand the displacement output (.disp file) from this run. The results file (.h3d) contains
only the displacement results for the three nodes specified in the node set output.
1. Click HyperView in the OptiStruct panel to load the results from the analysis into the next
page.
2. Click Close to close the message log menu which appears that informs about the result files
loaded into HyperView.
3. In the HyperView window, select File on the menu bar, and select Open > Session. An Open
Session File window opens.
4. Find the directory where the job was run and open the file
frf_response_analysis_freq.mvw. If you launched from the OptiStruct panel, click Yes to
discard the current session.
Two graphs are displayed. The graph title shows Subcase 1(subcase1)-Displacements of grid
3.
The top graph shows Phase Angle verses Frequency. The bottom graph shows Displacement
Response verses Frequency.
5. Click the Define Curves button and delete the X Trans and Y Trans curves.
The excitation is applied on Z direction then, the main effect will be detected on this direction.

6. Click the Curve Attributes button and change the line attribute to continue .
7. On the same panel, click Symbol Attributes and select the square symbol.
8. Click the Axes button and change to Vertical to edit the vertical axis.
9. Click the Scale and Tics (Magnitude) tab and change it to Logarithmic.
10. Change the Min: to 5 and the Max: to 200000.
11. Click the Scale and Tics (Phase) tab and change the Tics per axis: to 7.
12. Click Horizontal X or change it using the drop-down list and change the Min: to 5 and the
Max: to 1000.
Frequency Response Function FRF (Node 3, Z-Displacement)

13. Click Coordinate info .
14. Click the Magnitude radio button.
15. Click the maximum button to see the maximum Y-magnitude ~ 15055 in the table. The peak
displacement of the baseline model.
Step 14: Create the Design Variables for Topology Optimization

1. Return to HyperMesh by changing the client selector to HyperMesh . Reload the
frf_response_input.hm file and save it as frf_response_optimization.hm.
2. From the Analysis page, enter optimization panel.
5. Click desvar = and enter plate.
6. Click props.
7. Check the box next to Design and click select.
8. Set the type: toggle to PSHELL.
9. Set the base thickness toggle to base thickness =.
10. Click base thickness = and enter 0.15.
11. Click create.
12. Click the parameters radio button.
13. Toggle minmemb off to mindim and then enter 2.
14. Toggle maxmemb off to maxdim and then enter 6.

15. Click update.
A topology design space definition, plate, has been created. All elements organized into the
design component collector are now included in the design space. The thickness of these
shells can vary between 0.15 (base thickness defined above) and the maximum thickness
defined by the T (thickness) field on the PSHELL card.
The object of this exercise is to determine where to locate ribs in the designable region.
Therefore, a non-zero base thickness is defined, which is the original thickness of the shells.
The maximum thickness, which is defined by the T field on the PSHELL card, should be the
allowable depth of the rib.
Currently, the T field on the PSHELL card is still set to 0.15 (the original shell thickness), this
needs to be changed to a higher value to create a design space where the material can be
removed.
17. In the Model browser, expand the Property folder.
18. Click Design to open the Entity Editor.
19. Replace 0.150 in the T field with 1.000.
Step 15: Create Responses

A detailed description of the available responses can be found in the OptiStruct User's Guide
under Responses.
Two responses will be defined here:
 Frequency Response Displacement (Constraint)
 Total Volume Response (Objective)
2. Click response = and enter frfdisp.
3. Click the response type: switch and select frf displacement.
4. Make sure the component switch is set to magnitude and the function switch is set to all
freq.
5. Click the yellow nodes button and choose node ID 3.
6. Choose the dof3 radio button.
7. Click create. A response, frfdisp, is defined for the maximum magnitude on dof3.
8. Click response = and enter volume.
9. Click the response type: switch and select volume from the pop-up menu.
10. Make sure the toggle is set to total.
11. Click create. A response, volume, is defined for the volume of the design space.
12. Click return to go to the optimization panel.

Step 16: Create the Constraints
The maximum displacement criterion for the load case in this problem is 600mm.
1. Select the dconstraints panel from the optimization panel
2. Click constraint= and enter constr.
3. Click response= and select frfdisp from the response list.
4. Check the box to the left of upper bound =.
5. Click upper bound = and enter the value 600.
6. Click loadstep and select subcase1.
7. Click create.

1. Select the objective panel from the optimization panel.
2. Click response = and select volume response.
3. Click create.
4. Click return twice to exit the panel.

for the model, frf_response_optimization.fem, in the File name: field, and click Save.
The name and location of the frf_response_optimization.fem file displays in the input
file: field.
model file was written. The frf_response_optimization.out file is a good place to look for

Important files written to the directory include:
frf_response_optimization.hgdata HyperGraph file containing data for the objective

function, percent constraint violations and constraint
for each iteration.
frf_response_optimization.his_dat The OptiStruct history file containing iteration number,

a objective function values, and percent of constraint
violation for each iteration.
frf_response_optimization.HM.comp HyperMesh command file used to organize elements

.cmf into components based on their density result values.
This file is only used with OptiStruct topology
optimization runs.
frf_response_optimization.HM.ent. HyperMesh command file used to organize elements

cmf into entity sets based on their density result values.
This file is only used with OptiStruct topology
optimization runs.
frf_response_optimization.html HTML report of the optimization, giving a summary of

the problem formulation and the results from the final
iteration.
frf_response_optimization.oss OSSmooth file with a default density threshold of 0.3.

You may edit the parameters in the file to obtain the
desired results.
frf_response_optimization.out OptiStruct output file containing specific information on

the file setup, the setup of your optimization problem,
estimates for the amount of RAM and disk space
required for the run, information for all optimization
iterations, and compute time information. Review this
frf_response_optimization.sh Shape file for the final iteration. It contains the

material density, void size parameters and void
orientation angle for each element in the analysis. The
.sh file may be used to restart a run and, if necessary,
to run OSSmooth files for topology optimization.
frf_response_optimization_des.h3d The .h3d file is a compressed binary file, containing

both model and optimization history data results. It
can be used to post-process results in Altair
HyperView.
frf_response_optimization_s#.h3d The .h3d file is a compressed binary file, containing

both model and first and last iteration data results for
the # load case. It can be used to post-process results
in Altair HyperView.
frf_response_optimization.stat Summary of analysis process, providing CPU

information for each step during the analysis process.

Post-processing the Topologic Results
Element Density and Element Thickness results are output from OptiStruct for all iterations. This
section describes how to view an iso-plot of the new design in HyperView.
Step 19: View a Static Plot of the Density Results

1. Click the HyperView button in the OptiStruct panel.
2. In the HyperView window, select File on the menu bar, and select Open > Session. An Open
Session File window opens.
3. Find the directory where the job was run and open the file frf_response_optimization.mvw.
5. Click the Contour toolbar button .
6. Set the last Load Case Simulation by clicking the Subcase Selection box above the
Results browser.
7. Change the averaging method to Simple.

8. Click Apply in the contour panel.
for the selected iteration. The last design iteration gives the optimized material layout.

Contour of the baseline model (final design iteration)
Step 20: Compare the Peak Displacement of the Optimization Run

1. From the File menu, select Open.
2. Open the analysis session FRF_response_analysis_freq.mvw.
3. Click the Build Plots icon to prepare to add curves on top of the existing analysis
information.
4. For the Data File:, load the optimization file with the final iteration analysis in it:
frf_response_optimization_s2.h3d.
5. For Subcase:, select the last iteration. Leave the X Type: as Frequency. Select Y Type:
Displacement (Grids), Y Request: N3, and Y Component: X,Y, and Z.
6. Click Apply to overlay the new information onto the original plot.

Original and final design results for the plate

OS-2098: Topology Optimization of an Excavator Arm Model
This tutorial demonstrates how to set up an optimization problem of an MBD system using the
equivalent static load method (ESL). The model is setup in HyperMesh, and the Topology
optimization job is run with OptiStruct. The Objective of the optimization is to maximize the
stiffness of the Lower arm of an excavator model, while keeping the mass to less than an
allowable value. The model units are kg, N, m and s.
Excavator model
Objective: Minimize the maximum compliance in an ESL loadstep.
Constraints: Upper bound on volume fraction.
Design variables: Element density of elements in the lower arm (flexible body)
component.

 Review an MBD transient analysis
 Change one of the rigid body to a flexible body
 Set up and run a topology optimization on a MBD system using the equivalent static load
method
 Post-process optimization results using HyperView

Exercise
Step 1: Launch HyperMesh, Set the User Profile, and Retrieve the File
2. A User Profiles GUI will appear, select OptiStruct and click OK. This loads the user profile. It
3. Click the Open Model icon .

4. Select the Excavator_MBD.hm file you saved to your working directory from the
The Excavator_MBD.hm database is loaded into the current HyperMesh session.
Step 2: Submit the Transient MBD Simulation in OptiStruct

The model Excavator_MBD.hm already has the excavator MBD analysis set up with all the bodies
defined as rigid bodies. Next is to run the analysis and look at the animation.
1. From Analysis page, click OptiStruct.
name for the model, excavator_MBD_analysis.fem, in the File name: field. For OptiStruct
input decks .fem is the suggested extension.
7. Click Save.
8. Change the options: field so that it is blank.
appears.
If the analysis was successful, no error messages are reported to the shell and messages
appear in the shell indicating that the analysis is complete.

Post-processing the MBD Results in HyperView
Step 3: Post-process the transient MBD analysis

1. When the message ANALYSIS COMPLETED is received in the dialog, close the dialog.
2. Click HyperView from within the OptiStruct panel. This will automatically load the results for
the current run into HyperView.
A message window appears to inform about the successful loading of the model and result
files.
3. Click Close to close the Message Log window.
4. Click the icon to start the animation and review the MBD model.
5. Close the HyperView window using the Delete Page icon and return back to HyperMesh.
Step 4: Change the Rigid Body into a Flexible Body

In this step, you are going to define topology optimization on the body Lower_Arm. It is originally
modeled as a rigid body and needs to be converted to a flexible body for the optimization.
2. Select the update option.
3. Double-click body= and select Lower_Arm.
4. Click review.
The lower arm component is highlighted. Body type PRBODY is shown for type=, indicating
that lower arm is modeled as a rigid body. You will update this body to a flexible body type,
and also define topology optimization on this body.
6. Enter 20 under the nmodes= to increase the number of modes included in the CMS method
to 20.
Updating body type for Lower_Arm
7. Click update.
A message appears in the lower left corner to indicate that the body has been update to a
new type.
8. Click return.

Step 5: Define Topology Design Variable
2. Select topology to enter the topology panel
panel.
4. Click DESVAR=, enter L_Arm_Topology, and press ENTER.
5. Click props and choose lowerarm from the list of props; click
select.
6. Choose type: PSOLID.
7. Click create.
8. Activate the parameters option.
9. Click the toggle next to minmemb off to activate mindim= and set the value to 0.05.
10. Click update.
Minimum member size control of 0.05 meter has been applied on this topology optimization
problem.
Step 6: Define Responses

Two responses types are defined: a compliance response for the objective function and volume
fraction for the constraint.
1. You should already be in the optimization panel; select the responses panel.
2. Click response = and enter Volfrac.
3. Select the switch below response type and select volumefrac from the pop-up menu.
4. Toggle total to by entity.
5. Click props in the cyan border and select lowerarm.
6. Click create. A volume fraction response, Volfrac, is defined for the topology design volume.
7. Click response = and enter Comp.
8. Select the switch below response type and select compliance from the pop-up menu.
9. Make sure the entity selection toggle is set to total.
10. Click create. A compliance response, Comp is created.

Step 7: Define Constraints on Volume Fraction Response
An upper bound constraint is to be defined for the volume fraction response defined in the
previous sections.
1. Select the dconstraints panel.
2. Click constraint = and enter Vol_Constr.
4. Click upper bound = and enter 0.5.
5. Click response = and select Volfrac from the list of responses.
6. Click create. A constraint is defined on the response Volfrac. The constraint will force the
volume fraction used in the design space to be less than 0.5.
Step 8: Define the Objective Reference

1. Click obj reference.
2. Enter MAX_Comp in the dobjref= field.
3. Check pos reference; this sets the value 1.0.
4. Check neg reference; this sets the value -1.0.
5. Click response and select Comp.
6. Set the loadsteps selection option to all to make sure the design objective reference includes
compliances from all the load steps that are calculated by the ESL method.
7. Click create.
Step 9: Define an Objective Function

The objective is to minimize the maximum compliance of the equivalent static loadsteps.
1. Choose the objective panel.
2. Click the left-most toggle and select minmax.
3. Click dobjrefs and select MAX_Comp.
4. Click create.

1. From the File menu, click Save As > Model.
2. Select the directory in which to save the file and, in File name:, enter
excavator_MBD_Topology.hm.
3. Click Save.
Step 11: Submit the ESL Optimization Job in OptiStruct

name for the model, excavator_MBD_Topology.fem, in the File name: field. For OptiStruct
input decks .fem is the suggested extension.
7. Click Save.
appears.
optimization is complete when the message OPTIMIZATION HAS CONVERGED appears in
the shell.
If the job was successful, the new results file can be seen in the directory where the input file
was saved. In addition to the regular output files, you will also see a text file named
excavator_MBD_Topology.eslout. This file is a good source to review the process of the ESL
optimization.
Note that depending on the type of hardware, the optimization run time may be substantial.
Post-processing Optimization Results using HyperView
Step 12: View element density results for the last iteration
1. When the message OPTIMIZATION HAS CONVERGED is received in the command window,
close the DOS window.
2. Click HyperView from within the OptiStruct panel. HyperView is launched and the results are
loaded.
files into HyperView.

4. Select the final Outerloop iteration in the Results browser as shown below to load the
optimized topology results.
5. Click the Iso Value panel toolbar icon .

6. Set the Result type: to Element densities (s).
7. Click Apply to see only the elements that have elemental density higher than what is shown
in the field for Current value:.
8. Enter a value of 0.5 in the Current value: field.

9. Make sure that Show values: is set to Above.
10. Using the Model browser on the left, display only the Lower_Arm component.
11. Check the boxes next to Features to visualize the complete design space.
12. You can also move the slider bar to change current value of Element densities to look at
material distribution for different density threshold values.

Topography Optimization
OS-3000: Topography Optimization of a Plate Under Torsion

This tutorial demonstrates how to perform topography optimization of a plate under torsion. A
finite element model of the design space with loads and constraints applied is shown in the image
below. It is assumed that the part is to be formed using a stamping process. The objective is to
minimize the displacement of the node where the force is applied in the positive z-direction. Only
the shape of the plate can be changed to achieve the objective, not the thickness.
Finite element model of the design space with loads and constraints.
A finite element model (shown in the above figure) is loaded into HyperMesh. The constraints,
load, material properties, and subcase (loadstep) of the model are already defined. Topography
design variables and optimization parameters are defined and the OptiStruct software determines
the optimal reinforcement patterns. The results are viewed as animations of the contours of
shape changes of the design space. Finally, the use of the grouping patterns is shown; based on
the shape changes suggested by OptiStruct, a possible pattern is chosen for ease of
manufacturing.
Objective: Minimize nodal displacement at grid point where loading is

applied.
Design Shape variables generated automatically on the designable space

variables: aligned with the elements normal.

 Setting up a topography optimization in HyperMesh
 Post-processing topology optimization results
 Introducing a manufacturing constraint in the optimization process

Exercise
Step 1: Launch the HyperMesh Desktop, Load the User Profile and
Retrieve the File
2. Choose OptiStruct in the User Profiles dialog and click OK. This loads the OptiStruct user
profile. It includes the appropriate template, macro menu, and import reader, paring down
the functionality of HyperMesh to what is relevant for generating models for OptiStruct.
3. From the File menu, click Open
4. Select the torsion_plate.hm file you saved to your working directory from the
5. Click Open. The torsion_plate.hm database is loaded into the current HyperMesh session,
Step 2: Check the Thickness of the Component

1. From the Model browser, expand the Property entities.
2. Right-click on design and select Card Edit.

A PSHELL card image panel should appear. OptiStruct stores information regarding shell
thicknesses on the PSHELL card.
3. Ensure that the thickness, T, is set to the value 1.0.
Setting Up a Topography Optimization in HyperMesh
Step 3: Define Design Variables for Topography Optimization

For topography optimization, a design space and a "bead" definition need to be defined. The
following section outlines how this is done. For further information on "bead" definition, refer to
the DTPG card in the Reference Guide.
1. From the Analysis page, enter optimization the panel.
2. Select the topography panel.
panel.
4. Click desvar= and enter topo.
5. Click the highlighted props.
7. Click create to create the shape design variables for the selected component.
8. A topography design space definition, topo, has been created. All elements organized into the
'design' component collector are now included in the design space.
9. Select the bead params subpanel using the radio buttons on the left-hand side of the panel.

10. The field next to desvar = should contain the name of the newly created design space by
default. If it does not, click desvar = and select topo from the list of topographical design
spaces.
11. Click minimum width= and enter 5.0. This parameter controls the width of the beads in the
model. The recommended value is between 1.5 and 2.5 times the average element width.
12. Click draw angle= and enter 60.0 (this is the default). This parameter controls the angle of
the sides of the beads. The recommended value is between 60 and 75 degrees.
13. Click draw height= and enter 4.0. This parameter sets the maximum height of the beads to
be drawn.
14. Check the box next to buffer zone. This parameter establishes a buffer zone between
elements in the design domain and elements outside the design domain.
15. Make sure the draw direction: toggle is set to normal to elements.
This parameter defines the direction in which the shape variables are created.
16. Make sure the boundary skip: switch is set to load & spc. This tells OptiStruct to leave
nodes at which loads or constraints are applied out of the design space.
17. Click update.
A "bead" definition has been created for the design space topo. Based on this information,
OptiStruct will automatically generate bead variable definitions throughout the design variable
domain, as shown on the DTPG card of the Reference Guide.
18. Select the bounds subpanel using the radio buttons on the left-hand side of the panel.
19. Ensure that topo is in the field next to desvar =. If it is not, click desvar = and select topo
from the list of topographical design spaces.
20. Click upper bound and enter 1.0 (this is the default). Upper bound on variables controlling
grid movement (Real > LB, default = 1.0). This sets the upper bound on grid movement
equal to UB*HGT.
21. Click lower bound and enter 0.0 (this is the default).
22. Click update. The upper bound sets the upper bound on grid movement equal to UB*HGT
and the lower bound sets the lower bound on grid movement equal to LB*HGT.
Step 4: Define the Responses

A detailed description can be found in the User's Guide under Responses. Define one response for
the objective: displacement at the node where the force is applied.
2. Click response = and enter displace.
3. Select the switch below response type and select static displacement from the pop-up
menu.
4. Click nodes and select by id from the extended entity selection menu that pops up.
5. Enter 2500 and press the ENTER key. The node where the force is applied is now selected.

6. Select dof3.
dof1, dof2, and dof3 refer to translation in the X, Y, and Z directions.
dof4, dof5, and dof6 refer to rotation about the X, Y, and Z axes.
total disp is the resultant of the translational displacements in x, y, and z directions.
total rotation is the resultant of the rotational displacements in x, y, and z directions.
7. Click create. A response, displace, is defined for the z-displacement of node 2500.

In this example, the objective is to minimize the displacement response defined in the previous
section.
1. Enter the objective panel from the optimization panel.
2. Click the switch in the upper-left corner of the panel, and select min from the pop-up menu.
3. Click response = and select displace from the response list. A loadstep button appears in
the panel.
4. Click loadstep and select torsion from the subcase (loadstep) list.

name for the model, torsion_plate.fem, in the File name: field. The .fem extension is
4. Click Save.
The name and location of the torsion_plate.fem file displays in the input file: field.
6. Set the run options toggle to optimization.
7. Set the memory toggle to memory default.
model file was written. The torsion_plate.out file is a good place to look for error messages

Important files for a topography optimization include:
torsion_plate.grid An OptiStruct file where the perturbed grid data is written.
torsion_plate.hgdata HyperGraph file containing data for the objective function,

constraint functions, design variables, and response functions for
each iteration.
torsion_plate.hist An OptiStruct output file for xy plotting containing the iteration

history of the objective function, maximum constraint violation,
design variables, DRESP1 type responses, and DRESP2 type
responses.
torsion_plate.html HTML report of the optimization, giving a summary of the

torsion_plate.out The OptiStruct output file containing specific information on the

file set up, the set up of the optimization problem, estimate for
the amount of RAM and disk space required for the run,
information for each optimization iteration, and compute time
flagged from processing the torsion_plate.fem file.
torsion_plate_des.h3d HyperView binary results file for information on shape changes.
torsion_plate_s1_h3d HyperView binary results file for displacement and stress results
for subcase 1.
torsion_plate.sh Shape file for the final iteration. It contains the material density,
void size parameters, and void orientation angle for each
element in the analysis. The .sh file may be used to restart a run
and, if necessary, run OSSmooth files for topology optimization.
torsion_plate.stat Summary of analysis process, providing CPU information for each

Post-processing Topology Optimization Results
Shape contour information is output from OptiStruct for all iterations. In addition, Displacement
and Stress results are output for the first and last iteration by default. This section describes how
to view those results using HyperView.
Step 7: View a Static Plot of Shape Contours

1. From the OptiStruct panel, click the HyperView button. This launches HyperView within the
HyperMesh Desktop and loads the torsion_plate_des.h3d and torsion_plate_s1.h3d files
reading the model and optimization results.
3. Click the Contour icon on the toolbar to enter the contour panel.

4. Set Result type: to Shape Change (v) and type to Mag.
5. Click to choose the last iteration from the Simulation list. A deformed plate appears.
6. Click Apply.
Is the max= field showing 4.0e + 00?
In this case, it is. If it is not, your optimization has not progressed far enough. Decrease the
OBJTOL parameter (set in the opti control panel on the optimization panel). This value,
4.0e+00, comes from the draw height defined earlier.
Contour plot showing the reinforcement pattern at the last iteration (converged solution)

Step 8: View a Transient Animation of the Shape Contour Changes
A transient animation of contour shapes will give a good idea of the shape changes happening
through different iteration.
1. Verify that the animate mode menu is set to Transient .
2. Click to start the animation.

3. Click to open the Animation Controls panel.
4. With the animation running, use the slider bar below Max Frame Rate: on the left side of the
panel to adjust the speed of the animation.
5. Click to pause the animation.

The displacement and stress results from the first and last iterations (default) are given in the
torsion_plate_s1.h3d file.
1. Click the forward arrow icon to go to the next page. This page has the subcase information
from the torsion_plate_s1.h3d file.
2. Verify that the animate mode menu is set to Linear Static. For a better visual of what it
happening with this model, turn on mesh lines and contour the results.
3. Click the Deformed icon on the toolbar to enter the panel.
4. Set Result type: to Displacement(v).
5. Select the first iteration (Iteration 0) in the Results browser, as shown below.
6. Set the animation mode to Linear Static .

7. Click to start the animation.
8. Click to go to the Animation Controls panel.

9. With the animation running, use the slider bar below Max Frame Rate: on the left side of the
panel to adjust the speed of the animation.
A deformation animation of the original model is shown in the graphics window.
Does the deformed shape look correct for the boundary conditions you applied to the mesh?
10. Click to stop the animation.

11. Use the Page Delete icon contained within the page control toolbar to delete the HyperView
page.
Introducing a Manufacturing Constraint in the Optimization Process
Next, pattern grouping will be added as a constraint for manufacturability.

The configuration obtained in the previous example (see the contour plot showing the
reinforcement pattern at the 17th iteration) might be difficult to manufacture. It does give an
idea of what kinds of patterns are likely to optimize the structure (in this case -- to minimize the
displacement at the selected node).
A possible pattern, suggested by the static contour plot obtained in the previous exercise, is to
use channels parallel to a diagonal. In this example, you choose the diagonal emerging from the
node where the load is applied.
Step 10: Add Pattern Grouping Constraint

1. Once back at the HyperMesh page, click return to exit the OptiStruct panel.
2. From the Analysis page, click optimization to enter the panel.
3. Click topography to enter the panel.
4. Select the pattern grouping subpanel using the radio buttons on the left-hand side of the
panel.
5. Click desvar = and choose topo from the list of topographical design spaces.
6. Click the pattern type: switch and select linear.
7. Make sure the sub-type: switch is set to basic.
8. Click anchor node and select the node at the corner where the load is applied by clicking on
it in the graphics window.
9. HyperMesh automatically moves the blue halo around the first node; select the node in the
opposite corner by clicking on it in the graphics window.

Pattern grouping node location.
10. Click update.


1. From the Analysis page, click OptiStruct to enter the panel.
name for the model, torsion_pattern.fem, in the File name: field. The .fem extension is
4. Click Save.
The name and location of the torsion_pattern.fem file displays in the input file: field.
6. Click the run options switch and select optimization.
7. Set the memory toggle to memory default.
model file was written. The torsion_pattern.out file is a good place to look for error
View the new results as before. Also check the objective value for the zero-th and last
iteration in the .out file. How does the final value for the objective compare to the final value
obtained using 'none' option for pattern grouping?

Step 12: View a Static Plot of Shape Contours
Repeat the steps in the previous exercise to view the contour plot of the shape change.
Contour plot showing the reinforcement pattern with pattern grouping constraint at the last iteration

OS-3010: Topography Optimization of an L-bracket
This tutorial focuses on the topography optimization of an L-bracket modeled with an attached
mass. The bracket is modeled with shell elements. The objective is to maximize the frequency of
the first mode by introducing beads or swages to the bracket. This can be achieved by using
topography optimization. The model is shown in the figure below. The regions around the holes
are specified as non-designable, while the bulk of the bracket is available for developing
stiffening beads.
L-bracket layout.
Objective: Maximize 1st frequency mode.
Constraints: Bead dimensions and layout.
Design variables: Perturbation of nodes normal to the shell's mid-plane.

 Setting up a topography optimization in HyperMesh
 Post-processing topography results

Exercise
Step 1: Launch the HyperMesh Desktop, Set the User Profile, and
Retrieve the File
4. Select the Lbkttopog.hm file you saved to your working directory from the optistruct.zip
5. Click Open.
Setting Up a Topography Optimization in HyperMesh
Step 2: Create Design Variables for Topography Optimization

For topography optimization, a design space and a bead definition need to be defined. The
following section outlines how this is done. For further information on bead definition, refer to the
DTPG card in the Reference Guide.
In this tutorial, the values of a bead width of 15mm, a bead height of 5mm, and draw angle of 85
degrees will be used. Symmetry of the bead pattern should be forced along the symmetry line of
the design space.
2. Click the topography panel.
4. Click desvar= and enter topo.
5. Click props.
7. Click create to create the shape design variables for the selected component. A topography
design space definition, topo, has been created. All elements organized into the design
component collector are now included in the design space.
8. Select the bead params subpanel using the radio buttons on the left side of the panel.
9. By default, the field next to desvar = should contain the name of the newly created design
space; if not, click desvar = and select topo from the list of topographical design spaces.
10. Click minimum width= and enter 15. This parameter controls the width of the beads in the
model. Recommended value is between 1.5 and 2.5 times the average element width.
11. Click draw angle= and enter 85. This parameter controls the angle of the sides of the beads.
The recommended value is between 60 and 75 degrees.

12. Click draw height= and enter 5. This parameter sets the maximum height of the beads to be
drawn.
13. Check the box next to buffer zone. This parameter establishes a buffer zone between
elements in the design domain and elements outside the design domain.
14. Set boundary skip: to load & spc. This tells OptiStruct to leave nodes at which loads or
constraints are applied out of the design space.
15. Set the draw direction: toggle to normal to elements. This parameter defines the direction
in which the shape variables are created.
16. Click update.
A bead definition has been created for the design space topo. Based on this information,
OptiStruct will automatically generate circular bead variable definitions throughout the design
variable domain as shown on the DTPG card of the Reference Guide.
17. Select the pattern grouping subpanel using the radio buttons on the left-hand side of the
panel.
18. By default, the field next to desvar = should contain the name of the newly created design
19. Click the pattern type: switch and select 1-pln sym from the pop-up menu.
20. Click anchor node and enter 337.
21. Click first node and enter 613.
22. Click update.
23. Select the bounds subpanel using the radio buttons on the left side of the panel.
24. By default the field next to desvar = should contain the name of the newly created design
25. Click upper bound and enter 1.0 (default).
26. Click lower bound and enter 0.0 (default).
27. Click update. The upper bound sets the upper bound on grid movement equal to UB*HGT
and the lower bound sets the lower bound on grid movement equal to LB*HGT.
Step 3: Create First Mode as a Response

A detailed description on Responses can be found in the OptiStruct User's Guide under
Responses.
2. Click response = and enter FREQ.
3. Select the switch below response type and select frequency from the pop-up menu.
4. Click Mode Number: and enter 1.
5. Click create. A response, FREQ, is defined for the frequency of the 1st mode.

Step 4: Maximize the First Mode as the Objective
In this step, the objective is to maximize the frequency response defined in the previous step.
1. Select the objective panel from the optimization panel.
2. Click the switch in the upper left corner of the panel, and select max from the pop-up menu.
3. Click response = and select FREQ from the response list. A loadstep button appears in the
panel.
4. Click loadstep and select STEP from the subcase (loadstep) list.

1. Select the Files panel toolbar icon.
2. Select the hm file subpanel.
3. Click save as to set the directory in which to save the file and, in File name:, enter
Lbkttopog.hm.
4. Click Save.


lbkttopog.grid An OptiStruct file where the perturbed grid data is written.
lbkttopog.hgdata HyperGraph file containing data for the objective function, constraint
functions, design variables, and response functions for each iteration.
lbkttopog.hist An OptiStruct output file for xy plotting containing the iteration history
of the objective function, maximum constraint violation, design
variables, DRESP1 type responses, and DRESP2 type responses.
lbkttopog.html HTML report of the optimization, giving a summary of the problem

formulation and the results from the final iteration.
lbkttopog.oss OSSmooth file with a default density threshold of 0.3. You may edit the
parameters in the file to obtain the desired results.
lbkttopog.out The OptiStruct output file containing specific information on the file set
up, the set up of the optimization problem, estimate for the amount of
RAM and disk space required for the run, information for each
optimization iteration, and compute time information. Review this file
for warnings and errors that are flagged from processing the
lbkttopog.fem file.
Lbkttopog_des.h3d HyperView binary results file for information on shape changes.
Lbkttopog_s1_h3d HyperView binary results file for displacement and stress results for
subcase 1.
lbkttopog.sh Shape file for the final iteration. It contains the material density, void
size parameters and void orientation angle for each element in the
analysis. The .sh file may be used to restart a run and, if necessary,
run OSSmooth files for topology optimization.
lbkttopog.stat Summary of analysis process, providing CPU information for each step
name for the model, Lbkttopog.fem, in the File name: field. The .fem extension is used for
4. Click Save.
The name and location of the Lbkttopog.fem file displays in the input file: field.
6. Click the run options: switch, and select optimization.
model file was written. The lbkttopog.out file is a good place to look for error messages that

Post-processing Topography Results
Shape contour information is output from OptiStruct for all iterations. In addition, Eigenvector
results are output for the first and last iteration by default. This section describes how to view
those results in HyperView.
Step 7: View a Transient Animation of Shape Contour Changes

1. From the OptiStruct panel, click HyperView. This launches HyperView in a new page within
the HyperMesh Desktop and loads lbkttopog_des.h3d.
A Message Log window appears indicating the location of the .h3d file.
3. Set the animation mode menu to Transient, as shown below:
4. Click the icon to start the animation.
5. Click the icon for Animation Controls.

6. Move the Max Frame Rate: slider to adjust the animation speed.
Step 8: Review the Optimized Frequency Difference

1. Click the Next Page arrow to proceed to the results for first and the last iterations on page
3.
2. Select the first iteration listed in the Results browser (Iteration 0).
The frequencies of all of the modes requested from the analysis are shown in the Subcase
drop-down.
Frequency of the first mode for Iteration 0

Look at the frequency values for the last iteration. Upon observation, the frequency for the
first mode has changed from around 48 Hz to around 93 Hz for first and last iterations,
respectively.
Frequency of the first mode for Iteration 12
Step 9: Apply Optimized Topography to the Model

1. Click the Next Page arrow to navigate back to the Design History page (page 2).
2. Click the icon to set the Current time: to the last step.
Topography results
3. From the File menu, select Export > Solver Deck.

4. Set Select format: to OptiStruct.
5. For File name:, select your working directory for the field and name the file deformed.fem
before clicking OK.
6. Click Yes to the pop-up dialog.
7. Import this file into HyperMesh with overwrite on and your final shape will now exist in the
model. (Some organization might need to happen at this point).

OS-3020: Automatic Recognition of Bead Results from
Topography Optimization of an L-bracket
The objective of this tutorial is to run the completed model from the previous tutorial, OS-3010
post-process the results, and use the autobead functionality.
The objective of autobead is to offer automation of bead interpretation so that a prototype-like
design could be created automatically.
L-bracket layout

 Execute a topography optimization
 Post-process a topography result with HyperView
 Generate a new model based on a topography result

Exercise
Execute a Topography Optimization
Step 1: Launch HyperMesh, Set the User Profile, and Import a File
3. Click the Import Solver Deck . An Import tab is added to your tab menu.
4. Set the Import type: to FE Model.
5. Choose the File type: OptiStruct.
6. For File:, click the Select file icon to open the OptiStruct file browser.
7. Select the Lbkttopog_bead.fem file you saved to your working directory from the
8. Click Import. The Lbkttopog_bead.fem OptiStruct input file is loaded into the current
HyperMesh session.
9. Click Close to exit the Import tab.
Step 2: Run the OptiStruct Job

name for the model, Lbkttopog_bead.fem, in the File name: field. The .fem extension is
used for OptiStruct input decks.
4. Click Save.
model file was written. The lbkttopog_bead.out file is a good place to look for error

Post-process a Topography Result with HyperView
Shape contour information is output from OptiStruct for all iterations. In addition, eigenvector
results are output for the first and last iteration by default. This section describes how to view
those results in HyperView.
Step 3: Review a Transient Animation of Shape Contour Changes

1. While in the OptiStruct panel, click HyperView.
2. When the Message Log dialog appears, click Close.
3. Click File > Open Session and select Lbkttopog_bead.mvw to load the results session into
the HyperView client.
4. Ensure that the animation mode is set to Transient and click the Play icon to start the
animation.
An animation of the shape changes over the course of the optimization is displayed.
5. To slow down the animation, move the Animation Controls slider underneath the Current
Frame Indicator and adjust the Max Frame Rate slider.
Step 4: Review the Optimized Frequency Value

1. On the toolbar, click the Next Page icon .
2. Set the animation mode to Modal .
3. Click the Load Case and Simulation Selection area above the Results browser.
4. Toggle between Iteration 0 and Iteration 12 in the Load case: list.
Notice the topography optimization yields an almost 100% increase in the frequency of the
first mode by reviewing the Mode 1-F value in the Simulation list. To animate the model, click
the modal icon, next to the director's chair.
Generate a New Model Based on a Topography Result
Step 5: Apply the Optimized Topography to the Model

1. Once back to HyperMesh, click return to exit the OptiStruct panel.
2. From the Post page, click the apply results panel.
3. Click simulation = and select DESIGN - ITER 12 from the list of simulations.
4. Click data type = and select Shape Change.

5. Choose displacements using the radio buttons on the left-hand side of the panel.
6. Click the component selection switch and select total disp.
7. Click nodes and select all from the extended entity selection switch.
8. Click mult = and enter 1.
9. Click apply.
The final nodal positions are applied to the structure. Be careful with saving the model now,
the HyperMesh database has changed. This model can be used for further analyses. Results
can now be viewed on the final shape.
10. Click reject to get back the original shape and return to go back to main menu.
Step 6: Extract/Import Final (concept) Geometry Using OSSmooth and

autobead
1. From the Post page, select the OSSmooth panel.
2. For file:, select the OptiStruct base input file from which to extract the final geometry.
3. For output:, select the IGES output format of the final geometry.
 The default output format is STL. Other format options are: Mview, Nastran, IGES, and
H3D.
 If you select IGES as the output format, select the output unit type. The default is mm
(millimeters).
4. Select load geom to load the new geometry into the current HyperMesh session.
5. Check the box next to autobead and enter a value of 0.3 for the bead threshold:.
6. Leave the rest of the options at their default settings.
7. Click OSSmooth.
8. Click Yes to overwrite.
The new geometry will be automatically loaded into the existing HyperMesh file, turn off the
display of all the elements to view the new concept geometry.
9. OSSmooth can automatically create geometry based on the new mesh. Click FE > Surf to
generate new geometry from the optimization results.
10. Click Save and Exit to continue.
11. Using the Mask tab, click Isolate for Geometry and on Hide for Load Collectors.

12. Use the Model browser to uncheck geometry display for the original components design
and fixed.

New geometry for the optimized part displayed in the HyperMesh Desktop graphics window

OS-3030: Random Response Optimization
A topography optimization with random response is performed on a flat plate in this tutorial. A
random response analysis has been set up. As shown in the following image, the flat panel is
constrained through an RBE2 element. Two frequency-varying accelerations are applied on the
independent node of the RBE2 element as excitations. They are correlated through a cross-
spectral density. The objective of the optimization is to minimize the maximum (minmax) Power
Spectral Density (PSD) acceleration in X direction at the center of the panel.
Model review

 Create a topography optimization with PSD response in HyperMesh
 Post-process the results in HyperView and HyperGraph

Exercise
Load the Model in HyperMesh
Step 1: Load the OptiStruct User Profile and Import the Model
the functionality of HyperMesh to what is relevant for generating OptiStruct models.
3. Click the Import panel toolbar icon . The File type: is OptiStruct.
4. Click the open file icon . A Select OptiStruct file browser window opens.
5. Select the panel.fem file you saved to your working directory from the optistruct.zip file.
6. Click Open. The location of panel.fem displays in the file: field.
7. Click Import. The panel.fem database is loaded into the current HyperMesh session.
Create Random Response Optimization
Step 2: Create design variables for topography optimization

In this exercise, the design space is composed of the shell elements with the property PSHELL_5.
A minimum bead width of 0.4, a bead height of 1, and draw angle of 60 degrees is used in the
bead definition. A 2-plane symmetrical pattern grouping constraint is defined to generate a
symmetrical bead design.
2. Click topography to enter the Topography Optimization panel.
3. Select the create subpanel by clicking the radio button on the left side of the panel.
4. Click desvar = and enter plate.
5. Click the highlighted props.
6. Check the box next to PSHELL_5 and click select.
7. Click create to create the topography design variable.
8. Select the bead params subpanel using the radio button.
9. Click desvar= and select plate.
10. Enter the bead parameters, as shown in the following image.

11. Click update.
12. Select the pattern grouping subpanel using the radio button.
13. Click desvar= and select plate.
14. Under pattern type:, click on the switch and select 2-plns sym.
15. For anchor node, first node and second node, click the switch to change from node id to
coordinates.
16. Enter the values as shown below to define a 2-plane symmetry constraint.
17. Click update.

18. Go to the bounds subpanel using the radio button.
19. Set Upper Bound = 1.0 and Lower Bound = -1.0.
20. Click update.
21. Click return and go back to the Optimization Setup panel.
The design variables for the topography optimization have been created. The design response
and objective need to be created next.
Step 3: Create the design response for random response optimization

The PSD acceleration in X direction at the center of the plate is defined as design response for
the random response optimization.
1. Starting from the Optimization Setup panel, click responses.
2. For the response = field, enter psdaccl.
3. Select the switch below response type, select psd acceleration.
4. Click the highlighted nodes field.

5. Click by id and enter 67.
Node 67 is close to the center of the plate.
6. Select dof1 for the PSD acceleration in X direction.
7. Click randps= and select RANDPS100, which specifies the Power Spectral Density for the
random response analysis.
8. Leave the frequency selection as all freq.
9. Have the region set to no regionid.
10. Click create and return to go back to Optimization Setup panel.
Step 4: Create the objective

The design objective of the random response analysis is to minimize the maximum PSD
acceleration at node 67. DOBJREF is first defined for minmax optimization.
1. Click obj reference in the Optimization Setup panel.
2. In the dobjref= field, enter psdacclref.
3. Click response= and select the response psdaccl.
4. Check the box next to neg reference= and leave the value as -1.0.
5. Check the box next to pos reference= and input the value 1.0e6.
The values of the response, psdaccl, will be normalized by the negative and positive
reference values.
6. Select all to apply this DOBJREF entry to all subcases.
7. Click create.
8. Click return and go back to Optimization Setup panel.
9. Click objective.
10. Toggle the option to minmax.
11. Click the highlighted dobjrefs and select psdacclref.
12. Click create and return back to the Analysis page.
Submit the Job

name for the model, panel_complete.fem, in the File name: field.
4. Click Save.
The name and location of the panel_complete.fem file displays in the input file: field.

5. Toggle memory options: to memory default.
6. Toggle run options: to optimization.
7. Toggle export options: to all.
8. Click OptiStruct. This launches the job. If the job is completed successfully, you should see
new results files in the directory from which panel_complete.fem was selected.
Post-process the Results
HyperView is used to view the bead design generated from the topography optimization.
“XYPUNCH, ACCE, PSDF/67(T1RM)” was used to output the PSD accelerations to punch files. The
PSD plot from punch output can be viewed with HyperGraph. The RMS and peak PSD values are
output to the .peak file and can be viewed with text editor.
Step 6: View the Bead Patterns in HyperView

click HyperView. HyperView is launched and the optimization results (_des.h3d) are loaded.
A message window appears to inform of the successful model and result files being loaded
into HyperView.
4. Select Shape Change (v) as the result type.
6. Click Apply. The shape change contour is shown in the window, as follows.

Results of random response optimization
Step 7: View the PSD Results in HyperGraph

1. Launch HyperGraph.
2. Click the Build Plots icon .

3. Load the panel_complete.pch file.
4. The X Type is Frequency (Hz).
5. Select Group 1 Acceleration as Y Type.
Node id 67 and X_Translation are highlighted.
6. Click Apply.
The PSD plot of acceleration in X direction on node 67 at iteration 0 is loaded.
7. Go to the Axes panel and convert the linear plot of PSD acceleration to logarithmic plot for
the y-axis.
8. Select the last group acceleration as Y Type and repeat steps 6 and 7.
The PSD plot of acceleration in X direction on node 67 at final iteration is loaded.
How much was the peak value of the PSD acceleration reduced?

PSD acceleration plots of the original and the optimized designs.

Combination Optimization
OS-3100: Combined Topology and Topography Optimization of

a Slider Suspension
This tutorial performs a combined topology and topography optimization on a slider suspension
using OptiStruct. The objective is to increase the stiffness of the slider suspension and make it
lighter at the same time. This requires the use of both topology and topography optimization.
The finite element model of the slider suspension contains force and boundary conditions. The
structure is made of quad elements and has both linear statics and normal modes subcases
(loadsteps). Steps are described to define topology and topography design space, responses,
constraints, and objective function. The optimized structure will be stiffer for both linear statics
and normal modes subcases and will have beads and less material.
Disk drive slider
Problem Statement
Perform combined topology and topography optimization on a disk drive slider suspension to
maximize the stiffness and weighted mode. The lower bound constraint on the seventh mode is
12 cycles/ms.
Objective Minimize the combined weighted compliance and the weighted

function: modes.
Constraints: 7th Mode > 12 cycles/ms.
Design variables: Element densities and nodes topography.

 Set up a combined optimization using HyperMesh
 Post-process optimization results in HyperView

Exercise
Step 1: Set the User Profile and Import a Finite Element Model
your tab menu.
4. Choose the proper File type: OptiStruct.
5. Click the Select Files icon and open the combined.fem file you saved to your working
6. Click Open.
7. Click Import.
8. Click Close to close the Import tab menu.
Step 2: Set up the Topology Design Space

2. Click topology.
3. Verify that you are in the create subpanel.
4. Click props, select 1pin, and click select.
5. For desvar =, enter the name pin.
6. Change type: to PSHELL.
7. Verify base thickness is 0.0.
8. Click create.
9. Click props, check only 3bend and click select.
10. For desvar =, enter the name bend.
11. Verify base thickness is 0.0.
12. Click create.
13. Click return.
Step 3: Set up the Topography Design Space

1. Click topography.
2. Verify that you are in the create subpanel.
3. Click props, check 1pin and 3bend, and click select.
4. For desvar=, enter the name tpg.

5. Click create.
6. Select the bead params subpanel.
7. For minimum width=, enter a value of 0.4; for draw angle=, 60; and for draw height=,
0.15.
8. Toggle draw direction: to normal to elements.
9. Toggle boundary skip: to load & spc.
10. Activate buffer zone.
11. Click update.
Use 1-plane symmetric beads, as it is the simplest and can be symmetric at the same time.
12. Go to the pattern grouping subpanel and set pattern type: to 1-plane sym.
13. Click anchor node, enter 41, and press ENTER.
14. Click first node, enter 53, and press ENTER.
15. Click update.
16. Select the bounds subpanel.
17. Verify the bounds are as follows:
upper bound = 1.0, lower bound = 0.0.
18. Click update.
19. Click return.
Step 4: Create Responses for Optimization

Since this problem is a combined linear static and normal mode analysis, you are trying to
minimize compliance and increase frequency for the two load cases, while constraining the
seventh frequency. Therefore, two responses are defined: comb and freq.
2. For response =, enter the name freq.
3. Change the response type to frequency.
4. For Mode Number, enter a value of 7.
5. Click create.
6. For response =, enter the name comb.
7. Change the response type to compliance index.
8. Click loadsteps and activate force.
9. Make sure that the option to define normalizing factor is toggled to autonorm.

10. Enter the mode numbers and their corresponding weights using the following chart.
Mode Weight
1 1.0
2 2.0
3 1.0
4 1.0
5 1.0
6 1.0
11. Click create.

12. Click return.
Step 5: Define Constraints

2. For constraint =, enter the name frequency.
3. Check lowerbound and enter a value of 12.
4. Click response= and select freq.
5. Click loadsteps and click the frequency checkbox, then click select.
6. Click create.
7. Click return.

1. Click objective.
2. Verify that objective is set to min.
3. Click response = and select comb.
4. Click create.
5. Click return.
Step 7: Define the Optimization Control Cards

1. Click opti control.
2. Click the checkbox for MINDIM to activate it and enter a value of 0.25.
Minimum member size is generally recommended to avoid checkerboarding. It also ensures
that the structure has the minimum dimension specified in this card.

3. Click the checkbox for MATINIT to activate it and enter a value of 1.0.
MATINIT declares the initial material fraction in a topology optimization. MATINIT has several
defaults based upon the following conditions: If mass is the objective function, the MATINIT
default is 0.9. With constrained mass, the default is reset to the constraint value. If mass is
not the objective function and is not constrained, the default is 0.6.
Step 8: Set Up Mode Tracking

During optimization, the frequencies and their mode shape may change order due to the change
in element densities and other design changes. To overcome this, define a parameter to track the
frequencies so that only the intended frequencies are tracked during optimization runs.
1. Click control cards and click next twice.
2. Click PARAM.
3. In the panel, check MODETRAK.
4. In the card panel, set MODET_V1 to Yes.
5. Click return.
Note that the PARAM button is now green, indicating that it is active.
Step 9: Submit the OptiStruct Job

2. For export options: toggle to all.
3. For run options: toggle to optimization.
4. For memory options: toggle to memory default.
name for the model, comb_complete.fem, in the File name: field. For OptiStruct input decks
.fem is the suggested extension.
7. Click Save.
8. Click OptiStruct. This launches an OptiStruct run in a seperate shell (DOE or UNIX) which
appears.

Post-process Optimization Results in HyperView
Step 10: Post-process the Shape Change Result (Topography)

1. When the message Job Complete is received in the HyperWorks Solver View window, close
the command window to return to HyperMesh.
2. In HyperMesh, click HyperView (from the OptiStruct panel) to launch HyperView. The
HyperView GUI window opens and the results get loaded automatically in HyperView.

4. By clicking on the drop-down menus next to each option, for Result type, select Shape
Change(v); for Scale, select Scale factor; and for Type, select Uniform.
5. For Value:, enter 1.0.
6. Below the Undeformed shape: section, click the drop-down menu next to Show and select
None.
7. Click Apply to display the shape change because of topography optimization.
8. In the Result browser, open the Load Case and Simulation Selection drop-down menu
and select the 25th iteration.
Topography result applied on slider suspension.
Step 11: Contour of the Optimum Material Distribution (Topologic)

2. Select the first drop-down list below Result Type and select Element Thicknesses(s).
3. Select the second drop-down list below Result Type and select Thickness.
4. Select Simple in the field below Averaging method.

Step 12: Add Iso-surface of the Optimum Material Distribution
(Topologic)
1. Click the Iso Value toolbar icon .
2. For the first drop-down list below Result Type, select Element Densities (s) and Density
in the second list.
3. Make sure that Above is selected in the field next to Show values.
4. Click Apply to display the density iso-surface plot.
5. Enter 0.3 in the field next to Current value and press ENTER.
An iso-surface plot is displayed in the graphics window. Those parts of the model with a
density greater than the value of 0.3 are shown in with density contour, the rest are removed
from the display.

OS-3200: Optimization-driven Design of a Composite Aircraft
Underbelly Fairing
Composite materials have become popular in the application of aircraft structures. The need for
innovative designs has posed a great challenge. This tutorial discusses the optimization-driven
design approach of a composite aircraft underbelly fairing using OptiStruct.
The design takes a three-phased approach:
Phase 1 Concept design synthesis
Free-size optimization identifies the optimal ply shapes and locations of
patches per ply orientation.
Phase 2 Design fine tuning
Size optimization identifies the optimal thicknesses of each ply bundle.
Phase 3 Ply stacking sequence optimization
Shuffling optimization obtains an optimal stacking sequence.
The process expands upon three important and advanced optimization techniques; free-size
optimization, size optimization and ply stacking sequence optimization. By stringing these three
techniques together, OptiStruct offers a unique and comprehensive process for the design and
optimization of composite laminates. The process is automated and integrated in HyperWorks by
generating the input data for a subsequent phase automatically from the previous design phase.
Problem Definition
The finite element model of the underbelly fairing was generated in HyperMesh, as shown in the
following image. Material properties for carbon-fiber were considered and represented using an
orthotropic material (MAT8) for two dimensional elements. The fairing was modeled with four ply
orientations (0°, 90°, 45° and -45°) of uniform thickness. The SMEAR option is applied in the
PCOMP card to eliminate stack biasing.
Two load cases were defined to represent the operating conditions – an internal uniform pressure
loading of 0.02MPa and an external gravity loading of 6.75g. The fairing was considered to be
riveted along its edges to the surrounding structure. Two equipment masses, weighing 2Kg and
3Kg each, were mounted to the fairing through RBE3 elements. The fairing has been designed
considering two major performance criteria: the first natural frequency is at least 20Hz, and the
maximum strain is less than 1000 micro-strain.
Model overview

Phase 1 – Concept Design Synthesis (free-size optimization)
In free-size optimization, the thickness of each designable element is defined as a design

variable. Applying this concept to the design of composites implies that the design variables are
the thickness of each ‘Super-ply’ (total designable thickness of a ply orientation) per element.
The following optimization setup is defined in the concept design phase to identify the stiffest
design for the given fraction of the material. To obtain more meaningful results, manufacturing
constraints are incorporated and carried through all design phases automatically.
Objective: Minimize the weighted compliance of the two load cases.
Design Element thicknesses of each ply orientation.

variables:
Manufacturing  Ply percentage for the 0s no more than 80% exist.

constraints:  The manufacturable ply thickness is 0.1.
 A balance constraint that ensures an equal thickness distribution for the
+45s and -45s.
Step 1: Load the OptiStruct user profile and import the model into
HyperMesh
functionality of HyperMesh to what is relevant for generating models OptiStruct.
4. The File type: is OptiStruct.
6. Select the fairing.fem file you saved to your working directory from the optistruct.zip
7. Click Open. The location of fairing.fem displays in the file: field.
8. Click Import. The fairing.fem database is loaded into the current HyperMesh session.
Step 2: Create the design variables for free-size optimization

2. Click free size to enter the free-size optimization panel.
3. On the create subpanel, type fairing in the desvar= field.
4. Click the switch under type and select PCOMP(G).

5. Click the highlighted props, select fairing_ply, and click select.
Figure 1: Field entries for the free-size panel
6. Verify that the fields in the create subpanel match the fields shown above and click create.
The design variable fairing is created for the free-size optimization. The manufacturing
constraints on ply percentage and ply balance will be defined next.
7. Go to composites subpanel. Make sure fairing is selected as the design variable.
8. Click edit and enter the DSIZE panel to define the manufacturing constraints on ply
percentage and ply balance.
9. Check the box in front of PLYPCT.
10. Set Ply Percentage Options to BYANG.
11. In the DSIZE_NUMBER_OF_PLYPCT = field, enter the value of 1. A PLYPCT continuation
line is added to the DSIZE data entry.
12. Check the box in front of BALANCE.
13. In the field of DSIZE_NUMBER_OF_BALANCE=, enter the value of 1. A BALANCE
continuation line is added to the DSIZE data entry.
14. Check the box in front of PLYMAN. A PLYMAN continuation line is added to the DSIZE data
entry.
15. Define the PLYPCT, BALANCE and PLYMAN constraints, as shown below.
Figure 2: DSIZE data entry fields
16. Click return to go back to the composites subpanel.

17. Click update.
18. Click return and go back to the optimization panel.

Step 3: Create the responses
1. Click responses.
2. Enter wcomp in the response= field.
3. Set the response type: to weighted comp.
4. Click the highlighted loadsteps.
5. Select gravity and pressure loadcases, and make sure the factors are 1.0 for both
loadcases.
6. Click return to go back to the response panel.
Figure 3: Responses Panel (Weighted Compliance)
7. Click create.
8. Enter volfrac in the response= field.
9. Set the response type: to volumefrac.
10. Make sure the total is selected and the toggle is set to no regionid.
Figure 4: Responses Panel (Volume Fraction)
11. Click create.

Step 4: Define constraints for optimization

2. In the constraint= field, enter con_vol.
3. Click response= and select volfrac.
4. Activate upper bound= and input a value 0.3.
Figure 5: Optimization Constraints Panel (Volume Fraction)
5. Click create.
6. Click return.

Step 5: Define the objective function
2. Select min as the optimization type.
3. Click response= and select wcomp.
Figure 6: Optimization Objective Panel (Weighted Compliance)
4. Click create.
Step 6: Define the output request

The output control on composite strain and stress results are defined here. OUTPUT,FSTOSZ (free
size to size) is used to output a ply-based input deck for size optimization.
2. Click next and then click GLOBAL_OUTPUT_REQUEST.
3. Select CSTRAIN and CSTRESS and input the following (Figure 7) to output all composite
strain and composite stress results for all elements to the H3D file.
Figure 7: Requesting CSTRAIN and CSTRESS results output to the .h3d file
4. Click return.
5. Click next and click the OUTPUT card.
6. In the OUTPUT panel, enter 1 as the number_of_outputs.

7. Set FSTOSZ as the KEYWORD and YES for FREQ.
Figure 8: Requesting the free-size to size (FSTOSZ) optimization output file for Phase 2.
OptiStruct automatically generates a sizing model after free-size optimization.

Step 7: Submit the free-size optimization job

name for the model, fairing_freesize.fem, in the File name: field.
4. Click Save.
The name and location of the fairing_freesize.fem file displays in the input file: field.
5. Toggle memory options: to memory default.
6. Toggle run options: to optimization.
7. Toggle export options: to all.
Figure 9: OptiStruct Panel
8. Click OptiStruct. This launches OptiStruct to run the job.

If the job was completed successfully, new results files can be seen in the directory from
which fairing_freesize.fem was saved.

A few default files written to your directory are:
fairing_freesize_s1(2).h3d Hyper 3D binary results file, with the static analysis

results of both subcases.
fairing_freesize_des.h3d Hyper 3D binary results file, with free size

optimization results.
fairing_freesize.out An ASCII output file contains specific information on

the model setup, compute time information, etc.
fairing_freesize_sizing.*.fem A ply-based sizing optimization input file generated

during free-sizing phase. This resulting deck contains
PCOMPP, STACK, PLY, and SET cards describing the
ply-based composite model, as well as DCOMP,
DESVAR, and DVPREL cards defining the optimization
data. The * sign represents the final iteration
number.
fairing_freesize_sizing.*.inc An ASCII include file contains the same ply-based

modeling and optimization data as in the input deck.
The * sign represents the final iteration number.

Step 8: View the element thickness results
1. When the job is complete, click HyperView (from the OptiStruct panel).
This launches HyperView and opens the session file fairing_freesize.mvw which contains
three pages with the results from three H3D files (click Close in the Message Log window):
Page 1 – optimization results in fairing_freesize_des.h3d
Page 2 – analysis results of subcase 1 in fairing_freesize_s1.h3d
Page 3 – analysis results of subcase 2 in fairing_freesize_s2.h3d
2. On Page 1, go to the Contour panel and select the plot options, as shown below.
Figure 11: Contour panel plot options (free-size optimization results)
3. Select the last iteration in the Load Case and Simulation Selection drop-down in the
Results browser.
Figure 12: Selecting the final iteration
4. Click Apply and then XY Top Plane View to view the results in the X-Y plane.
The element thickness results from the free-size optimization are shown in the following
image. The regions indicated in red or in colors tending towards red (from the legend) can be
interpreted as thicker regions, while those in blue or tending towards blue are thinner regions.
The contour plot indicated above is the total thickness distribution that includes contributions
from each ply orientation, i.e. a thickness contribution from the 0s, +/-45s and the 90s. It

also indicates the shape and layout of plies per orientation as can be seen in the ply thickness
plot.
Figure 13: Element thicknesses contour plot after free-size optimization
Step 9: View the ply thickness results

1. From the Contour panel, select Ply Thicknesses (s) as the Result type. The other plot
options should be selected, as shown below.
Figure 14: Ply Thicknesses contour plot
2. Select the last iteration in Load Case and Simulation Selection drop-down (similar to
Figure 12).
3. Click Apply.
The thickness distribution of 0 degree super ply is generated and shown in Figure 15. It
represents the ply shapes and patch locations of the 0 degree ply bundles.

Figure 15: Ply Thickness Contour plot of the 0 degree super-ply
4. Repeat step 1 through 3 to create the ply thickness contours for super-ply 2 (45°), 3 (-45°),
and 4 (90°) by selecting Layers 2, 3 and 4, respectively in the Contour panel.
5. Figures 16 and 17 represent the ply shapes and patch locations of +/-45 and 90° ply bundles.
Due to the balance constraint applied, the thickness distribution of the +45° and the -45°
super ply are the same.
Figure 16: Ply Thickness Contour plot of the -45/+45 degree super-plies

Step 10: View the ply bundles through element sets

The optimized ‘Super-ply’ thickness is subsequently represented as ‘Ply Bundles’. Four ply
bundles per fiber orientation (Super ply) are output by default, based on an intelligent algorithm
in OptiStruct. These ply bundles represent the shape and location of the plies per fiber orientation
through element sets. In this case, a total of 16 ply bundles are created after free size
optimization converges: element sets 1 through 4 represent the ply bundles for 0 degree super-
ply; element sets 5 through 8 represent ply bundles for +45° super-ply; element sets 9 through
12 represent ply bundle -45° super-ply; element sets 13 through 16 represent ply bundles for
90° super-ply.
1. Go back to the HyperMesh session.
2. Click the Import panel toolbar icon .
4. Click the open file icon in the File: field.

5. Select the fairing_freesize_sizing.*.inc file, located in the same directory where the file
fairing_freesize.fem is saved.
6. Click Import to import the model into session.
7. Turn the display off for all the load collectors: go to the Model browser, right-click on
LoadCollector and select Hide.
8. On the Analysis page, click entity sets.

9. Click review on the right side of the window and select set 5 which represents the ply bundle
1 of the +45° orientation super-ply (Figure 18). (The ply bundles can also be reviewed under
Ply in the Model browser, right-click on any PLYS and click Edit).
Figure 18: Element set 5 representing ply bundle 1 of the +45 degree super ply
10. Repeat step 10.9 to review the element sets 6 though 8 (Figures 19 through 21).

The shapes of the plies as indicated through the element set can be used as-is in design
Phase 2, or modified easily by updating the element sets in HyperMesh to improve the
manufacturability. In this case, the element sets are used as-is.

Phase 2 – Design Fine Tuning (size optimization)
In the second design phase, a size optimization is performed to fine tune the thicknesses of the
optimized ply bundles from Phase 1. To ensure that the optimization design meets the design
requirements, additional performance criteria on natural frequencies and composite strains are
incorporated into the problem formulation. A normal modes analysis load case is added to
calculate the natural frequencies of the fairing under assembled conditions. The optimization
setup is also modified to factor in these additional performance targets, among others.
The following is the modified optimization setup:
Design Ply thicknesses, which have been defined in the size input deck from Phase 1
variables:
Objective: Minimize the total designable volume
Constraints:  Natural frequencies (1st ~ 5th) > 0.02 KHz

 Composite strains in the fairing < 1000 micro-strain
Manufacturing constraints are preserved and transferred to the DCOMP card. A minimum
manufacturable ply thickness of 0.1, defined in Phase 1, is transferred to the PLY card. It allows
for the optimal ply bundle thicknesses to be a multiple of the minimum ply thickness value, and
helps in calculating the total number of plies required per fiber orientation.
Step 1: Load the OptiStruct user profile and import the model
Follow Step 1 in the free-size phase (Phase 1) to load the fairing_freesize.*.fem file into
HyperMesh.
Step 2: Review the design variables for size optimization

The size design variables were generated automatically at the free-size stage. They can be
reviewed in the size panel within the optimization panel.
Figure 22: Reviewing the automatically created Size design variables
Step 3: Review the manufacturing constraints

The manufacturing constraints were carried over to the size optimization phase automatically.
They can be reviewed in the composite size panel in HyperMesh.
1. From the optimization panel, click composite size.
2. Go to the parameters subpanel, click dcomp=, and select DCOMP9.

3. Click edit and review the DCOMP card image, as shown below. PLYPCT and BALANCE
constraints (from DSIZE) are transferred to the DCOMP card. The manufacturable ply
thickness constraint 0.1 in the PLYMAN continuation line (from DSIZE) is transferred to the
PLY card.
Figure 23: DCOMP entry
4. Return to the parameters subpanel, and click update.
Step 4: Delete the responses defined in the free-size phase

The optimization will be re-formulated to satisfy the main design requirements. The responses of
weighted compliance and volume fraction used in the free-size phase will be removed.
1. Go to the Delete panel by clicking on the toolbar.
2. Click the switch and select optiresponses.
3. Click the highlighted optiresponses and select wcomp and volfrac.
4. Click select.
The responses defined in free-sizing phase are deleted. The constraint and objective function
defined based on them are automatically removed.
6. Click return.
Step 5: Set up the normal modes analysis

Add a normal modes analysis to calculate the natural frequencies.
2. In the Entity Editor, enter eigrl in the Name field.
4. For Card Image, select EIGRL from the list.
5. Click ND and enter 8 to request the first 8 modes (Figure 24).
7. For Name, enter norm_modes.
9. Click Analysis type and select normal modes from the drop-down menu.
11. In the Select Loadcol dialog, select spc from the list of load collectors and click OK.

13. In the Select Loadcol dialog, select eigrl from the list of load collectors and click OK.
Step 6: Create the responses for size optimization

The responses of volume, natural frequency, and composite strain are created for size
optimization.
1. Click optimization and then click responses.
2. For the response = field, enter volume.
3. Set the response type to volume.
4. Make sure the total volume is defined and the toggle is set to no regionid.
Figure 24: Defining the Volume response
5. Click create.
6. For the response = field, enter freq1.
7. Set frequency as the response type.
8. In the Mode Number field, enter 1 to create the frequency response for the first mode and
make sure that the toggle is set to no regionid.
Figure 25: Defining the Frequency response
9. Click create.
10. Repeat step 6.6 through 6.9 to create frequency responses for mode 2, 3, 4, and 5.
11. For response =, enter cstrain.
12. Select composite strain as the response type.
13. Toggle the selection option to plies.
14. Click the highlighted plies and select all plies.
15. Select maj. Principal as the strain type.
The cstrain response should be set, as shown below.

Figure 26: Defining the composite strain response
16. Click create.

17. Click return to go back to optimization panel.
Step 7: Create optimization constraints

The responses of frequency and composite strain are defined as the optimization constraints.
1. From the optimization panel, click dconstraint.
2. For constraint =, enter freq1.
3. Click response= and select freq1.
4. Activate the lower bound and enter 0.02.
5. Click the highlighted loadsteps and select the loadcase norm_modes.
Figure 27: Defining the Frequency optimization constraint
6. Click create.
7. Repeat steps 7.2 through 7.6 to create constraints freq2, freq3, freq4, and freq5
respectively with the same lower bound of 0.02.
8. For constraint=, enter cstrain.
9. Click response= and select cstrain.
10. Activate the upper bound= and enter 0.001.
11. Click loadsteps and select loadcases gravity and pressure.
Figure 28: Defining the composite strain optimization constraint
12. Click create.


Step 8: Create objective function for the optimization
1. Click objective.
3. Click response= and select volume.
Figure 29: Defining Volume as the optimization objective
4. Click create.
Step 9: Define the output request for shuffling deck

The output control on composite strain and stress results defined in the previous phase are
carried over automatically. OUTPUT,SZTOSH (sizing to shuffling) writes a ply stacking
optimization input deck.
2. Go to the OUTPUT panel.
3. Set SZTOSH as the KEYWORD and YES for FREQ.
4. Enter 1 as the number_of_outputs.
Figure 30: Output request to automatically generate a shuffling deck

Step 10: Submit the size optimization job
2. Follow the instructions in Step 7.7 from the free-size phase (Phase 1) to save the input file as
fairing_size.fem and set up the run/memory options.
Figure 31: Saving the phase 2 input file
3. Click OptiStruct to launch OptiStruct to run the optimization.
Figure 32: HyperWorks Solver View window to show the progress of the optimization
If the job was completed successfully, new results files can be seen in the same directory
where fairing_size.fem was saved.

A few default files are:
fairing_size_s1(s2)(s3).h3d Hyper 3D binary results file, with the analysis results of

each subcase.
fairing_size_des.h3d Hyper 3D binary results file, with size optimization results.
fairing_size.out An ASCII output file containing specific information on the

model setup, compute time information, etc. Review this
fairing_size_shuffling.*.fem A ply stacking optimization input deck. The DESVAR and

DVPREL cards from the previous stage are removed, and a
bare DSHUFFLE card is introduced. The * sign represents
the final iteration number.
fairing_size_shuffling.*.inc An ASCII include file containing ply stacking optimization

data.
Step 11: View the thickness results in HyperView

1. Invoke HyperView.
2. Follow the instructions in Step 8 from Phase 1 to create the element thickness contour, as
shown below.
Figure 33: Element thickness contour plot (final iteration) after phase-2 size optimization
3. Set the Result type to Orientation Thicknesses (s) to create the thickness contour for
each ply orientation.

4. Set the Result type to Ply Thicknesses (s) to create the thickness contour for each ply
bundle.
After the free-size and size optimizations, a weight reduction of ~65% of the original design
was achieved without violating any of the prescribed design constraints. The optimum ply
shape and patch locations in Phase 1, and subsequently optimized ply bundle thicknesses in
Phase 2, have been established, and allow us to determine the required number of plies. This
brings us to the third and final phase of the design process in which you try to identify a
proposal for the optimal stacking sequence of the plies.

Phase 3 – Ply Stacking Sequence Optimization
This algorithm is aimed at providing a global view of what the optimal stacking sequence could
be. An input deck for the ply stacking sequence optimization, fairing_size_shuffling.*.fem,
was generated from a previous design stage. Each ply bundle is divided into multiple PLYs whose
thickness is equal to the manufacturable thickness (0.1 in this case), and the STACK card is
updated accordingly. In this design phase, composite plies are shuffled to determine the optimal
stacking sequence.
It is important that design performances are preserved. Hence, the optimization problem is
retained as previously formulated in the size optimization phase. Two manufacturing constraints
are applied:
 The maximum successive number of plies of a particular orientation does not exceed 4
plies.
 The + 45s and – 45s are reversed paired.
Follow Step 1 from the free-size phase to load the fairing_size_shuffling.*.fem file in
HyperMesh.
Step 2: Update the composite strain response

Since the ply bundles were divided into multiple plies in the shuffling model, the ply information
in CSTRAIN response needs to be updated, as well.
1. Go to the optimization panel.
2. Click responses.
3. Click response= and select cstrain.
4. Click the highlighted plies and select all of the plies.
5. Click select and go back to the responses panel.
Figure 34: Updating the CSTRAIN response
6. Click update.
7. Click return.
Step 3: Create the manufacturing constraints for shuffling

A DSHUFFLE card was created automatically during the sizing phase. Two manufacturing
constraints will be added for the shuffling optimization.
1. From the optimization panel, click composite shuffle.

3. Click dshuffle= and select DSHUFFLE1.
Review the type and stack ID.
4. Go to parameters.
5. Click dshuffle = and select DSHUFFLE1.
6. Check the small box in front of pairing constraint.
7. Select reverse as the pair type and make sure that ply angles1 and ply angles2 are 45.0
and -45.0, respectively.
8. Click update.
9. Click edit.
10. Define the MAXSUCC constraint, as shown below.
Figure 35: Defining the MAXSUCC constraint
11. Click return.

12. Click update.
Step 4: Submit the shuffling job

1. On the Analysis page, click OptiStruct.
2. Follow the instructions in Step 7.7 in free-size phase (Phase 1) to save the input file as
fairing_shuffling.fem and set up the run/memory options.
3. Click OptiStruct to launch OptiStruct to run the optimization.

Figure 36: HyperWorks Solver View Window showing the progress of shuffling optimization
where fairing_shuffling.fem was saved.
The following result files are generated:
fairing_shuffling.prop A property file contains the composite materials and ply

properties at the last iteration.
fairing_shuffling.shuf.html An html file contains the history of the shuffling

optimization and the view of the ply stacking sequence.
Step 5: Post-process the results

1. Go to the directory where fairing_shuffling.shuf.html is located and double-click the file.
It is automatically loaded in your default Internet browser window, as shown in Figure 37.
The plies are color coded based on their fiber orientations.

Figure 37: Shuffling Optimization History
The above image shows the history of the shuffling optimization. The columns represent the
global trend of the ply stacking sequence at a particular iteration, with the last column being
the final solution.

The weight of the fairing has not been changed during the shuffling design phase. Reviewing
the results from this process:
 Lowest natural frequency = 0.02 KHz (>0.02 KHz)
 Maximum strain = 9.947e-4 (<1.e-3)
This light weight design therefore meets all of the performance requirements, is feasible and
manufacturable.

OS-3300: Using the Lattice Optimization Process in OptiStruct
Lattice Optimization in OptiStruct is a two-phase process to create blended Solid and Lattice
structures from concept to the detailed final design. The first phase performs a concept-level
topology optimization to optimally partition solid, void, and intermediate space and create the
lattice elements. The second phase optimizes the size of each lattice element to determine the
final optimized structure. The completed model can then be manually reinterpreted to fit a
number of different manufacturing operations, including, but not limited to, 3D printing.
Note: Running Lattice Optimization requires HyperWorks version 13.0.210 or later.

 Set up a basic lattice concept-level (Phase I) optimization using the DTPL card
 Set up and review the basic options associated with lattice optimization
 Set up a basic lattice fine-tuning (Phase II) optimization and review the results
Problem Statement
 Geometry: Control Arm, sectioned into non-design and designable components

 Load cases: 1: Vertical load (Z-) on the control arm end

Phase I: Concept Level Design
In the model, the non-design regions surround the load-bearing points and without the design
space, the non-design area is discontinuous. This allows the optimization to determine the most
efficient structure to transition the load and stress throughout the structure.
The Model browser shows that there is already an optimization set up.

Objective: Minimize compliance
Constraints: Volume Fraction (0.3)
Design spaces: “design” PSOLID (5) and Stress constraint (200)
Responses: Compliance and Volume Fraction
Lattice optimization differs from topology as a concept-level optimization in that elements with
intermediate densities will be mathematically interpreted as solid, lattice, or void, depending on
your settings in the setup phase. You will add continuation cards and parameters in a text editor
to change this from standard topology to lattice optimization.
Step 1: Import the model controlarm.fem into HyperMesh Desktop

2. Select OptiStruct in the User Profiles dialog and click OK. This loads the user profile.
5. Click the open file icon in the File: field. A Select OptiStruct file browser window
opens.
6. Select the controlarm.fem file you saved to your working directory from the optistruct.zip
7. Click Open. The location of controlarm.fem displays in the File: field.
8. Click Import.
Step 2: Add the LATTICE continuation card to the DTPL card

1. Close HyperMesh Desktop and open controlarm.fem in a text editor.
2. Locate the optimization data in the deck. The DTPL card contains the data on the design
space.

3. Below the DTPL line, add the following line:
+ LATTICE 1 0.1 0.7 200.
Each field begins with the field’s data and is padded with spaces to a total of 8 characters
long.
Field Descriptions
+: A continuation of the preceding line/card, DTPL
LATTICE: This optimization should use lattice (porous) topology parameters.
1: Sets the lattice type (LT) according to the solid element type that it is replacing. 1 is
the default or enter 2 as an option.
Element Types:
CHEXA: By default, this generates pyramidal lattices with quadrilateral bases and
triangular internal adjoining faces. For option 2, it creates a tetrahedral matrix to
replace the CHEXA element.
CPENTA: This creates a pair of lattices, one pyramidal, one tetrahedral regardless of
setting (1 or 2).
CPYRA: This creates a pyramidal lattice regardless of setting (1 or 2).
CTETRA: This creates a tetrahedral lattice regardless of setting (1 or 2).
0.1: The lower bound (LB) for lattice structure. Any elements with a topology density
below this value is considered void (empty) at the end of Phase I.
0.7: The upper bound (UB) for lattice structure. Anything above this element density in
the optimization is considered fully solid. Elements where element density is between
the lower and upper bound are considered porous and is replaced by lattice elements at
the end of Phase I.

200.: Sets a stress constraint target for optimization for the second phase of lattice
optimization (LATSTR). That means for Phase II, OptiStruct will automatically create a
stress constraint (refer to Lattice Structure Optimization in the User's Guide). The
stress target for Phase I (via the STRESS continuation card which was already present
in this deck and set to 200), is not automatically ‘copied’ to Phase II.
4. Save the controlarm.fem text file.
Step 3: Add the optimization parameters DOPTPRM to control the

optimization
1. Below the final stress continuation card for the DTPL entry, add the following two lines:
DOPTPRM,POROSITY,MED
DOPTPRM,LATLB,CHECK
DOPTPRM indicates that optimization parameters to control the optimization are being added.
DOPTPRM, POROSITY determines the penalty factor applied to all designable elements
throughout the optimization. In regular topology optimization, a penalty is applied to avoid
medium dense elements by significantly reducing their stiffness. In Lattice optimization,
medium dense elements can be accepted as they can be manufactured as a lattice structure.
You can apply a smaller penalty or nothing, which controls the number of medium dense
elements and consequently lattice type elements. This parameter has three options:
LOW: Sets the penalty factor to 1.8. This setting accurately represents the structural
relationship between intermediate dense solid elements and lattice type elements, which
result in a model that has few lattice elements, as medium dense elements are widely
removed, due to the penalty.

MED: Sets the penalty factor to 1.25. This penalizes intermediate dense elements to some
extent and results in a moderate presence of lattice zones.
HIGH: Sets the penalty factor to 1, negating any penalty to the Young’s Modulus and
density relationship. This usually leads to a high number of lattice elements, but also
produces a mathematical over-estimation of stiffness for structures known to be porous,
which leads to a larger discrepancy between the structural performance of Phases I and II.
In some cases a certain value for LB can lead to important parts of the structure being
interpreted as void. For instance, for a high number, such as 0.5 or where important parts of
the structure have low densities. In those cases, the removal of the void elements can lead to
a non-functioning structure. DOPTPRM, LATLB aims at preventing such scenarios. It will force
OptiStruct to check the structure for large differences in compliance between the final
iteration of Phase I and the one where the elements with density below LB are removed. If
the structure is found to be too ‘soft’, the lower bound for lattice zones can be adjusted
downward during the optimization to create a more continuous or stiff structure that more
closely represents the original mesh. This parameter has the following options:
CHECK: Requests that OptiStruct check the lattice optimized representation of the
model for differences in compliance.
AUTO: Allows OptiStruct to automatically adjust the lower bound of the lattice-
optimized model downward to increase the model continuity.
NONE: No check for performance loss is made.
2. Click File > Save to save the controlarm.fem text file.
Step 4: Run the optimization

1. Open the HyperWorks Solver Run Manager and browse for the controlarm.fem file.
2. Click Run to run the optimization.

3. When the optimization has completed, open the controlarm.out file in a text editor, to check
how the optimization progressed. Make sure that the optimization is fully converged and that
the constraint is satisfied.
OptiStruct provides a summary of the lattice optimization and its effects on the model, at the
end of the output file.
Since DOPTPRM, LATLB, CHECK was applied, OptiStruct checked the drop-in compliance, due to
the removal of elements with density below LB. The drop is relatively small and this LB can be
considered a good choice.
Phase II: Fine-Tuning Design
Step 1: Open the model controlarm_lattice.fem in a text editor

At the end of Phase I, OptiStruct automatically created a new file, controlarm_lattice.fem,
from your original optimization model. In this model, the original designable elements with a
density below LB have been removed, those above UP remain unchanged and those in-between
are replaced by bars (CBAR) representing the lattice structure.
The second phase of this optimization will optimize the radius of each joint in the lattice structure
to determine where there is a need for material. The necessary design variables (DESVAR) and
design variable property relationships (DVPREL1), along with the stress constraints are
automatically created. In many cases, the model can be run as is, but it is advised to always
review the optimization setup.
Step 2: Review the model to verify the changes to the original model
1. The beginning of the deck shows that the new file has retained your original objective, but
added a new optimization parameter indicating that this size optimization is Phase II of a
lattice structure optimization.

2. OptiStruct has inserted the CBAR elements, which represent the new lattice material, below
the GRID cards, which provides details about the model nodes.
3. Each CBAR element has its own PBAR property definition, listed later in the deck, which
indicates each element can be individually optimized.

4. Each joint between multiple CBAR elements has a design variable created for it.
5. At the end of the file are the design variable property relationships (DVPREL1), which relate
properties to their associated design variable for the size optimization in the second phase.
These are followed by the responses, the constraints, and the objective.
Note: The volume fraction response in the original model has been replaced by total volume in
the size optimization phase, which will now be minimized and a new response has been
added to constrain the von Mises stress in the lattice region to 200. This was created from
the value in the last field of the LATTICE continuation card in the first phase.
Step 3: Run the second optimization phase

1. Close the controlarm_lattice.fem file in the text editor.
2. Load the controlarm_lattice.fem file in the HyperWorks Solver Run Manager.

4. Open the controlarm_lattice.out file in a text editor to review critical information about
the optimization run.
Verify that the optimization is fully converged and that the constraint is satisfied.
Note: The difference in lattice penalty (lower than 1.8, set by the optimization parameters)
causes the compliance of the final Phase I model to differ from the initial Phase II
model. This compliance difference is also affected by solid elements retained in the
Phase II model, which recover their full density/stiffness. For this reason, post-
processing a lattice optimization requires that you analyze changes to the model
compliance between the Phase I final optimization compliance and the Phase II initial
compliance calculation and again at the end of Phase II.
5. Load the controlarm_lattice_optimized file in the HyperWorks Solver Run Manager.
6. Click Run for verification purposes.
Since the optimization removes CBAR elements of small radius after the last optimization, the
compliance for the last optimized run should be confirmed against the
controlarm_lattice_optimized.fem file, an analysis of the optimized structure provided by
OptiStruct.
7. Compare the final compliance between the controlarm_lattice.out and
controlarm_lattice_optimized.out files.

Final compliance from the optimization run
Final compliance from the analysis model
Step 4: Post-process the results from the Phase II optimization

1. Import the file controlarm_lattice_optimized.fem into a new HyperMesh Desktop session.
2. From the 1D Element Representation menu, select 1D Detailed Element
Representation to show the CBAR elements in the model with their radii applied.

An overall view of the optimized solid/lattice model
Detail of the front of the optimized lattice/solid model showing the variation in CBAR radius
3. Load the file controlarm_lattice_s1.h3d into a new HyperView session.

4. From Preferences > Options, toggle Enable element marks and set the BAR
representation to Cylinder, with a Size of mark (model %) set to 0.125.

5. Click Apply and OK to exit the options.
6. Using the Contour panel , select CBAR/CBEAM Stresses (ROD) and set Subtype to
NORMAL S1N(A).
7. Click Apply to contour the beam element visualization.
Iteration 0 (Initial Sizing Design)

Last Iteration (Final Design)

OS-3400: Optimization-driven Design of an Open Hole Tension
(OHT) Specimen
Composite materials have become popular in the application of a variety of structures. The need
for innovative designs has posed a great challenge. This tutorial discusses the optimization-driven
design approach of an open-hole tension specimen using OptiStruct.
The design takes a three-phased approach:
Phase 1 Concept design synthesis
Free-size optimization identifies the optimal ply shapes and locations of
patches per ply orientation.
Phase 2 Design fine tuning
Size optimization identifies the optimal thicknesses of each ply bundle.
Phase 3 Ply stacking sequence optimization
Shuffling optimization obtains an optimal stacking sequence.
The process expands upon three important and advanced optimization techniques; free-size
optimization, size optimization and ply stacking sequence optimization. By stringing these three
techniques together, OptiStruct offers a unique and comprehensive process for the design and
optimization of composite laminates. The process is automated and integrated in HyperWorks by
generating the input data for a subsequent phase automatically from the previous design phase.
Together with these steps, an initial and final analysis will be utilized to determine the baseline
and final characteristics of the designed part.
Problem Definition
The composite design optimization methodology presented within this tutorial was developed to
solve very complex composite design optimization problems. The methodology breaks down the
complex composite design optimization problem, which is not solvable by itself, into several
simpler composite design optimization problems, which are solvable by themselves. The
cumulative solution to each of the simpler composite design optimization problems provides a
solution to the complex design optimization problem. This process of breaking down complex
problems into several simpler problems is consistent with the engineering method.

Model overview
Initial Model Setup and Baseline Analysis
The following set of steps completes the analysis setup of the initial model and provides a
baseline analysis for comparison with the final optimized structure.
Step 1: Load the OptiStruct user profile and open the model into
HyperMesh
3. Select the Open Model file toolbar icon

4. Select the oht_analysis.hm file you saved to your working directory from the
5. Click Open. The oht_analysis.hm database is loaded into the current HyperMesh session.
Step 2: Create a new material for carbon epoxy

1. Right-click in the Model browser and select Create > Material to create a new material.
2. In the Entity Editor, for Name, enter carbonepxy.

3. Set the value for Card Image to MAT8 and enter the values shown below:
Step 3: Create a new element set containing the initial shape of each ply
1. Right-click in the Model browser and select Create > Set to create a new set.
2. In the Entity Editor, for Name, enter ply_shape.
3. Set the value for Card Image to SET_ELEM.
4. Click Entity IDs and click the yellow Elements entity selector.
5. Use the yellow elems entity selector to select all of the elements in the model.
6. Click proceed to continue.

Step 4: Create the basic plies for the analysis
1. Right-click in the Model browser and select Create > Ply to create a new ply.
2. For Name, enter ply1.
3. Set Material type to ORTHOTROPIC.
4. Set Material to carbonepxy.
5. Set Thickness to 0.1, and Orientation to 0.
6. Switch the Shape drop-down selector to Set, and use the yellow Set entity selector to select
the ply_shape set created in the previous step.
7. Ensure that Output results is checked.
8. Click Create.

9. Using these steps, create three more plies: ply2 with orientation 90, ply3 with orientation 45,
and ply4 with orientation -45.
10. Close the dialog box to continue with the exercise.
Step 5: Create the laminate for the analysis

1. Right-click in the Model browser and select Create > Laminate to open the create laminate
dialog box.
2. Set Name to laminate.
3. Set Card image to STACK.
4. Set Laminate option to Smear.
5. In the Define laminate section, select ply1 for the first row, with each successive ply on a
consecutive row. Leave all other parameters set as default and click Create to create the
laminate.
6. Close the dialog box to continue with the exercise.

Step 6: Create a property and assign it to all elements in the model
1. Right-click in the Model browser and select Create > Property to create a new property and
load it into the Entity Editor.
2. For Name, enter laminate_property.
3. Set Card Image to PCOMPP.
4. In the Model browser, right-click on the laminate_property property and select Assign.
5. Use the yellow elems entity selector to select all elements in the model and click proceed to
continue.
Step 7: Review the model

1. Select the element visualization icon and change the mode to 2D Detailed Element
Representation using the drop-down selector.
This will thicken all shells in the model to their total thickness, displaying them as 3-
dimensional representations of their thicknesses.
2. Click the Layers icon and select Composite Layers.

This separates the view into individual plies.
3. To assist in determine which plies are which in the layup, change the element color mode to
By Prop .
This represents each of the plies in the model according to the color of its ply as shown in the
Model browser. If all of the plies in the model are the same color, change the ply colors in the
Model browser so that each is different to help differentiate the plies in the graphics area.

Step 8: Create control cards to set the request and output parameters
1. In the control cards panel on the Analysis page, enter the GLOBAL_OUTPUT_REQUEST
panel.
2. Check the box for CSTRAIN. Set EXTRA(1) to MECH and OPTION(1) to ALL.
3. Check the box for DISPLACEMENT. Set OPTION(1) to ALL.
4. Check the box for STRESS. Set OPTION(1) to NO.
This requests that NO homogeneous stress be output. This control card output must be
explicitly added as a request since homogeneous stress is output by default. In turning it off,
the values will not be calculated by the solver for output.
5. Click return to return to the control cards panel.
6. Enter the OUTPUT panel. Set number_of_outputs to 2.
7. For the first OUTPUT, set KEYWORD to HTML and OPTION to NO.
This turns off HTML output for all analyses and optimizations which have this keyword
combination.
8. For the second OUTPUT, set KEYWORD to H3D and FREQ to FL.
This request that OptiStruct’s .h3d output file be output at the first (F) and last (L) iteration.
For analysis, this does not matter, but for optimization it applies when you get to the
optimization runs.
Step 9: Run the baseline analysis

1. Enter the OptiStruct panel on the Analysis page.
2. Ensure that export options is set to all and run options is set to analysis.
3. Click OptiStruct to export the model and run the baseline analysis as oht_analysis.fem.
Step 10: Post-process the baseline analysis in HyperView

1. When the run is complete, click HyperView in the OptiStruct panel to load the results into
HyperView.
2. Enter the Contour panel .
3. Set Result type to Composites Strains(Mech) (s) and subtype to Normal X Strain.
4. To view the individual strain contributions from any one ply, select the appropriate ply name
in the Layers drop-down.
5. Click Apply.

Step 11: Return to HyperMesh and deactivate the composite
visualization enhancements
1. Return to the HyperMesh client by using Delete Page icon to close the HyperView session.
2. Click the element visualization icon on the button bar to return the mode to 2D
Traditional Element Representation using the drop-down selector.
3. Use the Layers drop-down selector to select Layers Off.

4. Return element color mode to By Comp.
Phase 1 – Concept Design Synthesis (free-size optimization)
In free-size optimization, the thickness of each designable element is defined as a design

variable. Applying this concept to the design of composites implies that the design variables are
the thickness of each ‘Super-ply’ (total designable thickness of a ply orientation) per element.
The following optimization setup is defined in the concept design phase to identify the stiffest
design for the given fraction of the material. To obtain more meaningful results, manufacturing
constraints are incorporated and carried through all design phases automatically.

Objective: Minimize the compliance of the load case.
Design Element thicknesses of each ply

variables: orientation.
Manufacturing  Ply percentage for the 0s no more than 80% exist.

constraints:
 The manufacturable ply thickness is 0.1.
 A balance constraint that ensures an equal thickness distribution

for the +45s and -45s.
Step 1: Create the design variables for free-size optimization

2. Click free size to enter the free-size optimization panel.
3. On the create subpanel
, enter free-size in the desvar= field.
4. Click the switch under type and select STACK.
5. Click the highlighted laminate, select laminate, and click return.
Figure 1: Field entries for the free-size panel
6. Verify that the fields in the create subpanel match the fields shown above and click create.
The design variable free-size is created for the free-size optimization. The manufacturing
constraints on ply percentage and ply balance will be defined next.
7. Go to the composites subpanel. Make sure free-size is selected as the design variable.
8. Click edit and enter the DSIZE panel to define the manufacturing constraints on ply
percentage, ply balance, and ply drop-off.
9. Check the box in front of PLYPCT.
10. Set Ply Percentage Options to BYANG.
11. In the DSIZE_NUMBER_OF_PLYPCT= field, enter the value of 2.
Two PLYPCT continuation lines are added to the DSIZE data entry.

12. In the first PLYPCT row, for PANGLE(1) enter 0, PPMIN(1) enter 0.2, and PPMAX(1) enter
0.7.
13. In the next PLYPCT row, for PANGLE(2) enter 90, PPMIN(2) enter 0.2, and PPMAX(2)
enter 0.7.
These values constrain the zero- and ninety-degree plies to between twenty and seventy
percent of the total thickness of the laminate for any element in the design space.
Figure 2: DSIZE data entry fields for the PLYPCT cards
14. Check the box in front of BALANCE.

15. Set Balance Constraints Options to BYANG.
16. In the DSIZE_NUMBER_OF_BALANCE= field, enter the value of 1.
A BALANCE continuation line is added to the DSIZE data entry.
17. In the BALANCE row, for BANGLE1, enter 45 and for BANGLE2, enter -45.
Figure 3: DSIZE data entry fields for the BALANCE card
18. Check the box in front of PLYDRP.

A PLYDRP continuation line is added to the DSIZE data entry.
19. Set Ply Drop-off Options to All.
20. In the DSIZE_NUMBER_OF_PLYDRP= field, enter the value of 1.
21. In the PLYDRP row, for PDTYP(1) enter PLYSLP and for PDMAX(1) enter 0.33.
Figure 4: DSIZE data entry fields for the PLYDRP card using the PLYSLP method
22. Click return to go back to the composites subpanel.

23. Click update > return and go back to the optimization panel.
Step 2: Create the responses

1. Click responses.
2. In the response= field, enter volfract.
3. Set the response type to volumefrac and that the sub-type is set to total.
4. Cick create.
5. In the response= field, enter compliance.
6. Set the response type to compliance.

7. Make sure that total is selected and the toggle is set to no regionid.
8. Click create.
Step 3: Define constraints for optimization

2. In the constraint= field, enter volfract.
3. Click response= and select volfract.
4. Activate upper bound= and enter a value of 0.3.

2. For optimization type, select min.
3. Click response= and select compliance.
4. Click the loadstep entity selector and select the loadstep nx_step.
Figure 5: Optimization Objective Panel (Compliance)
5. Click create.
Step 5: Add an output request to output the next optimization step

The output control on composite strain and stress results are defined here. OUTPUT,FSTOSZ (free
size to size) is used to output a ply-based input deck for size optimization.
2. Enter the OUTPUT card.
3. In the OUTPUT panel, enter 3 as the number_of_outputs.
4. On the third line, under KEYWORD, select FSTOSZ and for FREQ, select YES.

Figure 6: Requesting the free-size to size (FSTOSZ) optimization output file for Phase 2.
With this keyword, OptiStruct automatically generates a sizing model after free-size
optimization.
6. Save the file as oht_opti_ph1.hm.
Step 6: Submit the free-size optimization job

2. Click save as following the input file field.
name for the model, oht_opti_ph1.fem, in the File name field.
4. Click Save.
The name and location of the oht_opti_ph1.fem file displays in the input file field.
5. Toggle export options to all.
6. Toggle run options to optimization.
7. Toggle memory options to memory default.
Figure 7: OptiStruct Panel
8. Click OptiStruct. This launches OptiStruct to run the job.

If the job was completed successfully, new results files can be seen in the directory from
which oht_opti_ph1.fem was saved.

A few default files which will be written to your directory are:
oht_opti_ph1_s1(2).h3d Hyper 3D binary results file, with the static analysis results
of both subcases.
oht_opti_ph1_des.h3d Hyper 3D binary results file, with free size optimization

results.
oht_opti_ph1.out An ASCII output file contains specific information on the

model setup, compute time information, etc. Review this file
oht_opti_ph1_sizing.*.fem A ply-based sizing optimization input file generated during

free-sizing phase. This resulting deck contains PCOMPP,
STACK, PLY, and SET cards describing the ply-based
composite model, as well as DCOMP, DESVAR, and DVPREL
cards defining the optimization data. The * sign represents
the final iteration number.
oht_opti_ph1_sizing.*.inc An ASCII include file contains the same ply-based modeling

and optimization data as in the input deck. The * sign
represents the final iteration number.

Step 7: View the element thickness results
1. When the job is complete, click HyperView from the OptiStruct panel.
This launches the HyperView client from HyperMesh Desktop and opens the session file
oht_opti_ph1.mvw which contains three pages with the results from two H3D files (click
Close in the Message Log window):
Page 2 – optimization results in oht_opti_ph1_des.h3d
Page 3 – analysis results of subcase 1 in oht_opti_ph1_s1.h3d
Note: If opening these files from standalone HyperMesh, the page numbers will be
decremented.
2. On the page with the results for oht_opti_ph1_des.h3d (open file name is shown in the
upper right corner by default), go to the Contour panel and select the plot options.
Figure 9: Contour panel plot options (free-size optimization results)
3. In the Results browser, select the last iteration in the Load Case and Simulation
Selection drop-down.
Figure 10: Selecting the final iteration
4. Click Apply and then XY Top Plane View to view the results in the X-Y plane.
The element thickness results from the free-size optimization are shown in the image below.
The regions indicated in red or in colors tending towards red (from the legend) can be
interpreted as thicker regions, while those in blue or tending towards blue are thinner regions.

The contour plot indicated above is the total thickness distribution that includes contributions
from each ply orientation, i.e. a thickness contribution from the 0s, +/-45s and the 90s. It
also indicates the shape and layout of plies per orientation as can be seen in the ply thickness
plot.
Figure 11: Element thicknesses contour plot after free-size optimization
Step 8: View the ply thickness results

1. From the Contour panel, select Ply Thicknesses (s) as the Result type. Select the other
plot options shown below.
Figure 12: Ply Thicknesses contour plot
2. Select the last iteration in the Load Case and Simulation Selection drop-down.
3. Click Apply.
The thickness distribution of 0 degree super ply is generated. It represents the ply shapes and
patch locations of the 0 degree ply bundles.

4. Repeat step 1 through 3 to create the ply thickness contours for super-ply 2 (45°), ply 3 (-
45°), and ply 4 (90°) by selecting Layers 2, 3 and 4, respectively in the Contour panel.
5. The figures below represent the ply shapes and patch locations of +/-45 and 90° ply bundles.
Due to the balance constraint applied, the thickness distribution of the +45° and the -45°
super ply are the same.
Figure 14: Ply Thickness Contour plot of the -45/+45 degree super-plies

Step 9: View the ply bundles in the optimization result fem

The optimized ‘Super-ply’ thickness is subsequently represented as ‘Ply Bundles’. Four ply
bundles per fiber orientation (Super ply) are output by default, based on an intelligent algorithm
in OptiStruct. These ply bundles represent the shape and location of the plies per fiber orientation
through element sets. In this case, a total of 16 ply bundles are created after free size
optimization converges: plies 1 through 4 represent the ply bundles for 0 degree super-ply; plies
5 through 8 represent ply bundles for 90 degree super-ply; plies 9 through 12 represent ply
bundle +45 degree super-ply; and applies 13 through 16 represent ply bundles for -45 degree
super-ply.
1. Return to the HyperMesh session by deleting the HyperView client windows.
2. Open a new model by clicking the New Model icon .
3. Click the Import Solver Deck panel toolbar icon .

4. The File type is OptiStruct.
5. Click the open file icon in the File field.

6. Select the oht_opti_ph1_sizing.*.inc file, located in the same directory where the file
oht_opti_ph1.fem is saved.
7. Click Import to import the model into session.
8. Turn the display off for all the load collectors: go to the Model browser, right-click on
LoadCollector and select Hide.
9. Using the Model browser, hide all plies.
10. To review the plies, expand the Ply tree in the Model browser and activate the mesh view
icon for each ply individually as shown below.

Figure 16: Model browser view showing ply 11300 selected (Laminate 1, Ply 1, Shape 3)

Figure 17: Graphics Area view of ply 11300 (Laminate 1, Ply 1, Shape 3)
The shapes of the plies as indicated through the element set can be used as-is in design
Phase 2, or modified easily by updating the element sets in HyperMesh or using ply
smoothing to improve the manufacturability. Ply smoothing operations are shown in the next
section.
Step 10: Use OSSmooth to perform ply smoothing operations on the

model
Ply smoothing is an automated method to further reduce the ply shapes into more manufactural
ply shapes. Although ply smoothing significantly improves the ply shapes for manufacturability,
often it is still necessary to manually edit the ply shapes after this step.
1. In the Post page, enter the OSSmooth panel.
2. Click the file selection icon to set Select model to oht_opti_ph1_sizing.35.fem.
3. Change the mode from Geometry to PLY Shape.
4. Use the file icon to set the output file selection to the original location with the name of
oht_opti_ph1_sizing.35.smoothed.fem.
5. Set smooth iterations: to 20.
6. In small region: deselect checkboxes for split disconnected and create geometry.
7. Set area ratio: to 0.010.
8. Click OSSmooth to run the analysis to smooth the model.

Figure 18: Graphics Area view of ply 11300 after smoothing operations in OSSmooth (Laminate 1, Ply 1, Shape 3)
Phase 2 – Design Fine Tuning (size optimization)
In the second design phase, a size optimization is performed to fine tune the thicknesses of the
optimized ply bundles from Phase 1. To ensure that the optimization design meets the design
requirements, additional performance criteria on may be incorporated into the problem
formulation. These new criteria will be fiber strain, matrix strain, and mass.
The following is the modified optimization setup:
Design Ply thicknesses, which have been defined in the size input deck from Phase
variables: 1
Objective: Minimize the total mass
Constraints:  Fiber Strain < 9000  (microstrain)

 Matrix Strain < 7000  (microstrain)
Manufacturing constraints previously applied are preserved and transferred to the DCOMP card.
Step 1: Save the model as oht_opti_ph2.hm
Step 2: Review and edit the size design variables

1. From the optimization panel, click size.
2. Click review and select autoply.
3. Set the initial value= to 0.04, the thickness of four plies.

4. Set the upper bound to 0.2, set the lower bound to 0.0.
5. Click update to update the design variable.
6. Repeat steps 2.3 through 2.5 on each of the size design variables to update the bounds and
starting value for each.
Note: The DESVARs have the same ID numbers as the design variable property relationship
(DVPREL) that they relate to. These ID numbers also refer to the plies created in the
previous optimization – in this way, they can easily be cross-referenced.
Step 3: Edit the manufacturable thickness and initial value of each ply
1. In the Model browser, select all plies as shown below.
Figure 19: A view of the Model browser showing all plies selected

2. In the Entity Editor, set TMANUF to 0.01 and Thickness to 0.04.
This changes the values for all plies simultaneously.
Step 4: Update the laminate calculation type

1. In the Model browser, right-click and select Laminate > laminate > Edit.
2. In the laminate edit dialog box, set Laminate option to Symmetric smear.
3. Click Update to exit.
The laminate option defines the laminate behavior. In this case SMEAR theory is used to
define the laminate behavior; that is the A-matrix is calculated exactly since it is stacking
sequence independent, the D-matrix is calculated as AT2/12, and finally the B-matrix is set to
zero. Adding the Symmetric option to the SMEAR theory just assures a symmetric laminate
will be output by adding/removing 2 plies at a time vs. 1 ply at a time.
Step 5: Delete the existing responses, constraints, and objective

1. Right-click in the Model browser, and select Optimization Response > Delete.
2. HyperMesh asks you to confirm the delete. Click Yes to continue.
When responses are deleted in HyperMesh, all constraints and objectives which depend on
those responses are deleted.
Step 6: Create the new responses for size optimization

The responses of volume, natural frequency, and composite strain are created for size
optimization.
1. Click optimization and then click responses.
2. In the response= field, enter fiber_e.
3. Set the response type to composite strain, set the component to mechanical, change
the entity selector to plies, and use the plies entity selector to select all plies in the model.
4. Set the response component to normal 1, and check the box for all plies.
Figure 20: The fiber mechanical strain response
5. Click create to create the new response.

6. In the response= field, enter matrix_e.

7. Set the response type to composite strain, set the component to mechanical, set the
entity selector drop-down to plies, and use the plies entity selector to select all plies in the
model.
8. Set the response component to normal 2, and check the box for all plies.
Figure 21: The matrix mechanical strain response
9. Click create to create the new response.

10. In the response= field, enter mass.
11. Set the response type to mass, set the type to total.
12. Click create.
13. Click return to go back to optimization panel.
Step 7: Create optimization constraints

The responses of fiber and matrix strain are defined as the optimization constraints.
1. From the optimization panel, click dconstraint.
2. For constraint=, enter fiber_e.
3. Click response= and select fiber_e.
4. Activate upper bound and enter 0.009.
5. Click the highlighted loadsteps and select the loadcase nx_step.
6. Click create.
7. Repeat steps 7.2 through 7.6 to create constraint matrix_e on response matrix_e for
loadstep nx_step with an upper bound of 0.007.
Step 8: Create objective function for the optimization

1. Click objective.
3. Click response= and select mass.
4. Click create.

Step 9: Edit the composite size design variable to update the
manufacturing constraints
1. From the Analysis page, select composite size.
2. Click review and select the free-size design variable.
This DESVAR has been carried over from the previous optimization as a size optimization with
manufacturing constraints preserved from the original optimization.
3. On the parameters subpanel, toggle minimum thickness to activate it and enter a value of
0.04.
4. Click edit and review the manufacturing constraints to ensure that PLYPCT is set to restrict 0
and 90-degree plies to between 0.2 and 0.7, BALANCE is set to 45 and -45 degree plies,
and PLYDRP is still set to TOTAL with a PDMAX of 0.33.
5. Click return to keep these parameters.
6. Click update.
Step 10: Define the output request for shuffling deck

The output control on composite strain and stress results defined in the previous phase are
carried over automatically. OUTPUT,SZTOSH (sizing to shuffling) writes a ply stacking
optimization input deck.
2. Go to the OUTPUT panel.
3. Change the final keyword, FSTOSZ, to SZTOSH and YES for FREQ.
Step 11: Submit the size optimization job

2. Click OptiStruct to launch OptiStruct and run the optimization.
where oht_opti_ph2.fem was saved.
A few default files are:
oht_opti_ph2_s1.h3d Hyper 3D binary results file, with the analysis results of

each subcase.
oht_opti_ph2_des.h3d Hyper 3D binary results file, with size optimization

results.
oht_opti_ph2.out An ASCII output file containing specific information on

the model setup, compute time information, etc. Review

oht_opti_ph2_shuffling.*.fem A ply stacking optimization input deck. The DESVAR and
DVPREL cards from the previous stage are removed, and
a bare DSHUFFLE card is introduced. The * sign
represents the final iteration number.
oht_opti_ph2_shuffling.*.inc An ASCII include file containing ply stacking

optimization data.
Step 12: View the thickness results in HyperView

1. Click HyperView in the OptiStruct panel when the run has completed.
2. Follow the instructions in Step 7 from Phase 1 to create the Thickness contour.
Figure 22: Element thickness contour plot (final iteration) after phase-2 size optimization
This brings us to the third and final phase of the design process in which you try to identify a
proposal for the optimal stacking sequence of the plies.

Phase 3 – Ply Stacking Sequence Optimization
This algorithm is aimed at providing a global view of what the optimal stacking sequence could
be. An input deck for the ply stacking sequence optimization, oht_opti_ph2_shuffling.*.fem,
was generated from a previous design stage. Each ply bundle is divided into multiple PLYs whose
thickness is equal to the manufacturable thickness (0.01 in this case), and the STACK card is
updated accordingly. In this design phase, composite plies are shuffled to determine the optimal
stacking sequence.
It is important that design performances are preserved. Hence, the optimization problem is
retained as previously formulated in the size optimization phase. Two manufacturing constraints
are applied:
 The maximum successive number of plies of a particular orientation does not exceed 4
plies.
 The outermost four layers of the layup must be -45, 0, 45, 90.
Step 1: Load the OptiStruct user profile and import the model into a new
session
Follow Step 1 from the free-size phase to load the oht_opti_ph2_shuffling.*.fem file into a
new HyperMesh session.
Step 2: Save the model as oht_opti_ph3.hm
Step 3: Update the design variable to input the constraints for the
shuffling optimization
1. In the optimization panel, click on composite shuffle to enter the composite shuffling
panel.
2. Click review and select free-size to review the design variable.
3. In the parameters subpanel, click edit to enter the DSHUFFLE card.
4. Check MAXSUCC and set MSUCC to 4.
5. Check COVER and set NUMBER_OF_VANG to 4.
6. In the DSHUFFLE card editor, set VREP to 1, VANG(1) to -45, VANG(2) to 0, VANG(3) to
45, and VANG(4) to 90.
This sets the outermost layer of the shuffling sequence to maintain one repetition of a set of -
45, 0, 45, 90 degree plies. This ply set is applied to both faces of this optimization, since the
laminate is symmetric.
7. Click return to exit the editor and click update to update the design variable.
8. Click return to return to the optimization page.

Step 4: Submit the shuffling job
1. In the OptiStruct panel on the Analysis page, click OptiStruct.
The following result files are generated:
oht_opti_ph3.prop A property file contains the composite materials and ply

properties at the last iteration.
oht_opti_ph3.shuf.html An html file contains the history of the shuffling optimization

and the view of the ply stacking sequence.
Step 5: Post-process the results

1. Go to the directory where oht_opti_ph3.shuf.html is located and double-click the file.
It is automatically loaded in your default Internet browser window.
The plies are color coded based on their fiber orientations.
Figure 23: Shuffling Optimization History
The above image shows the history of the shuffling optimization. The columns represent the
global trend of the ply stacking sequence at a particular iteration, with the last column being
the final solution.
The weight of the part has not been changed during the shuffling design phase, rather the
plies were reordered to obtain the maximum performance.
This light weight design therefore meets all of the performance requirements, is feasible and
manufacturable.

Post-Optimization Final Analysis
The following set of steps provides a final optimized structure for comparison with the initial
model.
Step 1: Load the OptiStruct user profile and open the model into
HyperMesh
1. Launch a new session of HyperMesh.
3. Click the Import Solver Deck icon and select oht_opti_ph3.fem.

4. Click Import. The oht_opti_ph3.fem database is loaded into the current HyperMesh session.
Step 2: Import the final optimization properties over the existing model
1. In the Import tab, browse for the oht_opti_ph3.prop file.
2. Expand the Import options section by using the drop-down toggle .
3. Check the box for FE overwrite and click Import to update the properties of the model with
the optimized parameters.
Step 3: Alter the control cards

1. Expand the Card tree in the Model browser and right-click on the OMIT card to select
Delete.
2. HyperMesh asks you to confirm the delete: Click Yes to continue.
3. Click on the OUTPUT card to load it into the Entity Editor. Change the number_of_outputs
to 2 to delete the final section in the card.
Step 4: Delete the optimization entities

1. Right-click in the Model browser on the Design Variable tree and select Delete.
2. Click Yes to continue.
3. Similarly, right-click in the Model browser on the Optimization Response tree and select
Delete.

Step 5: Review the model
1. Find the element visualization button and change the mode to 2D detailed element
representation using the drop-down selector.
This will thicken all shells in the model to their total thickness, displaying them as 3-
dimensional representations of their thicknesses.
2. Click Layers to select Composite Layers.
This will separate the view into individual plies.
3. To assist in determine which plies are which in the layup, change the element color mode to
By Prop .
This represents each of the plies in the model according to the color of its ply as shown in the
Model browser. If all of the plies in the model are the same color, change the ply colors in the
Model browser so that each is different to help differentiate the plies in the graphics area.
Figure 24: Visualization of model thickness in HyperMesh with half of the elements in the model masked
Step 6: Run the final analysis

1. Enter the OptiStruct panel on the Analysis page.
2. Ensure that export options is set to all and run options is set to analysis.
3. Click OptiStruct to export the model and run the baseline analysis as oht_final.fem.

Step 7: Post-process the final analysis in HyperView
1. When the run is complete, click on the HyperView button in the OptiStruct panel to load the
results into HyperView.
2. Enter the Contour panel . Set Result type to Composites Strains(Mech) (s) and set the
subtype to Normal X Strain.
This corresponds to the fiber strain in the model.
in the Layers drop-down. Confirm that no ply exceeds 9000 microstrain (9e-3).
4. Set Result type to Composites Strains(Mech) (s) and set the subtype to Normal Y
Strain. This corresponds to the matrix strain value.
in the Layers: drop-down. Confirm that no ply exceeds 7000 microstrain (9e-3) for the
matrix.
The final design weighs ~0.33 lbs.
Figure 25: A plot of maximum Normal Y strain across all plies, showing that no element exceeds 0.007 me

Size Optimization
OS-4000: 3D Size Optimization of a Rail Joint

This tutorial demonstrates how to perform a size optimization on an automobile rail joint modeled
with shell elements. The structural model with loads and constraints applied is shown in the
figure below. The deflection at the end of the tubular cross-member should be limited. The
optimal solution would be to use as little material as possible.
Structural model of a rail joint.
The structural model, shown above, is loaded into HyperMesh. The constraints, loads, material
properties, and subcases (loadsteps) are already defined in the model. Size design variables and
optimization parameters are defined, and OptiStruct determines the optimal gauges for the
components. The results are then reviewed in HyperView.
Constraints: A given maximum nodal displacement at the loading grid point for
two loading conditions.
Design Gauges of the two parts.

variables:

 Setup a size optimization in HyperMesh
 Post-process size optimization results in HyperView

Exercise
Set up a Size Optimization in HyperMesh Desktop
Step 1: Launch the HyperMesh Desktop, set the User Profile and Retrieve
the File
2. Choose the OptiStruct in the User Profiles dialog and click OK. This loads the user profile. It
User Profiles GUI can also be accessed from the Preferences menu on the toolbar.
3. Select the Open Model file toolbar icon .

4. Select the joint_size.hm file you saved to your working directory from the optistruct.zip
5. Click Open.
Step 2: Create the Size Design Variables for Optimization

2. Click the size panel.
3. Make sure the desvar subpanel is selected using the radio buttons on the left-hand side of
the panel.
4. Click desvar = and enter tube.
5. Click initial value = and enter 1.0.
6. Click lower bound = and enter 0.1.
8. Make sure the move limit toggle is set to move limit default.
9. Make sure the discrete design variable (ddval) toggle is set to no ddval.
10. Click create.
A design variable, tube, has been created. The design variable has an initial value of 1.0, a
lower bound of 0.1, and an upper bound of 5.0.
11. Repeat steps 4 through 10 to create the design variable rail using the same initial value,
lower, and upper bounds.
A design variable, rail, has been created. The design variable has an initial value of 1.0, a
12. Select the generic relationship subpanel using the radio buttons on the left-hand side of the
panel.
13. Click Name = and enter tube_th.

14. Click prop and select tube2 from the list of property collectors.
15. Make sure the toggle is set to Thickness T.
16. Click designvars. The list of design variables appears.
17. Check the box next to tube.
Note the linear factor (value is box beside tube) automatically gets set to 1.000.
18. Click return.
19. Click create.
A design variable to property relationship, tube_th, has been created relating the design
variable tube to the thickness entry on the PSHELL card for the property tube2.
20. Repeat steps 13 through 19 to create the design variable to property relationship rail_th
relating the design variable rail to the thickness entry on the PSHELL card for the property
tube1.
Step 3: Create the Volume and Static Displacement Response

A detailed description can be found in the OptiStruct User's Guide under Responses.
5. Click create. A response, volume, is defined for the total volume of the model.
6. Click response = and enter X_Disp.
7. Click the response type: switch and select static displacement from the pop-up menu.
8. Click nodes and select by id from the pop-up menu.
9. Enter 3143 (node at center of rigid spider at loading point) and press ENTER.
10. Select dof1 and click create. A response, X_Disp, is defined for the x-displacement of the
node 3143.
11. Click response = and enter Z_Disp.
12. Click nodes and select by id from the pop-up menu.
13. Enter 3143 (node at center of rigid spider at loading point) and press ENTER.
14. Select dof3 and Click create. A response, Z_Disp, is defined for the z-displacement of the
node 3143.

Step 4: Create Constraints on Displacement Response
response volume.
Upper bound constraints are to be defined for the responses X_Disp and Z_Disp.
2. Click constraint = and enter Disp_X.
3. Check the box for upper bound =.
5. Click response = and select X_Disp from the list of responses. A loadsteps button appears
in the panel.
6. Click loadsteps.
7. Check the box next to FORCE_X and click select.
8. Click create.
A constraint is defined on the response X_Disp. The constraint is an upper bound with a value
of 0.9. The constraint applies to the subcase FORCE_X.
9. Click constraint = and enter Disp_Z.
12. Click response = and select Z_Disp from the list of responses.
14. Check the box next to FORCE_Z and click select.
15. Click create.
A constraint is defined on the response Z_Disp. The constraint is an upper bound with a value
of 1.6. The constraint applies to the subcase FORCE_Z.

In this example, the objective is to minimize the volume response defined in the previous
section.
1. Click objective to enter the panel.
2. The switch in the left should be set to min.
3. Click response = and select volume from the response list.

1. From the File menu, select Save as > Model. A Save As dialog appears.
2. Select the directory where you would like to save the database and enter the name for the
database, joint_sizeOPT.hm, in the File name: field.
3. Click save.

2. Click save as.
3. Select the directory where you would like to write the model file and enter the name for the
file name, joint_sizeOPT.fem, in the File name: field. The .fem file extension is used for
4. Click Save.
The name and location of the joint_sizeOPT.fem file displays in the input file: field.
8. Click OptiStruct to run the optimization. This launches the OptiStruct job.
model file was written. The joint_sizeOPT.out file is a good place to look for error messages
Important files for size optimization include:
joint_sizeOPT.hgdata HyperGraph file containing data for the objective function, percent
constraint violations and constraint for each iteration.
joint_sizeOPT.prop OptiStruct property output file containing all updated property data
from the last iteration for size optimization.
joint_sizeOPT.hist OptiStruct iteration history file, containing the iteration history of

the objective function and of the most violated constraint. This file
can be used for a xy plot of the iteration history.
joint_sizeOPT.out OptiStruct output file containing specific information on the file

setup, the setup of the optimization problem, estimates for the
amount of RAM and disk space required for the run, information for
all optimization iterations, and compute time information. This file
contains compliance, volume calculations, and gauge information
for all optimization iterations. It is highly recommended to review
joint_sizeOPT.res HyperMesh binary result file.

joint_sizeOPT_des.h3d HyperView binary result file, containing the design iteration results.
joint_sizeOPT_s1.h3d HyperView binary result file, containing the analysis results of

subcase with ID 1.
joint_sizeOPT_s2.h3d HyperView binary result file, containing the analysis results of

subcase with ID 2.
joint_sizeOPT.stat Summary of analysis process, providing CPU information for each

Post-process Size Optimization Results in HyperView
Displacement and stress results are output by OptiStruct (by default) for linear static analyses.
This section describes how to view those results in HyperView. Size optimization results from
OptiStruct are given in the .h3d files and joint_sizeOPT.out.
joint_sizeOPT_des.h3d Contains the element thickness for all five iterations.
joint_sizeOPT_s1.h3d Contains displacement and stress results for the linear static
analysis for iteration 0 and iteration 4 of subcase with ID 1
(subcase Force_X).
joint_sizeOPT_s2.h3d Contains displacement and stress results for the linear static
analysis for iteration 0 and iteration 4 of subcase with ID 2
(subcase Force_Z).
joint_sizeOPT.out Contains gauge and volume information for all iterations.
The results contained in the HyperView binary results file will be examined first. Then the gauge
history in the joint_sizeOPT.out file will be reviewed.
Step 8: View the Size Optimization Results (gauge thickness)

1. When the message Process completed successfully appears in the command window, click
HyperView.
HyperView launches and the results are loaded. A message window appears to inform about
the successful loading of the model and result files into HyperView. Notice that all three .h3d
files get loaded, each into a different page in HyperView. The files joint_sizeOPT_des.h3d,
joint_sizeOPT_s1.h3d, and joint_sizeOPT_s2.h3d get loaded in page 2, page 3, and page
4, respectively. The optimization iteration results (gauge thickness) are loaded in the first
page. The name of the page is displayed as Design History to indicate that the results
correspond to optimization iterations.
4. Make sure the first drop-down list below Result type: is on Element Thicknesses (s).
5. Make sure the second drop-down list is set to Thickness.

6. Make sure the field below Averaging method is None.
7. Set the last load case simulation in the HyperView Results browser, as shown below. Scroll
down to choose the last iteration (Iteration 4, in this case), and click OK.
8. Click Apply.
A contoured image representing shell thickness should be visible. Each element in the model
is assigned a legend color, indicating the thickness value for that element for the current
iteration.
Thickness contour at last iteration.
Step 9: View the Displacement Results

It is helpful to view the deformations of the model to determine if the boundary conditions have
been met and also to see if the model is deforming as expected. These analysis results are
available in pages 3 and 4.

1. Click the Next Page toolbar icon .
The third page, which has results loaded from the file joint_sizeOPT_s1.h3d, is displayed.
The name of the page is displayed as Subcase 1 – FORCE_X to indicate that the results
correspond to subcase 1.
2. Set the animation mode to Linear Static.
4. Select the first drop-down list below Result type: and select Displacement [v].
5. Select the second drop-down list and select X.
6. Click Apply. The resulting contours represent the x component displacement field resulting
from the applied loads and boundary conditions.
7. Click the Measure toolbar icon .

8. Click Add to add a new measure group. The Measure panel helps measure different results.
Here, you will measure the displacement at node 3143 for which you have constrained the
displacement.
9. Click the drop-down menu and select Nodal Contour as shown below.
10. Click Nodes, which opens a new window to select nodes By ID.
11. Click By ID to open a new window.
12. Enter 3143 in the field next to Node ID and click Ok.
Displacement on X-direction for the X-force loadcase at the first iteration.
The x-displacement value for 3143 (center of rigid spider, where loading is applied) is shown
in the graphic area. The x-displacement is larger than the upper bound constraint, which was
defined earlier, of 0.9.

13. In the HyperView Results browser, select the last iteration by double-clicking on the last
Iteration #.
The contour now shows the x-displacement results for Subcase 1 (FORCE_X) and iteration 4,
which corresponds to the end of the optimization iterations. Note that the x-displacement is
now less than 0.9.
Displacement on X-direction for the X-force loadcase at the last iteration.
14. Click the Next Page icon again to move to the fourth page.
The fourth page shows results loaded from the joint_sizeOPT_s2.h3d file. The name of the
page is displayed as Subcase 2 – Force_Z to indicate that the results correspond to subcase
2.
16. Select the first drop-down menu below Result type: and select Displacement [v].
17. Select the second drop-down menu and select Z.
18. Click Apply. The resulting contours represent the z component displacement field resulting
from the applied loads and boundary conditions.
19. Repeat steps 8 through 14 to measure and display the z-displacement value for node 3143.

Alternate Way to View the Gauge Thickness Results
From the UNIX or MSDOS shell, open the joint_sizeOPT.out file in a text editor. Review all five
iterations, noting the volume, constraint information, and gauge at each iteration.
Have the displacement constraints been met?
What are the resulting gauges for the rail and tube?

OS-4010: Size Optimization of a Welded Bracket
This tutorial demonstrates how to perform a size optimization on a welded bracket modeled with
shell elements. The structural model with loads and constraints applied is shown in the figure
below. The objective is to minimize the amount of material used in the model subject to certain
stress specifications. The gauge changes of the bracket are linked to each other so that the
gauge is identical for both sides at the optimal design.
Structural model of the welded bracket.
The structural model, as shown, is loaded into HyperMesh. The constraints, loads, material
properties, and subcases (loadsteps) are already defined in the model. Size design variables and
optimization parameters are defined and the OptiStruct software determines the optimal gauges.
The results are then reviewed in HyperMesh.
Constraints: Maximum von Mises Stress of the brackets < 100 Mpa.
Design Gauges of the brackets.

variables:

 Setting up the size optimization problem in HyperMesh

Exercise
the Database File
profile. It includes the OptiStruct template, macro menu, and import reader, paring down the
functionality of HyperMesh to what is relevant for use with OptiStruct.
3. Select the Open Model toolbar icon .

4. Select the bracket_size.hm file you saved to your working directory from the
The bracket_size.hm database is loaded into the current HyperMesh session, replacing any
existing data.
Step 2: Define the Design Variables

2. Select the size panel.
3. Select the desvar subpanel using the radio buttons on the left-hand side of the panel.
4. Click desvar = and enter part1.
8. Set the move limit toggle to move limit default.
9. Click create.
A design variable, part1, has been created. The design variable has an initial value of 2.5, a
10. Repeat steps 4 through 9 to create the design variable part2 using the same initial value,
lower, and upper bounds.
panel.
12. Click name = and enter part1_th.
13. Click the entity selection switch and choose prop.
14. Click prop and select part1 from the list of component collectors. A property selection switch
now appears below the comp button.
15. Click the property selection switch and select Thickness T from the pop-up menu.

17. Check the box next to part1.
The linear factor (value is box beside part1) is automatically set to 1.000.
18. Click return.
19. Click create.
A design variable to property relationship, part1_th, has been created relating the design
variable part1 to the thickness entry on the PSHELL card for the component part1.
20. Repeat steps 12 through 19 to create the design variable to property relationship part2_th
relating the design variable part2 to the thickness entry on the PSHELL card for the
component part2.
Step 3: Link the Design Variables

1. Select the desvar link panel.
2. Click dlink = and enter link1.
3. Click designvar=, under dependent:, and select part2.
4. Click designvars, under independent:, and activate part1.
Note the linear factor (value is box beside part1) automatically is set to 1.000.
5. Click return.
6. Set C0 = 0.000 and CMULT = 1.000.
7. Click create.
The design variable part2 is now linearly dependent on the design variable part1.

3. Click the response type: switch and select volume from the pop-up menu. Make sure type
is set to total.
5. Click response = and enter stress1.
6. Click the response type: switch and select static stress from the pop-up menu.
7. Click props and select the component part1.
8. Click select. A stress type selector switch appears.
9. Click the response selector switch and select von mises from the pop-up menu.
10. Click the switch under von mises and select both surfaces from the pop-up menu.

11. Click create. A response, stress1, is defined for the von Mises stress of the elements in the
component part1.
13. Click props.
14. Click one of the pink shell elements in the graphics window to select the component part2.
15. Click select.
component part2.

section.
2. Click the switch in the upper left corner of the panel, and select min from the pop-up menu.
5. Click return to return to the Optimization Setup panel.
Step 6: Define Constraints

response volume.
Upper bound constraints are to be defined for the responses stress1 and stress2.
2. Click constraint = and enter stress1.
3. Click response = and select stress1 from the list of responses. A loadsteps button appears
in the panel.
4. Click loadsteps.
5. Check the box next to STEP and click select.
7. Click upper bound = and enter 100.
8. Click create. A constraint is defined on the response stress1. The constraint is an upper
bound with a value of 100. The constraint applies to the subcase STEP.
10. Click response = and select stress2 from the list of responses.

15. Click create. A constraint is defined on the response stress2. The constraint is an upper
bound with a value of 100. The constraint applies to the subcase STEP.

1. From the File menu, click Save As. A Save file browser window opens.
2. Select the directory where you would like to save the database, enter the name
bracket_size.hm for the database, and click Save.

name for the model, bracket_size.fem, in the File name: field. The suggested file extension
for OptiStruct input decks is .fem.
4. Click Save.
The name and location of the bracket_size.fem file displays in the input file: field.
6. Set the run options: toggle to optimization.
model file was written. The bracket_size.out file is a good place to look for error messages
bracket_size.hgdata HyperGraph file containing data for the objective function, percent
constraint violations and constraint for each iteration.
bracket_size.his_dat OptiStruct iteration history file, containing the iteration history of

the objective function and of the most violated constraint. Can be
used for an xy plot of the iteration history.
bracket_size.html HTML report of the optimization, giving a summary of the problem

formulation and the results from the final iteration.

bracket_size.out OptiStruct output file containing specific information on the file set-
up, the set-up of your optimization problem, estimate for the
amount of RAM and disk space required for the run, information for
all optimization iterations, and compute time information. This file
contains compliance, volume calculations, and gauge information
for all optimization iterations. It is highly recommended this file be
reviewed for warnings and errors.
bracket_size. prop OptiStruct property output file containing all updated property data
from the last iteration for size optimization.
bracket_size.h3d HyperView binary results file.
bracket_size.sh Shape file for the final iteration. It contains the material density,
void size parameters and void orientation angle for each element
in the analysis. The .sh file may be used to restart a run and, if
necessary, run OSSmooth files for topology optimization.
bracket_size.stat Summary of analysis process, providing CPU information for each

Viewing the Results
Size optimization results from OptiStruct are given in two places. The bracket_size.out file
contains gauge and volume information for all iterations. The bracket_size.h3d file contains the
element thickness for all five iterations and Displacement and Stress results for the linear static
analysis for iteration 0 and iteration 3. This section describes how to review all results. The
results contained in the HyperMesh binary results file will be examined first. The gauge history in
the bracket_size.out file will then be reviewed.
Step 9: View the Stress Results

After the size optimization, the stress value should be reviewed to make sure the stress
constraints are not violated.
click HyperView.
This launches HyperView and opens the results. A message window appears to inform about
the successful loading of the model and result files into HyperView. Notice that all of the .h3d
files get loaded, each into a different page in HyperView. The files bracket_size_des.h3d
and bracket_size_s2.h3d get loaded in pages 2 and 3, respectively.
3. Click the Next Page toolbar icon .
The third page has the results loaded from the bracket_size_s1.h3d file. The name of the
page is displayed as Subcase 1 – STEP to indicate that the results correspond to subcase 1.

5. Select the first drop-down menu below Result type: and select Element Stresses [2D &
3D] (t).

6. From the second drop-down menu, select vonMises.
8. Click Apply.
model is assigned a legend color, indicating the von Mises stress value for that element
resulting from the applied loads and boundary conditions. If you did not change the Iteration
step, you should contour the stress of the initial step. To contour the final step, set the last
iteration of that loadcase using the Model browser.
9. Click the last Iteration # in the Simulation list.
Notice only two iterations are displayed; the First and Last (FL) is the default setting for
optimization runs. To change this setting, add an OUTPUT control card with a frequency
setting of ALL.
This will now contour your final iteration of that loadcase. Review the stress to see that it is
under the proper constraints.
Step 10: View the Thickness Results

1. Click the Previous Page toolbar icon to move to the First page.
2. Make sure Result type: is set to Element Thicknesses (s).
3. Also make sure that you select Iteration 2 from the Load Case and Simulation Selection
window.
4. Click Apply.
Alternatively, you can also open the bracket_size.prop file in a text editor to view the final
gauge thicknesses of the two parts.

Review
The .out file contains a summary of the optimization process. From the information in the .out
file, you can see how the objective, constraints, and design variables are changing from one
iteration, to the next.
Have the stress constraints been met?
What are the resulting gauges for the two parts?
Did the design variable linking work?

OS-4020: Composite Bike Frame Optimization
In this tutorial the steps required to perform a ply orientation optimization for a composite
structure are covered. The figure below illustrates the model that is used in this tutorial.
Bicycle frame model
Constraints: A given maximum nodal displacement.
Design variables: Layer thickness.

 Setup the size optimization of a composite bike frame
 Post-process the composite size optimization results in HyperView

Exercise
Set up the Size Optimization of a Composite Bike Frame
Step 1: Launch the HyperMesh Desktop and Set the User Profile

4. Select the bicycle_frame.hm file you saved to your working directory from the
5. Click Open. The bicycle_frame.hm database is loaded into the current HyperMesh session,
The structural model has already been set up with the necessary elements, parts, property,
and material data. The next step is to load the frame to simulate a sprint scenario.
Step 2: Create Load Collectors for the Loads and Boundary Conditions
1. In the Model browser, right-click and click Create > Load Collector.
2. For Name, enter crank.
This creates a new load collector, crank.
5. Similarly, create another load collector named spcs.
Step 3: Create Loads

1. Click Set Current Load Collector at the right bottom corner of the HyperMesh window to
enter a new panel in which the load collectors are listed.
2. Select crank from the list of load collectors.

3. From the Analysis page, select forces to enter the panel.
5. Click the entity selection switch, immediately to the right of the create radio button and
select nodes from the pop-up menu.

6. Select the node at the center of the rigid spider, as seen in the figure below, by clicking on it
in the graphical display area.
7. Set the coordinate system toggle to global system.
8. Click magnitude = and enter -100.0.
9. Click the direction definition switch below magnitude = and select the z-axis from the pop-
up menu.
10. Click create. This creates a point force at the pedal location.
12. From the Analysis page, select the moments panel.
15. Select the node at the center of the rigid spider as seen in the figure below, by clicking on it
in the graphical display window.
16. Set the coordinate system toggle to global system.
17. Click magnitude = and enter 100.0.
18. Click the direction definition switch below magnitude = and select the x-axis from the pop-
up menu.
19. Click create. This creates a moment at the pedal location.
Loads applied to bottom bracket of a bicycle
Note: This is a simplified loading regime that represents the

transformed loads from a person's foot on the pedal.
20. Click return.

1. Click Set Current Load Collector at the right bottom corner of HyperMesh window, as in
step 3, to enter a new panel in which the load collectors are listed.
2. Select spcs from the list of load collectors.
Note that spcs now appears on the footer bar to indicate that it is the current load collector.
3. From the Analysis page, select constraints to enter the panel.
6. Select the nodes shown below to constrain the structure by clicking on the center of the rigid
spiders, as seen in the next two figures.
SPCs applied to rear wheel location of frame

SPCs applied to upper and lower portion of head tube.
7. Constrain dof1, dof2, dof3, dof4, dof5, and dof6.

Dofs with a check are to be constrained, while dofs without a check will be free.

2. For Name, enter crank.
3. Click Analysis type and select Linear Static from the drop-down menu.
5. In the Select Loadcol dialog, select spcs from the list of load collectors and click OK.
7. In the Select Loadcol dialog, select crank from the list of load collectors and click OK.
An OptiStruct loadstep has been created which references the constraints in the load collector
spcs and the forces in the load collector crank.

Step 6: Set up the Design Variables
1. From the 2D page, select the HyperLaminate panel. This launches the HyperLaminate GUI.
The next steps are performed in the HyperLaminate GUI.
2. Expand the Design Variable portion of the tree structure on the left-hand side of the screen.
The DESVAR branch appears.
3. Right-click on DESVAR. A floating menu appears with the option New.
4. Click New. This creates a new design variable, which is named NewDv1 by default, and the
tree structure is expanded.
5. Rename the design variable to thk1 by right-clicking on NewDv1, select Rename, and
overwriting the default design variable name.
6. In the Initial value: field, enter 1.0.
7. In the Lower bound: field, enter 0.0.
8. In the Upper bound: field, enter 2.0.
9. Click Apply.
10. In a similar manner, and with identical values, create a total of 5 design variables following
the procedure outlined in steps 4 through 9 for thk2, thk3, thk4, and thk5.
Alternately, you can right-click on thk1 and select Duplicate from the floating menu to
create an identical design variable. Repeat this process to create a total of 5 design variables,
then rename the new design variables by right-clicking on them and selecting Rename.
11. Examine the PCOMP branch to see all of the PCOMPs in the model.
12. Select the seat_tube PCOMP. Details of the laminate appear in the GUI.
13. Click the check box next to Optimization at the top of the middle panel.
New fields appear in the Ply lay-up order table allowing design variables to be associated to
ply thicknesses or ply orientations.
14. Click on the field under Designvar under Optimization in row 1.
15. Choose thk1 from the drop-down menu.
16. Repeat steps 14 and 15 for the other rows, as shown below:
17. Click Update Laminate.

This associates the design variables thk(i) with the thickness for the ply(i) of this laminate.
In this case, ply(11-i) too, since this is a symmetric laminate.

18. Repeat this process for TOP_tube and down_tube using the same DVs as on the seat_tube
property.
19. Click Exit from the File menu.
Exiting the HyperLaminate GUI and returning to HyperMesh.
Step 7: Create a Displacement and Volume Response

Create a response to measure the total displacement of the node where the loads have been
applied and set the objective to minimize this response.
1. From the Analysis page, select optimization to enter the panel.
2. Select responses to enter this panel.
3. Click response= and enter disp.
5. Click the total disp radio button.
6. Click nodes and select the node at the bottom bracket where the loads were applied by
clicking on it in the graphical display window.
7. Click create.
8. Click response= and enter volume.
10. Leave total set.
11. Click create.
Step 8: Create Constraints on the Displacement Response

2. Click constraint= and enter Disp.
5. Click response = and select disp from the list of responses. A loadsteps button appears in
the panel.
6. Click loadsteps.
7. Check the box next to crank and click select.
8. Click create.
A constraint is defined on the response disp. It states that any solution (min. volume) needs
to have a displacement lower than 1.8 mm to be feasible.

1. Select objective to enter the panel.
2. Click the left-hand switch and select min.
3. Click response= and choose volume from the pop-up menu.
4. Click create.

1. From the Analysis page, select OptiStruct to enter the panel.
2. Following the input file: field click save as.
name for the model, bicycle_frameOPT.fem, in the File name: field. The .fem extension is
4. Click Save.
The name and location of the bicycle_frameOPT.fem file displays in the input file: field.
model file was written. The bicycle_frameOPT.out file is a good place to look for error
Post-processing the Composite Size Optimization Results in HyperView
Step 11: Review the Results in HyperGraph

View the design variable and objective history.
1. Open a session of HyperView using the Add Page icon.
2. From the File menu, select Open. An Open Session File browser window appears.
3. Select the bicycle_frameOPT_hist.mvw file that was created from your OptiStruct run and
click Open.
This file contains plots of the objective, constraints, and design variables against iteration
history. The first page shows the Objective function.

Objective function (Volume) for each iteration.
The second page shows the Maximum Constraint Violation.
Maximum constraint violation (% [disp > 1.8 mm]) for each iteration.
The next pages show the Design Variables (DVs) which are grouped together making it
possible to compare the behavior of the different plies. This plot can be created by opening
the bicycle_frameOPT.hgdata file.

Design variable values for each iteration.

OS-4030: Discrete Size Optimization of a Welded Bracket
This tutorial demonstrates how to perform a size optimization on a welded bracket modeled with
shell elements using discrete design variables. The structural model with loads and constraints
applied is shown in the figure below. The objective is to minimize the amount of material used in
the model subject to certain stress specifications.
The structural model, as shown in the figure, is loaded into HyperMesh. The constraints, loads,
material properties, and subcases (loadsteps) are already defined in the model. Size design
variables and optimization parameters are defined, and OptiStruct determines the optimal
gauges. The results are then reviewed in HyperView.
Constraints: Maximum von Mises stress of the brackets < 120 MPa.
Design variables: Gauges of the brackets.

 Setup a size optimization with discrete design variables in HyperMesh
 Post-process the optimization results in HyperView

Exercise
Retrieve the Database File

4. Select the bracket_size.hm file you saved to your working directory from the
5. Click Open. The bracket_size.hm database is loaded into the current HyperMesh session,
Setting Up a Size Optimization with Discrete Design Variables in

HyperMesh
Step 2: Create the Design Variables

1. From the Analysis page, click optimization to enter the panel.
2. Select discrete dvs to enter this panel.
3. Click on the field next to name= and enter DDV1.
4. Click on the field next to from= and enter the value 0.5. With the same method, enter 3.0
for to= and 0.1 for increment=. The TAB key can be used for faster inputs.
5. Click create.
This sets up a discrete design variable with a starting value of 0.5 and ending value of 3.0.
The variables are incremented by 0.1, making the possible values as 0.5, 0.6, 0.7, and so on
until 3.0.
6. Create another discrete design variable, DDV2, with the same discrete values as DDV1.
8. Select the size panel.
9. Select the desvar subpanel using the radio buttons on the left-hand side of the panel.
10. Click desvar = and enter part1.
14. Toggle no ddval to ddval =.
15. Click ddval= and select DDV1 from the list.

16. Click create.
A design variable, part1, has been created. The design variable has an initial value of 2.5, a
lower bound of 0.5, and an upper bound of 3.0 and is linked to a DDVAL (Discrete Design
Variable Value) of the name DDV1.
17. Repeat steps 10 through 16 to create the design variable part2 using the same initial value,
lower, and upper bounds, linking it to a DDVAL of name DDV2.
panel.
19. Click name = and enter part1_th.
20. Click the entity selection switch and choose prop.
21. Click prop and select part1 from the list of component collectors. A property selection switch
now appears below the prop button.
22. Click the property selection switch and select Thickness T from the pop-up menu.
24. Check the box next to part1.
25. The linear factor (value in box beside part1) is automatically set to 1.000.
26. Click return.
27. Click create.
A design variable to property relationship, part1_th, has been created, relating the design
variable part1 to the thickness entry on the PSHELL card for the component part1.
28. Repeat steps 19 through 26 to create the design variable to property relationship part2_th,
relating the design variable part2 to the thickness entry on the PSHELL card for the
component part2.
Step 3: Create the Responses

7. Click props.
8. Click one of the green shell elements in the graphics window to select the component part1.
9. Click select. A stress type selector switch appears.
10. Click the stress type selector switch and select von mises from the pop-up menu.
11. Click the selector switch, below the stress selector and choose the both surfaces option.

component part1.
14. Click props.
15. Click one of the pink shell elements in the graphics window to select the component part2.
16. Click select.
component part2.

response volume.
Upper bound constraints are to be defined for the responses stress1 and stress2.
3. Click response = and select stress1 from the list of responses. A loadsteps button appears
in the panel.
4. Click loadsteps.
8. Click create.
A constraint is defined on the response stress1. The constraint is an upper bound with a
value of 100. The constraint applies to the subcase STEP.
10. Click response = and select stress2 from the list of responses.
15. Click create.
A constraint is defined on the response stress2. The constraint is an upper bound with a
value of 120. The constraint applies to the subcase STEP.

section.
5. Click return to return to the Optimization Setup panel.

1. From the Analysis page, select OptiStruct to enter the panel.
2. Click save as.
name for the model, discrete_bracket_size.fem, in the file: field. .fem is the suggested
4. Click Save.
The name and location of the discrete_bracket_size.fem file displays in the input file:
field.
model file was written. The bracket_size.out file is a good place to look for error messages
Step 7: View the Stress Results

After the size optimization, the stress value should be reviewed to make sure that the stress
constraints are not violated. The analysis results are available on page 3 (the second page has
the optimization results).
click HyperView.
This launches the HyperView into a new page and opens the results. A message window
appears to inform about the successful loading of the model and result files into HyperView.
Notice that all of the h3d files get loaded, each into a different page in HyperView. The files
discrete_bracket_size_des.h3d and discrete_bracket_size_s2.h3d get loaded in pages
2 and 3, respectively.

3. Click the Next Page toolbar icon to move to the third page.
The third page has the results loaded from the discrete_bracket_size_s1.h3d file. The
name of the page is displayed as Subcase 1 – STEP to indicate that the results correspond to
subcase 1.
3D] (t).
6. From the second drop-down menu, select vonMises.
8. Click Apply.
von Mises contour for the initial design.
model is assigned a legend color, indicating the von Mises stress value for that element
resulting from the applied loads and boundary conditions. If you did not change the Iteration
step you should be contouring the stress of the initial step. To contour the final step, set the
last iteration of that loadcase using the icon on the animation toolbar, or use the Results
browser, as follows.
9. Use the bottom drop-down menus in the Results browser to select the last Iteration # in the
Simulation list.

Notice only two iterations are displayed; the First and Last (FL) is the default setting for
optimization runs. To change this setting, add an OUTPUT control card with a frequency
setting of ALL.
This will now contour your final iteration of that loadcase. Review the stress to see that it is
under the proper constraints.
von Mises contour for the optimum design.
Review
The .out file contains a summary of the optimization process. From the information in the .out
file, you can see how the objective, constraints, and design variables are changing from one
iteration to the next.
Have the stress constraints been met?
What are the resulting gauges for the two parts?
Hints
Go to the des.h3d page, clear the contour if one was applied, set to the last simulation step and
apply the Element Thickness contour.
Append discrete_bracket_size.mvw to review objective, constraints, and other information.

OS-4040: Size Optimization of a Shredder
A size optimization is performed in this tutorial using OptiStruct. Size optimizations involve the
changing of the properties of either 1D or 2D elements. These properties include area, moments
of inertia of the 1D elements, and the thickness of 2D elements. Size optimization is performed
when it is not necessary to remove materials, generate beads or change the shape of the
structure.
With size optimization, the cross-sectional properties of the elements are changed to meet the
necessary objective. Properties are linked with design variables (DESVAR) using DVPREL cards.
This tutorial goes through the steps involved in defining a size optimization for a model
comprised of shell and bar elements. You will update the PBARL property to simulate the
properties of the bar elements and then link that to the design variable. The resulting design will
have higher frequencies and updated element properties.
This tutorial outlines using OptiStruct macros under an OptiStruct user profile to setup the
optimization problem.
Finite element model of a shredder.
Problem Statement
Objective: Minimize the global mass
Constraints: Transverse modes higher than 6 Hz
Design variables: Beam width, beam thickness, beam depth, and shell thickness

 Perform a finite element analysis and check the results
 Define a size optimization with 1D element property
 Post-process the optimization results

Exercise
Step 1: Launch the HyperMesh Desktop, Set the User Profile, and Import
an FE Model File
2. Choose OptiStruct in the User Profiles and click OK. This loads the user profile. It includes
the appropriate template, macro menu, and import reader, paring down the functionality of
your tab menu.
5. Set the Import type: to FE Model by clicking on the icon .

6. Choose the proper File type: OptiStruct.
7. Click the Select Files icon and select the shredder.fem file you saved to your working
8. Click Open.
9. Click Import.
Performing a Finite Element Analysis and Checking the Results
Step 2: Run a Normal Modes Analysis of the Model

A normal mode analysis of this model is performed prior to the definition of the optimization
process. An analysis identifies the responses of the structure before optimization to ensure that
constraints defined for the optimization are reasonable.
shredder_analysis.fem in the File name: field.
4. Click Save.
The name and location of the shredder_analysis.fem file displays in the input file: field.
model file was written. The shredder_analysis.out file is a good place to look for error

Step 3: View the Eigen Modes of the Shredder
1. From the OptiStruct panel, click HyperView. A HyperView client launches in a new page and
the session file, shredder_analysis.mvw, is loaded. This file is linked with the
shredder_analysis.h3d file, which contains the model and results.
2. Click Close to exit the Message Log menu that appears.
3. Set the animation type to Modal .
4. Select the Deformed toolbar icon .
5. Leave Result type set to Eigen Mode(v).
6. Set Scale: to Model Units.
7. Set Type: to Uniform: and for Value, enter in a scale factor of 1000.
This means that the maximum displacement will be 1000 modal units and all other
Using a scale factor higher than 1.0, amplifies the deformations while a scale factor smaller
than 1.0 would reduce them. In this case, you are accentuating displacements in all
directions.
8. Under Undeformed shape:, set Show: to Edges.
9. Set Color: to Mesh.
10. Click Apply.
11. In the Results browser, use the Simulation drop-down to select Mode 1 and click OK.
12. Click the contour icon and click Apply to plot the Eigen Mode contour.
13. Click the Note icon and remove the first two lines, leaving the rest as below, and click
Apply.
14. Click the Page Window Layout icon to choose the four window layout .

15. Click in the first window and, from the Edit menu, click Copy Window.
16. Click in the second window and, from the Edit menu, click Paste Window.
17. Repeat step 18 for the 3rd and 4th windows.
First mode on contour on all windows.

18. Next, update the 2nd, 3rd, and 4th windows with the 2nd, 3rd, and 4th modes. This can be done
easily by selecting the window and clicking in the mode selection box above the HyperView
Entities tree (in the Results browser). Select each window and then use the selector drop-
down to choose which mode you wish to display in that window.
First four eigen modes contour.
19. Click the play icon in the animation controls to start the animation, and click again to stop
the animation.
The 3rd and 4th mode (~ 3.9 and 4.8 Hz) has a transversal shape that can reduce the
performance of the shredder when it gets excited. The objective, then, is to get the minimum
mass to greater than 7Hz.
20. From the File menu, click Save as > Report Template.
21. Change Save as type: to Report definition (*tpl).
22. For File name:, enter report.tpl.

23. Use the page navigation icons to navigate back to the HyperMesh client on the first page.
Defining Design Variables and Beam Cross-section Properties
Step 4: Define Design Variables using the Size Panel

The design variables for this problem are the thickness of the cover, width, thickness, and depth
of the bar. You will define the first design variable using the size panel.
3. Make sure the desvar subpanel is selected using the radio button on the left hand side of the
panel.
4. Click desvar =, and enter the name coverthck.
5. Enter the following values: initial value = 3.0, lower bound = 1.0, upper bound = 6.0.

6. Click create.
7. Similarly create four more design variables with following initial values, lower bounds and
upper bounds from the size panel.
Name Initial Value Lower Bound Upper Bound
Beamwide 50 30 90
Beamhigh 100 80 125
Beamthck 10 5 15
1
Beamthck 20 15 30
2
Step 5: Assign Cover Thickness to a Design Variable

1. From the size panel, select the generic relationship subpanel using the radio button on the
left.
2. For name =, enter the name coverthck.
3. For C0, enter a value of 0.0.
4. Click prop and select cover.
5. Verify that the property switch is set to Thickness T.
6. Click designvars and check the box next to coverthck.
7. Click return.
8. Click create.
9. Click return.
Step 6: Define Property Relations for Beam Dimensions

The dimensions are defined as shown in the image below. In this step, each dimension of a C
beam will be defined as a design variable. The table has values of property on the initial design.
Name Represents Value
DIMs(1) Beam Wide 50
DIMs(2) Beam High 100
DIMs(3) Beam Thck1 10
DIMs(4) Beam Thck2 20

1. From the size panel, select the generic relationship subpanel by selecting the radio button.
2. For name =, enter the name DIM1.
4. Click the yellow prop box, and select frame2.
5. Verify that the property is Dimension1.
6. Click designvars and check the box next to Beamwide.
7. Click return and create.
8. For dvprel =, enter the name DIM2.
11. Toggle the property to Dimension2.
12. Click designvars and check the box next to Beamhigh.
18. Click designvars and check the box next to Beamthck1.
24. Click designvars and check the box next to Beamthck2.
25. Click create.
26. Click return.

1. Click the responses panel.
2. For response =, enter the name mass.
3. Select the response type as mass.
4. Click create.
5. For response =, enter the name f3.
6. Change the response type: to frequency.

7. Enter a value of 3 for Mode Number.
8. Click create.
9. Repeat steps 7.5 through 7.8 to create response= f4 and Mode Number 4.

2. For constraint =, enter the name c_f3.
3. Check lower bound = and enter a value of 6.0.
4. Click response = and select f3.
5. Click loadstep and check the box beside ld1, then click select.
6. Click create.
7. Repeat steps 8.2 through 8.6 with the following values: constraint= c_f4, lower bound =
6.0, response = f4, and loadstep ld1.

1. Click objective.
2. Set objective option to min.
3. Click response = and select mass.
4. Click create.

1. From the File menu, select Save as > Model.
2. In the Save file window, browse for the working directory and save the database as
shredder_optimization.hm.
3. Click Save.
Step 11: Run the Size Optimization


model file was written. The shredder_optimization.out file is a good place to look for error
Post-process the Optimization Results
Step 12: View Thickness Results from the Optimization Run

1. When the message Process completed successfully appears in the command window,
close the solver GUI window.
2. Click HyperView from within the OptiStruct panel. This automatically loads the results for the
current run into HyperView.
files.
4. Navigate to the Design History page, if you are not already there through the use of the page
navigation arrows, as shown below.
5. From the Model browser, select the last Iteration # and click OK, as shown in the image
below.

7. Select the first drop-down menu below Result type: and select Element Thicknesses (s)
and Thickness.

8. Click Apply.
The resulting colors represent the thickness fields resulting from the applied loads and
boundary conditions. Notice the final optimized thickness of the cover component is 1.0.
9. Open the shredder_optimization.prop file using any text editor to review final optimized
PBAR property. The following figure illustrates what you will be looking for.
The final dimensions could be rounded off to:

Beam 70.10
Wide
(DIM1):
Beam 125
High
(DIM2):
Beam 5
Thck
(DIM3):
Beam 15
wide
(DIM4):
This .prop file can be read into HyperMesh with over write mode on and the PBARL card will
be updated.

OS-4050: Optimization of a Horizontal Tail Plane
The purpose of this tutorial is to optimize the thickness of the aluminum ribs for a horizontal tail
plane (model shown below).
Horizontal tail plane model
It is assumed that the tail is cantilevered about its inboard section. Three loading scenarios are
considered; one where the tail experiences pressure loads of 0.25 psi on the bottom skin, a
second where the tail experiences a tip load of 400 lbs, and a third where the tail experiences
both the pressure load and tip load simultaneously. The applied loading is represented in the
following figure.
Loading experienced by horizontal tail plane
The materials available for this part are described in the following table. The optimum design
should be as light as possible without failing or buckling under the given loading conditions.

Glass_fabric Core Aluminum 2024-T3
E1 4Msi (4.0e6 psi) 2ksi (2000 psi) E 10.6Msi (10.6e6 psi)
E2 6Msi (6.0e6 psi) 4ksi (4000 psi) Nu 0.33
NU12 0.1 0.3 G 4.06Msi (4.06e6 psi)
G12 800ksi (800000 psi) 3ksi (3000 psi) Rho 0.1 lb/in3
G1,Z 800ksi (800000 psi) 4ksi (4000 psi) Yield 50ksi (50000 psi)
G2,Z 800ksi (800000 psi) 4ksi (4000 psi)
RHO 0.07 lb/in3 0.001074 lb/in3
Xt 35ksi (35000 psi) 500 psi
Xc 35ksi (35000 psi) 500 psi
Yt 35ksi (35000 psi) 500 psi
Yc 35ksi (35000 psi) 500 psi
S 4ksi (4000 psi) 150 psi
The optimization problem may be stated as:
Objective: Minimize mass.
Constraints:  Composite skins must not fail.

 Aluminum ribs must not yield.
 Buckling must not occur.
Design variables:  Composite ply thicknesses.

 Rib thicknesses.

 Create material and geometric properties with HyperLaminate
 Create static and buckling subcases.
 Perform baseline finite element analysis
 Run a size optimization and compare results with initial design.

Exercise
Step 1: Launch HyperMesh Desktop, Set the User Profile, and Retrieve
the File
3. From the File on the main menu, select Open > Model.
4. Select the tail_baseline.hm file you saved to your working directory from the
5. Click Open.
Step 2: Create Isotropic Materials and Properties and Assign to Metallic

Ribs
1. Click the Model tab on the tab menu to open the Model browser.
3. In the Name field, enter al2024-t3.
4. Set Card Image as MAT1.
5. Fill in the fields for E, NU and RHO with values 10.6e6, 0.33 and 0.1, respectively.
These values are taken from the table Aluminum 2024-T3 at the beginning of the tutorial.

7. For Name, enter Ribs.
8. Set Card Image as PSHELL.
10. In the Select Material dialog, select a12024-t3 from the list of materials and click OK.
11. Enter the thickness for the shell component by clicking T and entering 1.0.
13. For Name, enter Ribs.
14. Set the Property to Ribs. This automatically sets the material to a12024-t3.
A property collector named Ribs has been created. It has a PSHELL definition with a thickness
of 1.0. It also references the Aluminum 2024-T3 material definition and the component name
Ribs.
Create Material and Geometric Properties with HyperLaminate
Step 3: Create Orthotropic Material Properties using HyperLaminate

2. On the left-hand tree structure, left click MAT8 to highlight it, and then right-click on the
highlighted MAT8. A floating menu appears with one option: New.
3. Click New.
A new material definition is created and appears in the left-hand tree structure on a branch
underneath MAT8.
4. Under the section Define/Edit material, click in the field to the right of Material:. The
default name NewMaterial1 shows.
5. Replace NewMaterial1 with Glass_fabric.

6. Fill in the fields for E1, E2, NU12, G12, G1, Z, G2, Z, RHO, Xt, Xc, Yt, Yc, and S with the
information provided in the table at the beginning of the tutorial. Refer to the examples in the
model, if needed.
7. Click Apply. An orthotropic material definition for Glass_fabric is now complete.
8. Repeat steps 3.4 through 3.7 to create other material called Core with the material properties
provided in the table. Also select a different color.
You should now have two new orthotropic material definitions on the MAT8 branch of the left-
hand tree structure.
Step 4: Create Composite Laminates using HyperLaminate

1. In the left-hand tree-structure, left-click on PCOMP to highlight it.
2. Right-click on the pre-highlighted PCOMP. A floating menu appears with one option: New.
3. Click New.
A new laminate definition is created and appears in the left-hand tree structure on a branch
underneath PCOMP.
4. Under the Laminate definition, replace NewLaminate1 with Inboard_section_top.
5. To the right of this field, click color and select a color for this laminate.
6. Under Stacking sequence convention, toggle Convection: to select Symmetric-Midlayer.
7. Under Add/Update plies, make the following selections/assignments:
- For Material, select Glass_fabric.
- For Thickness T1, enter 0.25.
- For Orientation (Degrees), enter 0.
- For No. of Repetitions, enter 1.
8. Click Add new ply three times.
9. Under Ply lay-up order, in the 2nd row, modify the information:
- For Material, select Core.
- For Thickness T1, enter 0.5.
10. Under Ply lay-up order, in the 1st row, modify the information:
The Ply lay-up order should appear like the image below.
Ply lay-up order for inboard_section_top.

The definition of the Inboard_section_top laminate is now complete. The following figure
shows the laminate as displayed in the right-hand side Review panel.
Inboard_section Laminate
12. Right-click on Inboard_section_top and select Duplicate.

13. Rename the PCOMP to Inboard_section_btm by right-clicking on the PCOMP or editing the
Name: field and changing the color.
14. Update the ply angles on the other four laminates (Outboard_section_btm,
Outboard_section_top, Midspan_section_btm, and Midspan_section_top) to be the same as
shown previously.
You should now have six laminate definitions on the PCOMP branch of the left-hand tree
structure. The tree-structure should look like the one shown in the figure below at this point.

HyperLaminate tree structure showing one isotropic material, four anisotropic materials, and six laminate definitions
16. From the File menu, select Exit.

This will let you exit the HyperLaminate GUI, and will export the information back to
HyperMesh.
Step 5: Assign Newly Created Properties to the Associated Component

At this point, the model is meshed and the material and geometric properties are defined.
However, the elements are not referencing the correct property and material information.
1. Expand the Component branch of the Model browser tree. Right-click on the
Inboard_section_top collector and select Assign.
2. Select the property Inboard_section_top from the list in the dialog box and click OK to
return to the main window.
3. Repeat this process to assign the Inboard_section_btm property to the
Inboard_section_btm collector.
Step 6: Organize Elements into their Respective Component Collectors

1. In the Model browser, right-click on LoadCollector, and select Hide.
2. Press the letter o on the keyboard (for the Options panel).
3. Set the mesh radio button on the left hand side of the panel.
4. Set the feature angle= to 37. This allows you to select elements by feature angle.
5. Click return.
6. From Tool page, select the organize panel.

7. Select one of the elements on the top inboard section, shown in brown in the picture below.
8. Click elems and select by face.
Notice a number of elements are selected on the top surface, stopping where the angle
between elements is greater than 37 degrees. The ribs elements in between the top and
bottom surface create a 90 degrees, thus the selection set stops here.
9. Click dest = and select Inboard_section_top from the list of component collectors.
10. Click Move.
11. Repeat steps 6.7 through 6.9 to generate a similar picture below.
Skin elements organized into correct component collectors.
12. Right-click on Tail and select Isolate Only. Only the elements forming the ribs which are in
the tail collector should now be displayed.
13. From Tool page, select the organize panel.
14. Click elems and select displayed.
15. Click Destination = and select Ribs from the list of component collectors.
16. Click Move.
17. In the Model browser, right-click on Component and select Show.
19. Press F2 on the keyboard.
20. Set the entity selection to comps.
21. Click preview empty and delete entity to clear any empty components (the tail component
in this case).
22. Click Return.

Step 7: Orient Elements Which Reference Composite Properties
1. From Tool page, select the normals panel.
2. Make sure the elements radio button is selected at the left of the panel.
3. Set the entity selection type to elems.
4. Click elems and select by collector.
5. Check the box next to Ribs.
6. Click the comps entity selection and select reverse from the extended selection list.
7. Click select.
8. Click display normals.
You may verify if the element normals are not all in the same direction. If they are not, follow
steps 9 and 10.
9. Click elem under orientation: and select an element whose normal is pointing inward.
10. Click adjust normals.
All "skin" normals should now point inwards. These skin normals are the local z-axes for each
element.
12. From the 2D page, select the composites panel.
13. Make sure the radio button is set to material orientation.
14. Select those elements belonging to the "skin" (all the comps except ribs) components.
15. Click the switch under Material orientation method: and select by vector from the drop-
down menu.
16. Click on the switch under by vector and select z-axis from the drop-down menu.
17. Click project.
This orients the local x-axis of each of the selected elements to be the projection of the global
z-axis. This is displayed graphically by the small white arrows that appear on each element.
Having defined the local x and z axes of the elements belonging to the component collectors
Inboard_section_top, Inboard_section_btm, Midspan_section_top, Midspan_section_btm,
Outboard_section_top, and Outboard_section_btm, you have fully established the local
orientation for each element referencing a composite laminate.
18. Click return.
Create Static and Buckling Subcases
Three loading scenarios are to be considered in this exercise: one where the tail experiences
pressure loads on the bottom skin, a second where the tail experiences a tip load, and a third
where the tail experiences both the pressure load and tip load simultaneously.
In previous steps, a load collector containing the pressure loads and another containing the tip
load were created, but a load collector containing both together is still needed. Next is to create a
load collector which is a combination of the load collectors pressure and tip_load.

Step 8: Create a Combination Load Collector
2. In the Name field, enter Combined.
4. Set Card Image to LOAD. For information on the LOAD card, refer to the OptiStruct online
help.
5. Click S and enter 1.0.
6. Click LOAD_Num_Set = and enter 2. This indicates how many load-collectors to combine.
7. In the pop-out window, enter S1(1) = 1.0, for L1(1), select pressure from the list of load
collectors, enter S1(2) = 1.0 and for L1(2), select tip_load from the list of load collectors.
8. Click Close.
A combination load collector, combining 1.0 times the loads in the pressure load-collector with
1.0 times the loads in the tip_load collector, is created.
Step 9: Create a Static and Associated Buckling Subcase

1. Click View > Browsers > HyperMesh > Utility to open the Utility tab.
2. In the Utility tab, select FEA.
3. Under Loadsteps:, click Buckling. The Create Buckling Subcases window appears.
With this window, a static subcase and an associated buckling subcase in one step will be
created.
4. For Name:, enter pressure_only. This is the user-defined name for the static subcase.
If you call the static subcase name, then the associated buckling subcase will be named
buck_name.
5. Select EIGRL from the drop-down menu that follows the field for Name:. This indicates that
eigenvalue analysis is to be used to calculate the buckling modes. Currently this is the only
option available.
6. In the field for V1:, enter 0.0.
This indicates that the lower bound for the eigenvalue extraction is 0.0. This prevents
negative buckling modes being calculated (negative buckling modes indicate that buckling will
occur if the loading is reversed).
7. The field for V2: may be left blank.
This is the upper bound for the eigenvalue extraction. You will select a number of modes to
calculate (instead of a range of eigenvalues) for this exercise.
8. In the field for ND:, enter 10.
This requests that the 10 lowest buckling modes (which are greater than V1) be calculated.
9. Select pressure from the drop-down list to the right of LOAD:.
10. Select constraints from the drop-down list to the right of SPC:.
11. Click Create.

You have now created a linear static subcase named pressure_only which combines the
pressure loads in the load-collector pressure with the single-point constraints in the load
collector constraints.
An associated buckling eigenvalue subcase named buck_pressure_only is also created
which will calculate the first 10 buckling modes greater than 0.0 for the pressure_only static
subcase.
12. Repeat steps 3 through 11 to create a static subcase named tip_load_only, which combines
the point loads in the load-collector tip_load with the single point constraints in the load
collector constraints, and an associated buckling subcase which will calculate the first 10
modes greater than 0.0.
13. Repeat steps 3 through 11 again to create a static subcase named combo, which combines
the loads in the load-collector combined (i.e. both pressure and tip_load) with the single point
constraints in the load collector constraints, and an associated buckling subcase which will
calculate the first 10 modes greater than 0.0.
14. Close the Create Buckling Subcases window.
Step 10: Request Stress, Strain, and Failure Results for Composite
Laminates
Stress, strain, and failure results are not output by default for composite laminates, but need to
be requested.
1. In the Model browser, right-click on the Outboard_section_top property and select Card
Edit.
The PCOMP card image for the Outboard_section_top laminate appears in the lower portion of
the display area. For more details on the PCOMP card image, refer to the OptiStruct online
documentation.
2. If HILL does not appear beneath [FT], click [FT] notice HILL appears beneath.
This activates failure theory calculation. If HILL is selected, a list of other failure theories
appear - use the Hill failure criteria for this exercise.
3. Click [SB] in the card image window and enter 3,500 in the field beneath it.
This is the interlaminate shear strength of the laminate, which is the bonding material shear
strength. 3.5ksi is an assumed value, as no material data was provided.
4. Click the button beneath SOUT(1) and select YES from the pop-up menu. This requests
stress and strain results to be output for ply1.
5. Set all other plies, i.e. SOUT(2), SOUT(3), SOUT(4) and SOUT(5) to YES also.
6. Click return to keep the changes you made to the card image.
7. Repeat steps 3 through 9 for the other composite laminates.
Note: Select all PCOMP props in step 3 to reduce steps. Make

sure HILL is selected.

9. From Analysis page, select the control cards panel, and enter GLOBAL_CASE_REQUEST.
10. Make sure CSTRAIN is selected from the list of control cards. The CSTRAIN card image
appears in the lower portion of the display area.

11. Make sure CSTRESS is selected from the list of control cards. The CSTRESS card image
appears in the lower portion of the display area.
Stress, strain, and failure results will now be output for the composite laminates.
12. Click return until you return to the main menu.
Step 11: Perform the Baseline Finite Element Analysis

2. Click save as, enter tail_baseline_complete.fem as the file name, and click Save.
7. Click OptiStruct to run the analysis job.
The message Processing complete appears in the window at the completion of the job.
OptiStruct also reports error messages if any exist. The file tail_baseline_complete.out
can be opened in a text editor to find details regarding any errors. This file is written to the
same directory as the .fem file.
8. Close the DOS window or shell and click return.
Step 12: Review the .out Analysis Summary File

In the directory where you ran the OptiStruct analysis, you should find a
tail_baseline_complete.out file. This file contains a summary of the analysis run.
Using a text editor of you choice, open the file tail_baseline_complete.out.
The file contains:
 A summary of the finite element model.
 A summary of the optimization parameters.
 Memory and disk space estimations.
 Analysis results.
The Volume, Mass, and Buckling Modes for the baseline model are given in the analysis results
section, as shown in the following tail_baseline_complete.out analysis results section:
ANALYSIS RESULTS :
------------------
ITERATION 0
(Scratch disk space usage for starting iteration = 30 MB)

(Running in-core solution)
Volume = 7.71079E+04 Mass = 2.49519E+03

Subcase Compliance
1 5.455666E+02
3 2.486638E+01
5 7.735856E+02
Subcase Mode Buckling Eigenvalue

2 1 1.583435E+01
2 2 1.610702E+01
2 3 1.638024E+01
2 4 1.665444E+01
2 5 1.681097E+01
2 6 1.693918E+01
2 7 1.715172E+01
2 8 1.723870E+01
2 9 1.739906E+01
2 10 1.748200E+01
4 1 8.267695E+01
4 2 8.326373E+01
4 3 8.393269E+01
4 4 8.466939E+01
4 5 8.541136E+01
4 6 8.618942E+01
4 7 8.695226E+01
4 8 8.765920E+01
4 9 8.834313E+01
4 10 8.907416E+01
6 1 1.329775E+01
6 2 1.351079E+01
6 3 1.372538E+01
6 4 1.394187E+01
6 5 1.416444E+01
6 6 1.417737E+01
6 7 1.439755E+01
6 8 1.445274E+01
6 9 1.464175E+01
6 10 1.466889E+01
Step 13: Review the Displacement Results

click HyperView. HyperView is launched and the results are loaded.
files into the HyperView client in a new page.
3. Set the animation type to Linear .
5. Make sure that the Result type: is Displacement [v]. The second drop-down menu shows
Mag.

Note that this capture is shown for the 1st subcase [pressure only]. You could also view the
same for other subcases.
Displacement contour for pressure_only subcase.
Step 14: Review the Stress Results in HyperView

1. Click the Entity Attributes toolbar icon .
2. Make sure that the box for Auto apply mode: is checked.
3. Click Off to the right of Display:. This will cause any component selected, either in the
display or from the list of components, to be hidden.
4. Hide all of the components except the ribs by clicking them in the GUI.
5. Click the Contour toolbar icon or select Contour from the Graphics menu.
6. Toggle the Result type: to Element Stresses (2D & 3D) [t].
7. Make sure the second drop-down menu shows von Mises.
8. Click Apply. This shows a contour plot of the von Mises stresses for the metallic ribs.

9. Click the Entity Attributes toolbar icon.
10. Click Flip. The Ribs component is now hidden and the composite laminate components are
displayed.
11. Click the Contour toolbar icon or select Contour from the Graphics menu.
12. Set Result type: to Composite Stresses (s) from the first row and Ply Failure from the
second row.
13. On the third list, select Entity with Layers: 1.
14. Click Apply.
A contour plot of the composite failure indices from the composite skins results is displayed
for the first layer.

Failure index for the first layer for the pressure only loadstep.
After calculating the failure indices for individual plies, OptiStruct calculates the potential
failure index for the composite shell element. This is based on the premise that failure of a
single layer qualifies as failure of the composite. Thus, a failure index for composite elements
is calculated as a maximum of all computed ply and bonding failure indices (note that only
plies with requested stress output are taken into account here).
15. Change Entity with Layers: to Max to have the maximum index for the laminate.

Max failure index found on all layers for pressure only loadstep.
Repeat this process to have the maximum failure index for all loadsteps.
MAX FAILURE INDEX = 3.73 e-3 (Combo Loadstep)
Run a Size Optimization and Compare Results with Initial Design
Now return to HyperMesh to set up the optimization problem. The first step in this process is to
define the design variables. The design variables for this exercise are the rib thicknesses and the
laminates used in the composite skins.
HyperMesh Desktop allows you to use one HyperMesh page and multiple pages from the
HyperView, HyperGraph, MotionView, and MediaView clients without having to switch
applications. To delete the HyperView page and return to the HyperMesh client, click the Delete
Page icon . To keep the page open but return to the HyperMesh client page, click the Previous
Page or Next Page icons until the HyperMesh client returns.

Step 15: Create and Reference a Thickness Design Variable for the
Metallic Ribs
1. From Analysis page, select the optimization panel.
2. From optimization panel, select the gauge panel.
3. Make sure the radio button is set to create.
4. Click props and select the Ribs collector.
5. Make sure that the top toggle is set to value from property. This sets the initial value of the
design variable to be the thickness value defined on the property card.
6. Toggle lower bound % to lower bound = and enter 0.01. This sets the lower bound for the
design variable.
7. Toggle upper bound % to upper bound = and enter 2.0. This sets the upper bound for the
design variable.
8. Make sure type: is set to PSHELL - T.
The following figure shows how the settings should look.
Gauge panel settings for rib thickness design variable
9. Click create.
10. Click return twice to go to the main page.
Step 16: Create Design Variables for Composite Laminates with

HyperLaminate
2. In the tree-structure on the left, click DESVAR to highlight it.
3. Right-click on the pre-highlighted DESVAR. A menu appears with options.
4. Select New. This creates a new design variable, which is named NewDv1 by default.
5. Rename the design variable istgf_th (inboard_section_top, glass_fabric, and thickness) by
double-clicking in the text field following Desvar: and overwriting the default design variable
name.
6. In the Initial Value: field, enter 0.25.
7. In the Lower Bound: field, enter 0.01.
8. in the Upper Bound: field, enter 1.0.
9. Click Apply.

10. In a similar manner, and with identical values, create one more design variables named
isbgf_th following the procedure outlined in steps 4 through 9.
Alternately, right-click on istgf_th and select Duplicate from the menu to create an identical
design variable. Repeat this process to create the other design variables, then rename the
new design variables by right-clicking on them and selecting Rename.
11. Review the other ten design variables in HyperLaminate and the information in the table
below.
Name Initial Value Lower bound Upper bound
mstgf_th 0.25 0.01 1.0
msbgf_th 0.25 0.01 1.0
ostgf_th 0.25 0.01 1.0
osbgf_th 0.25 0.01 1.0
istc_th 0.5 0.01 2.0
isbc_th 0.5 0.01 2.0
mstc_th 0.5 0.01 2.0
msbc_th 0.5 0.01 2.0
ostc_th 0.5 0.01 2.0
osbc_th 0.5 0.01 2.0
Twelve total composite design variables now exist, one for the thickness of the glass fabric for
each composite laminate component, and the other for the thickness of the core for each
composite laminate component. As the laminates are symmetric, the glass fabric will
reference the same design variables on either side of the core.
Step 17: Update Composite Laminate Properties as Design Variables

using HyperLaminate
1. Click Inboard_section_top under the PCOMP branch of the tree-structure. Details of the
laminate appear in the GUI.
2. Click the checkbox next to Optimization. New fields appear in the Entry Rows table, allowing
design variables to be associated to ply thicknesses or ply orientations.
3. Under Ply lay-up order, click on the field under Designvar, under Thickness in row 1.
4. Select istgf_th from the drop-down menu.
Now the design variable istgf_th is associated to the thickness of the Glass_fabric material
used in ply1, and, in this case, ply5 (as this is a symmetric-midlayer type laminate) of the
Inboard_section_top component collector.
5. Click in the field under Designvar, under Thickness in row 2.

6. Select istc_th from the drop-down menu.
Now the design variable istc_th is associated to the thickness of the Core material used in
ply2 and ply4 of the Inboard_section_top component collector.
7. Click in the field under Designvar, under Thickness in row 3.
8. Select istgf_th from the drop-down menu.
9. Click Update Laminate to save the design variable assignments.
10. Repeat steps 1 through 9 for Inboard_section_btm composite laminate component
collector, associating the appropriate design variables.
This will close the HyperLaminate GUI, exporting the design variable and updated laminate
information back to HyperMesh.
Step 18: Create the Mass, Static Stress and Composite Failure Responses
2. Select responses.
3. Click response= and enter mass.
4. Click the response type: switch and select mass from the pop-up menu.
5. Click create. The optimization response mass, which is the total mass of the structure, is
created.
6. Click response= and enter vm_strs.
8. Click props and select the Ribs collector.
9. Click Select. A new selector switch appears next to comps.
10. Make sure that the switch is set to von Mises.
11. Click the switch below von Mises and set it to both surfaces.
12. Click create. The optimization response vm_strs, which is the von Mises stress for the
metallic ribs, is created.
13. Click response= and enter hl_ist.
14. Click the response type: switch and select composite failure from the pop-up menu.
15. Click props and select the Inboard_section_top collector.
16. Click the switch next to props and select hill.
17. Click the switch below hill and select all plies.
18. Click create. The optimization response hl_ist is created.
This is the hill failure criteria for all plies of the composite skins of the Inboard_section_top
component collector.
19. Repeat steps 12 through 18 to create optimization responses for the hill failure criteria for the
plies of the other composite laminate skins. The responses could be similarly named: hl_osb,
hl_ost, hl_msb, hl_mst, and hl_isb.

20. Click response= and enter buckle.
21. Click the response type: switch and select buckling from the pop-up menu.
22. Click Mode Number: and enter 1.
23. Click create. The optimization response buckle, which is the lowest calculated buckling mode
for the structure, is created.
24. Click return to return to the optimization panel.
Step 19: Create Constraints and an Objective

Finally, the constraints and objectives must be defined. You will attempt to minimize the total
mass of the structure, while keeping the von Mises stress in the metallic ribs below yield, the
composite failure index of the composite skins below 1.0, and the buckling modes of the
structure above 1.0.
2. Click constraints = and enter cnst1.
3. Click response = and select vm_strs.
4. Check the box preceding upper bound =.
5. Click upper bound = and enter 50,000.
6. Click loadsteps and select the loadsteps pressure_only, tip_load_only, and combo.
7. Click select.
8. Click create. This defines a constraint on the von Mises stress of the metallic ribs to be less
than 50ksi for all of the static subcases.
10. Click response = and select hl_ist.
11. Check the box preceding upper bound =.
13. Click loadsteps and select the loadsteps pressure_only, tip_load_only and combo.
14. Click select.
15. Click create. This defines a constraint on the hill failure criteria for the Inboard_section_top
laminate to be less than 1.0. for all of the static subcases.
16. Repeat steps 9 through 15 for all the other failure criteria responses, creating cnst3 through
cnst7.
18. Click response = and select buckle.
19. Uncheck the box preceding upper bound =.
20. Check the box preceding lower bound =.
22. Click loadsteps and select the loadsteps buck_pressure_only, buck_tip_load_only and
buck_combo.

23. Click select.
24. Click create. This defines a constraint on the lowest calculated buckling mode of the structure
to be greater than 1.0 for all of the linear buckling subcases.
27. Click the left-hand switch and select min.
28. Click response = and select mass from the pop-up menu.
29. Click create. This defines the objective of the optimization to minimize the mass of the
structure.
Step 20: Create Additional Run Parameters to Aid Buckling Constraints

For the buckling constraint to be effectively maintained, an additional parameter needs to be
defined.
1. Select the opti control panel.
2. Check the box preceding MAXBUCK=. The box preceding GBUCK= is checked automatically.
Together, these two options ensure that up to 10 modes are considered in the buckling
constraint. Refer to the OptiStruct online help for a more detailed description.
3. Click return.

2. Click save as, enter tail_opt.fem as the file name, and click Save.
OptiStruct also reports error messages if any exist. The file tail_opt.fem.out can be

Step 22: Review the .out Optimization Summary File
In the directory where you ran the OptiStruct optimization, you should find a tail_opt.out file.
This file contains a summary of the optimization run.
Using a text editor of your choice, open the file tail_opt.out.
The file contains:
 A summary of the finite element model.
 A summary of the optimization parameters.
 Memory and disk space estimations.
 An optimization iteration history.
The value of the objective, the retained constraints, and the design variables are provided for all
iterations in the optimization iteration history section. The sample output for the final iteration is
shown in the plot of objective against iteration below.
The final iteration provides information on the mass of the optimized structure, the values of the
design variables for the optimized structure and the values of the objective and retained
constraints for the optimized structure.
Step 23: Review the Iteration History in HyperView

In addition to looking at the information in the tail_opt.out file, graphically review the iteration
history of the optimization using HyperView.
1. Create a new page with the HyperView client by using the Add Page icon .
2. From the File menu, select Open > Session. The Open Session File window appears.
3. Select the file tail_opt_hist.mvw from the directory where you ran the OptiStruct
optimization.
This is a HyperView session which creates plots of the objective, constraints, and design
variables against iteration number using information from the tail_opt.hist file.
The figure below shows page 1 of the session, which is the plot of the objective against
iteration. It shows how the mass decreased through the optimization process and how
convergence is achieved when the change in mass levels out.
Similar plots are available for the design variables and the constraints. There is also a plot
showing the maximum constraint violation for a given iteration against iteration. When this
value is zero, it indicates that there is no constraint violation.

Step 24: Compare the Baseline Results with Optimized Results in
HyperView
1. Click File > New > Session to start a new session.
2. Change the current client to HyperView using the client selector drop-down .
3. Click the down arrow to the right of the Select application toolbar icon and select
HyperView .
5. Create a two pane view by clicking on the Page Window Layout icon and selecting the two
view icon from the pop-up menu.

6. Activate the left-hand pane by clicking anywhere in it. The active pane is the one surrounded
by the blue halo.
7. Click the Load results toolbar icon . The Load Model File panel opens.
8. Select the Tail_baseline_complete.h3d file from the directory where you ran your
OptiStruct baseline analysis.
9. Click Open.
The path and file name for Tail_baseline_complete.h3d appears in the fields to the right of
Load model and Load results. This is good because the Hyper3D format contains both model
and results data.
10. Click Apply. The model and results are loaded in the current HyperView window.
11. Activate the right-hand window by clicking on it.
12. Repeat steps 5 through 8 to load the file tail_opt_s1.h3d from the directory where you ran
your OptiStruct optimization.
For the optimization, analysis results are written to files named *_s#.h3d (static analysis
results, where # is the subcase ID) and *_m#.h3d (eigenvalue analysis results, where # is the
subcase number), while the density, thickness and shape results are written to the file
*_des.h3d.
13. Activate the left-hand pane by clicking on it.
15. Select Displacement (v) from the drop-down menu under Result type:.
16. Click Apply.
17. Activate the right-hand pane.
18. In the Load Case Simulation Selection window above the Results browser, select subcase 1
(pressure only) in the Load Case area and select the last ITER # in the Simulation area.
19. Click OK.

21. Select Displacement (v) from the drop-down menu under Result type:.
22. Click Apply.
Now visible is a side-by-side comparison of the displacement results before the optimization
with those after the optimization (figure below); note the big change in the value of the total
displacement. The optimized displacement results are greater than the baseline
because you were optimizing for mass without displacement constraints.

23. With the animation mode set to Linear static , click the Play icon to animate the
deformation.
24. Click again to stop the animation.
Similar steps can be followed to compare stress and composite failure plots before and after
the optimization.
Notice how the maximum value for the composite failure index is almost at the design limit of
1.0.
Assigning Thicknesses and Orientations
Step 25: Import the Optimum Property Information into HyperMesh

1. From the File menu, select New > Session.
2. Set the Client Selector drop-down to the HyperMesh client .

This clears all results information out of the client, including all pages. This will not affect your
files on your hard drive.
3. From the File menu, click Import > Solver Deck.
4. Click the file folder icon at the end of the File: field and select the tail_opt.fem file from
the directory where you ran the optimization.
5. Click Import. This loads the *.fem that the optimization was run with into HyperMesh.

6. Click the file folder icon at the end of the File: field and select the tail_opt.prop file from
the directory where you ran the optimization.
The tail_opt.prop file is created by OptiStruct at the end of the optimization run and
contains the optimized property data for model.
7. In the Import tab, click the arrow before the import options to expand.
8. Check the box beside FE overwrite.
9. Click Import.
10. From the 2D page, select the HyperLaminate panel.
11. Click through the PCOMP properties and review the new thickness.
Conclusion
The objective of this tutorial was to achieve the lightest design by varying the laminate properties
and rib thicknesses. Experimenting with other materials and other laminate configurations could
lead to a lighter design.

OS-4070: Free-sizing Nonlinear Gap Optimization on an
Airplane Wing Rib
In this tutorial, an existing finite element model of an aluminum wing rib model is used to
demonstrate how to do free-sizing optimization using OptiStruct. HyperView is used to post-
process the thickness pattern in the rib.
Wing rib model
There are four shell components in the model: the mounting flange, the web, the top and bottom
flanges, and the lug. The web is connected to the lug by gap elements. Appropriate properties,
loads, boundary conditions, and nonlinear subcases have already been defined in the model. The
design region is the web and the rest of the components are non-design. Since a large portion of
aerospace components are shell structures which are manufactured by machining or milling
operations, free-sizing optimization is very suitable for those components. To understand the
limitations of topology optimization for such applications, a nonlinear gap topology optimization
will also be done on the wing rib model.

Objective: Minimize weighted compliance WCOMP.
Constraints: Volume fraction on the web < 0.3.
Design variables for free Thickness of each shell element in the design space.
sizing optimization:
Design variables for Element density of each element in the design domain.
topology optimization:

 Setup a free-sizing optimization with nonlinear gap elements
 Post-process the thickness convergence in the design domain
 Setup a topology optimization with nonlinear gap elements
 Post-process the material distribution in the design domain
 Review and compare results from free-size optimization and topology optimization
Exercise
the File
3. From the File menu on the toolbar, select Open Model. An Open Model browser window
opens.
4. Select the rib_complete.hm file you saved to your working directory from the
5. Click Open.
Step 2: Create Design Variable for Free-sizing Optimization

2. Select the free size panel.
3. Choose the create subpanel using the radio button on the left.
4. Click desvar= and enter shells.
5. Verify that type: is set to PSHELL.
6. Click props, choose the Web component and click select.
7. Click create. This creates the design variable for free-sizing optimization.

Step 3: Create Manufacturing Constraints for Free-sizing
1. While still in the Free Size Optimization panel, select the parameters subpanel.
2. Click desvars and select the shells design variable created previously.
3. Toggle minmemb off and, for mindim =, enter 2.0.
4. Click update.
5. Click return.
Step 4: Create Optimization Responses, Objective, and Constraints

First, the weighted compliance response will be created.
2. For response =, input the name wcomp.
3. Click the switch for response type and click weighted comp.
4. Click loadsteps and select both the Coup_Ver and Pressure loadcases. The weighting
factor should be 1.0 for both.
5. Click return.
6. Click create.
7. For response =, input the name volfrac to create the volume fraction response.
8. For response type, click volume frac.
9. Leave the type as total.
10. Click create.
11. Click return.
12. Click the dconstraints panel to define the volume fraction constraint.
13. For constraint =, input the name vol.
14. Click response =, and select the volfrac response.
15. For upper bound =, input a value of 0.3.
16. Click create.
17. Click return.
18. Click the objective panel to define the objective.
19. Toggle to min if not already done.
20. For response =, select the wcomp response.
21. Click create.
22. Click return twice to exit the panel. The optimization parameters have now been defined.
Step 5: Run Free-sizing Nonlinear Gap Optimization


3. Select the directory where you would like to write the optimization file and enter the name
rib_freesize.fem in the File name: field.
4. Click Save.
The name and location of the rib_freesize.fem file displays in the input file: field.
model file was written. The rib_freesize.out file is a good place to look for error messages
rib_freesize.hgdata HyperGraph file containing data for the objective function,
iteration.
rib_freesize_hist.mvw This file is a HypeView session file and may be opened from
the File menu in HyperView or HyperGraph. The file
automatically creates individual plots for each of the results
(objectives, constraints) contained in the .hist file. Each
plot occupies its own page within HyperView (HyperGraph).
rib_freesize.HM.comp.cmf This is a HyperMesh command file. When executed in

HyperMesh, the .HM.comp.cmf file organizes all elements in
the model into ten new components based on their element
thicknesses at the final iteration. The components for this
run are named 0.0-0.01, 0.01-0.02, 0.02-0.03, and so on,
up to 0.09-0.1, considering the plate thickness of the Web is
0.1mm.
rib_freesize.HM.ent.cmf This is a HyperMesh command file. When executed in

HyperMesh, the .HM.ent.cmf file organizes all elements in
the model into ten new sets based on their element
thicknesses at the final iteration. The set for this run are
named 0.0-0.01, 0.01-0.02, 0.02-0.03, and so on, up to
0.09-0.1, considering the plate thickness of the Web is
0.1mm.
rib_freesize.html HTML report of the optimization, giving a summary of the

rib_freesize_frame.html The file contains two frames. The top frame opens one of
the .h3d files using the HyperView Player browser plug-in.
The .h3d file opened depends on the results selected for
display in the bottom frame. The bottom frame opens the
_menu.html file, which facilitates the selection of results to
be displayed.

rib_freesize_menu.html This file facilitates the selection of the appropriate .h3d file
for the HyperView Player browser plug-in in the top frame of
the _frames.html file, based on chosen results.
rib_freesize.oss The file contains default settings for running OSSmooth after
a successful optimization.
rib_freesize.out OptiStruct output file containing specific information on the

file setup, the setup of the optimization problem, estimates
for the amount of RAM and disk space required for the run,
information for all optimization iterations, and compute time
flagged from processing the rib_freesize.fem file.
rib_freesize.res HyperMesh binary results file.
rib_freesize.sh Shape file for the final iteration. The .sh file may be used to
restart a run.
rib_freesize.stat Summary of analysis process, providing CPU information for

rib_freesize_des.h3d HyperView binary results file for element thickness

information.
rib_freesize_s1.h3d HyperView binary results file for displacement and stress

results for subcase 1.
rib_freesize_s2.h3d HyperView binary results file for displacement and stress

rib_freesize.fsthick The element definitions for those elements that were part of
a free size design space. The optimized thickness of these
elements is provided as nodal thickness values (Ti).
rib_freesize.hist ASCII table file with:

Iteration Objective Max_Const_Violation
Design_variables DRESP1s DESP2s.
rib_freesize.mvw This file is a HypeView session file and may be opened from
the File menu in HyperView. The file automatically creates
individual load the optimization results (dens.h3d) and the
loadstep results (s#.h3d).

Post-process the Thickness Convergence in the Design Domain
Element thickness distributions are output from OptiStruct for all iterations. In addition,
Displacement and Stress results are output for each subcase for the first and last iteration by
default. This section describes how to view those results in HyperView.
This should open a new window with the HyperView client and load the rib_freesize.h3d,
reading the model and the results.
2. Click close to close the message window.
3. Click the Entity Attributes icon on the toolbar and undisplay all of the components,
except Web. This is accomplished by activating the Auto apply mode: (Display OFF) and
then clicking on the component that you want turned off in the GUI.
4. Click the Mesh:, shaded mesh option .
5. Click the Web component to get a shaded mesh.
6. Go to the Contour panel and set the Result type: to Element Thicknesses.
7. In the loadcase selection area above the Results browser, select the last iteration listed in the
Simulation list and click OK.
8. Click Top View to get a top view of the Web.

This will show the contour element thickness on the Web component.
Thickness contour from free-sizing nonlinear gap optimization, on the Web of plate thickness 0.1mm

As can be seen from the figure above, the result from free-sizing optimization is a web with
optimized thickness distribution that can be reduced subsequently into larger zones for
simplification of the manufacturing process. Moreover, the design obtained from free-sizing
offers the freedom to create cavities, ribs, and varying thickness simultaneously, which is not
possible in topology optimization.
9. Close the HyperView client pages by clicking Delete Page until the HyperMesh client is on
screen again.
Setting Up a Topology Optimization with Nonlinear Gap Elements
Step 6: Create Design Variables for Topology Optimization

1. First, save the current HyperMesh file by selecting the File menu and clicking Save as >
Model.
2. Select the directory where you are running the optimization and enter rib_freesize.hm for
the file name.
3. Click save.
4. Right-click on the Design Variable section of the Model browser and select Delete.
6. Choose the topology panel.
8. For desvar = input the name shells.
9. Click props, choose the Web component, and click select.
10. Under type, choose PSHELL and leave the base thickness as 0.0.
11. Click create. The web component has now been defined as the design component for
topology optimization.
Step 7: Create Manufacturing Constraints for Topology Optimization

1. First, save the current HyperMesh file by selecting the File menu and clicking on Save as >
Model.
2. Select the directory where you are running the optimization and enter the name
rib_topology.hm for the file.
3. Click save.
4. Select the parameters subpanel using the radio buttons on the left of the Topology
Optimization panel.
5. For desvars =, select shells.
6. Toggle minmemb off and for mindim =, enter the value 2.0 for minimum member size
control.
7. Click update.

Step 8: Run the Topology Nonlinear Gap Optimization
The optimization responses, constraints, and objective have already been defined.
2. Make sure the rib_topology.fem file shows in the input file: field.
model file was written. The rib_topology.out file is a good place to look for error messages
rib_topology.hgdata HyperGraph file containing data for the objective function,
iteration.
rib_topology.HM.comp.cmf HyperMesh command file used to organize elements into

components based on their density result values.
rib_topology.HM.ent.cmf HyperMesh command file used to organize elements into

entity sets based on their density result values.
rib_freesize.HM.ent.cmf This is a HyperMesh command file. When executed in

HyperMesh, the .HM.ent.cmf file organizes all elements in
the model into ten new sets based on their element
thicknesses at the final iteration. The sets for this run are
named 0.0-0.01, 0.01-0.02, 0.02-0.03, and so on, up to
0.09-0.1, considering the plate thickness of the Web is
0.1mm.
rib_topology.html HTML report of the optimization, giving a summary of the

rib_topology_frame.html The file contains two frames. The top frame opens one of
the .h3d files using the HyperView Player browser plug-in.
The .h3d file opened depends on the results selected for
display in the bottom frame. The bottom frame opens the
_menu.html file, which facilitates the selection of results to
be displayed.
rib_topology_menu.html This file facilitates the selection of the appropriate .h3d file
for the HyperView Player browser plug-in in the top frame
of the _frames.html file, based on chosen results.
rib_topology.oss OSSmooth file with a default density threshold of 0.3. You

results.

rib_topology.out OptiStruct output file containing specific information on the
file setup, the setup of the optimization problem, estimates
for the amount of RAM and disk space required for the run,
information for all optimization iterations, and compute
time information. Review this file for warnings and errors
that are flagged from processing the rib_topology.fem
file.
rib_topology.res HyperMesh binary results file.
rib_topology.sh Shape file for the final iteration. It contains the material
density, void size parameters, and void orientation angle
for each element in the analysis. The .sh file may be used
to restart a run.
rib_topology.stat Summary of analysis process, providing CPU information for

rib_topology_des.h3d HyperView binary results file for information on element

density.
rib_topology_s1.h3d HyperView binary results file for displacement and stress

rib_topology_s2.h3d HyperView binary results file for displacement and stress

Post-processing the Material Distribution in the Design Domain
Element density results are output from OptiStruct for all iterations. In addition, displacement
and stress results are output for each subcase for the first and last iteration by default. This
1. From the OptiStruct panel, click HyperView. This opens new pages with the HyperView client
and loads the session file, rib_topology.mvw that is linked with .h3d files where the model
and results are defined.
2. Click close to close the message window.
3. Click the Entity Attributes icon on the toolbar and undisplay all of the components, except
the Web component. This is accomplished by activating the Auto apply mode: (to Display
Off) and clicking on the components that you want turned off in the GUI.
4. Click the Mesh: panel shaded mesh option.
5. Click the Web component to get a shaded mesh.
6. Go to the Contour panel and set the Result type: to Element Densities.
7. Click in the bottom right portion of the GUI to activate the Load Case and Simulation
Selection dialog.
8. Select the last iteration listed in the Simulation list and click OK.
9. Click Top in the view controls to get a top view of the Web.

10. Click Apply to show the contour of element density on the Web component.
Contour of element density on the Web component from topology nonlinear gap optimization
The results from topology optimization show very discrete results as expected.
Reviewing and Comparing Results from Free-size Optimization and

Topology Optimization
Results from the topology optimization show a truss type design with extensive cavities and
voids, while the results from free-sizing optimization tend to come up with shear panels. While
solid/void density distribution is the only choice for solid elements; for shell structures,
intermediate densities can be interpreted as different thicknesses and penalizing then could result
in potentially inefficient shell structures. Moreover, since a large portion of aerospace structures
are shell structures, a shear panel type design is often desirable for manufacturing purposes
especially for machine milled shell structures. Free-sizing optimization can prove to be very
beneficial in those situations.

OS-4080: Minimization of the Maximum Stress of a Rotating
Bar: A Size Optimization
This tutorial demonstrates how to set up the multi-body dynamics (MBD) size optimization of a
rotating bar in HyperMesh and how to run the optimization job in OptiStruct. The structural
model is shown in the figure below. Angular velocity at the revolute joint defined left end of the
bar is 10*SIN(2*TIME) rad/sec. The objective is to minimize the maximum stress of the structure
subject to certain mass specifications. The bar consists of five bar elements with a solid circle
cross section (each element has its own PBARL with ROD cross section). The design variables are
the radius of each bar property.
Rotating bar
Objective: Minimize maximum normal stress.
Constraints: Mass < 10kg.
Design Radius of each bar properties (PBARL).

variables:

 Setup an ESL MBD optimization problem in HyperMesh
Exercise
Setting Up an ESL MBD Optimization Problem in HyperMesh
Step 1: Launch HyperMesh Desktop, Set the User Profile and Retrieve the
File
4. Select the rotating_bar_design.hm file you saved to your working directory from the
5. Click Open.

Step 2: Define Boundary Condition for Structural Analysis in ESL
Optimization
Structural analysis and optimization of the flexible bodies of this model are performed in ESL
optimization. Thus, the boundary condition for the flexible bodies needs to be defined.
2. In the Name: field, enter BCforOpt.
3. From the Preferences menu, select Graphics.
4. Make sure the graphics subpanel is select. Check the box for coincident picking.
5. Click return to go to main menu.

6. On the Model browser tab, select the display Properties view .
Only 6 dof per flexible body should be fixed to remove 6 rigid body motion of each flexible
body.
8. From the graphics area, click the left end of the model. There should be two node numbers at
one location. Select node number 1.
9. Make sure all dofs (dof1 to dof6) are checked and their values are set to 0.00.
10. Click create.
11. Click return.
Step 3: Define a Driving Motion Not Supported by HyperMesh

In this tutorial, the driving motion at a joint, MOTNJE is defined. However, MOTNJE is currently
not supported by HyperMesh. Thus, you need to enter this card and a corresponding MBVAR card
manually.
1. From the Analysis page, select the control cards panel.
2. Click BULK_UNSUPPORTED_CARDS.
3. Make sure the following two cards are listed. If they are not listed, enter the cards.

4. Click OK.
5. Click return.
Step 4: Include Boundary Condition and MOTION in the Predefined MBD

Subcase for Structural Analysis and Optimization
1. Click on the load step SUBCASE1 in the Model browser.
2. In the Name field, enter Dynamic.
3. Make sure that the Analysis type is set to multi-body dynamics.
4. For SPC, select BCforOpt from the list of load collectors.
5. For MBSIM, select MBSIM1 from the list of load collectors.
6. For MOTION, select MBSIM1 from the list of load collectors.
Step 5: Define the Size Design Variables for Optimization

3. Make sure that the desvar subpanel is selected using the radio buttons on the left-hand side
of the panel.
4. Click desvar = and enter rad1.
5. Click initial value = and enter 10.
8. Set the move limit toggle to move limit default.
9. Set the discrete design variable (ddval) toggle to no ddval.
10. Click create. A design variable, 'rad1’, has been created. The design variable has an initial
value of 10, a lower bound of 0.05, and an upper bound of 100.
11. Repeat steps 4 through 10 to create the design variable rad2, rad3, rad4, and rad5 using the
same initial value, lower, and upper bounds.

panel.
13. Click name = and enter bar1_rad1.
14. Set the entity selection switch to prop.
15. Click prop and select PBARL_1 from the list. A property selection switch now appears below
prop.
16. Make sure the property selection switch is set to Dimension 1.

18. Check the box next to rad1.
Note the linear factor (value is box beside tube) automatically gets set to 1.000.
19. Click return.
20. Click create.
A design variable to property relationship, bar1_rad1, has been created relating the design
variable rad1 to the radius entry on the PBARL card for property PBARL_1.
21. Repeat steps 13 through 20 to create the design variable to property relationship bar2_rad2,
bar3_rad3, bar4_rad4, and bar5_rad5 relating the design variables to the radius entry on the
PBARL cards for the property PBARL_2, PBARL_3, PBARL_4, and PBARL_5.
Step 6: Create the Mass and Stress Responses

A detailed description about the responses can be found in the OptiStruct User's Guide topic,
Responses
2. Click response = and enter Mass.
5. Click create. A response, mass, is defined for the total mass of the model.
6. Click response = and enter Stress.
8. Click the entity selection switch and choose props.

9. Click props and select all properties in the list.
10. Click select.
11. Make sure that stress is normal stress and stress recovery point is set to all.
12. Click create. A response, Stress for all the bar elements, is defined.

Upper bound constraint is to be defined for the response Mass.
2. Click constraint = and enter Mass.
3. Click response = and select Mass from the list of responses.
6. Click create. A constraint is defined on the response Mass. The constraint is an upper bound
with a value of 10.0.

In this example, the objective is to minimize the maximum stress of the model while the model
rotates.
1. Select the obj reference panel.
2. Click dobjref = and enter MaxStress.
3. Click response = and select Stress.
4. Check the boxes next to neg reference = and pos references =.
5. Make sure the toggle switch is set to loadsteps.

6. Click loadsteps and select Dynamic.
7. Click select.
8. Click create.
11. Click the switch in the upper left corner of the panel and select minmax from the pop-up
menu.
12. Click dobjrefs = and select MaxStress.
13. Click select.
14. Click create.
15. Click return to go to the optimization panel. The objective function is now defined.
Step 9: Save HyperMesh Database

1. From the File menu, select Save as > Model.
2. Enter rotating_bar_design.hm in the file name field.
3. Click Save.

Notice the input file: field is populated with the same path you just saved the .hm file to with
a new .fem extension.
appears.
optimization is complete when the message Processing completed successfully appears in
the shell.
was saved. In addition to ordinary output files, you can see a text file with the name
rotating_bar_design.eslout. This file is a good source to see the process of the ESL
optimization.

After ~ 7 interations, the model should converge to the descending values as shown below:
Optimization results (from rotating_bar_design.eslout).

OS-4090: Manufacturing Constraints in a Free-size
Optimization of a Composite Structure
Composite wing model.
One of the advantages with composite materials is that the structural performance can be
controlled precisely by choosing the appropriate ply thickness, ply orientation, stacking sequence,
ply materials, and so on. The ability to vary many different parameters provides greater
flexibility, but at the same time it is tougher to optimize the part as the number of design
variables increases many fold. OptiStruct has the ability to directly or indirectly optimize the ply
thickness, ply orientation and stacking sequence for composite structures.
Free-size optimization handles the thickness of each ply in each element as a design variable and
optimizes the structure by determining the optimal thickness distribution for each ply in the
laminate. Refer to the Free-Size Optimization and Composite Topology and Free-size Optimization
pages of the OptiStruct User's Guide help for more details.
For several reasons, every composite manufacturer has their own manufacturability standards for
the laminated composites. These additional manufacturing constraints are to be included with
free-size optimization to achieve an acceptable manufacturing solution. OptiStruct supports
different manufacturability constraints that can be defined with free-size optimization. This
tutorial helps explain the procedure used to define the manufacturing constraints in the free-size
optimization of composite structures.
Objective: Minimize the Mass.
Constraints: Displacement of selected 6 nodes < 3 mm.
Design Thickness of each ply of each element in the design space.

variables:

In this tutorial, a free-size optimization with the following manufacturing constraints will be set
up:
 Minimum laminate thickness of 0.2
 Ply thickness should be at least 10% and at most 60% of total laminate thickness, defined
for all the plies in the design space
 The thickness of ply with a ply angle of 45 degrees to be same as the thickness of ply with
a ply angle of -45 degrees
 Set up a free-size optimization with manufacturing constraints
 Post-process the free-size optimization results
Exercise
Step 1: Launch HyperMesh Desktop, Load the User Profile and Retrieve
the File
4. Select the Composite_Wing.hm file you saved to your working directory from the
5. Click Open to load the model into the HyperMesh session.
Step 2: Review the Model Setup

The model is already set up for analysis. The model properties, loads, boundary conditions, and
loadsteps are already defined. The model has 15 components out of which the TopSkin and
BottomSkin components are defined with the composite property PCOMP. The rest of the
components are defined with PSHELL property which references the material property,
Aluminum. In the following section, you will review the layup information for the TopSkin and
BottomSkin components using the HyperLaminate panel.

Wing geometry
1. From the 2D page, select the HyperLaminate panel. This opens the HyperLaminate GUI in
which the ply lay-up information can be defined, reviewed and edited. Size design variables
can also be set up in this panel for performing size optimization.
2. Expand the Laminates portion of the tree structure on the left-hand side of the screen.
3. Select the TopSkin component for review by clicking on the component name. This loads the
TopSkin component properties in the Laminate definition section and Review section. The
Laminate definition section shows the ply material, ply thickness, ply orientation, etc. which is
shown graphically under the Review section.
The same layup information is also defined for the BottomSkin component. In this tutorial,
you will define free-size optimization on the TopSkin and BottomSkin components.
Exiting the HyperLaminate GUI and returning to HyperMesh.
Setting Up a Free-size Optimization with Manufacturing Constraints
Step 3: Create a Design Variable for Free-sizing Optimization

1. From the Analysis page, select optimization to enter the panel.
2. Select free size to enter this panel.
3. Select the create subpanel using the radio button on the left.
4. Click desvar= and enter Skins.
5. Click the selection switch below type: and select PCOMP(G).
6. Click props, choose the TopSkin and BottomSkin properties, and click select.
7. Clicks create. This creates the design variable for free-sizing optimization.

Step 4: Add a Minimum Dimension (mindim) Manufacturing Constraints
for Free-size Optimization
1. While still in the free size optimization panel, select the parameters subpanel.
2. Click desvars and select the Skins design variable created previously.
3. Toggle minmemboff for mindim =, and enter 5.0.
This step defines the minimum member size control to be 5.0. Member size control gives you
some control over the member size in the final free-size design and the resulting structure will
have discrete members that are easy to interpret during post-processing.
4. Click update.
Step 5: Add Minimum Thickness Manufacturing Constraints for Free-

sizing Optimization
In this section, the percentage following manufacturing constraints needs to be defined.
 Minimum laminate thickness of 0.2.
 A Minimum of 10% and a maximum of 60% thickness (of total laminate thickness)
constraints defined for all the plies. This means that for each element, none of the plies will
have thickness less than 10% or greater than 60% of the totals laminate thickness.
 The thickness of ply with ply angle of 45 degree to be same as the thickness of ply with ply
angle of -45 degree.
1. While still in the free size optimization panel, select the composites subpanel.
2. Click desvar= and select the Skins design variable created previously.
3. Under the laminate thickness: section, toggle minimum thickness off to minimum
thickness =.
4. Enter 0.2 in the field that appears next to minimum thickness =.
5. Click update to update the above defined minimum laminate thickness constraint to the free-
size design variable.
6. Click edit to open the panel.
7. Select PLYPCT by clicking in the box.
8. Click the switch below PLYPCT and select Specify Number.
9. Enter 4 in the field next to DSIZE_NUMBER_OF_PLYPCT=, to specify that ply percentage
constraints will be defined on 4 plies.
This opens 4 additional lines, as shown in the image below, in which you can enter the ply
percentage constraints. The table below explains the 4 different fields in which ply percentage
constraint is defined.
PAN Ply orientation to which the PLYPCT constraints are applied.
GLE
PPM Minimum ply percentage thickness for the PLYPCT constraint.
IN
PPM Maximum ply percentage thickness for the PLYPCT constraint.
AX

PTM Manufacturable ply thickness.
AN
10. In the first field next to COMP PLYPCT and below PANGLE, enter 0 to define that ply
percentage constraints are defined for the ply with ply angle of 0 degree. Enter 0.1 for
PPMIN and 0.6 for PPMAX. The PTMAN field can be left blank.
The above step defines that for each element, the thickness of the ply with ply angle 0,
should be no less than 10% or more than 60% of the total thickness.
11. Similarly define the same constraints of 0.1 for PPMIN and 0.6 for PPMAX for the plies with
ply angle 45, -45 and 90 as shown in the image above.
12. Similarly, activate BALANCE by clicking on the box, and define 1 in the field for
DSIZE_NUMBER_OF_BALANCE=.
The BALANCE constraint ensures that two plies will always be of equal thickness.
BALA BALANCE flag indicating that a balancing constraint is applied.
NCE
BANG First ply orientation to which the BALANCE constraint is applied.
LE1
BANG Second ply orientation to which the BALANCE constraint is applied.
LE2
13. In the field below BANGLE1, enter 45 and in the field below BANGLE2 enter -45.
The above step defines that the plies with ply angle of 45 and -45 will always have the same
thickness.
14. Click return to return from the panel.
15. Click update to update the above defined manufacturing constraints to the free-size design
variable.
16. Click return to return from the free size panel.
Step 6: Create Displacements and Mass Responses

To create a displacement as a response, you will need to supply a meaningful name for the
response, set the response type to displacement, select the nodes for which the response is
defined, and select the type of displacement (dof).

1. Click responses.
2. Click response= and enter disp.
3. Change the response type: to static displacement.
4. Click nodes to open the extended entity selection window and select by sets.
5. Click the box next to Nodes to select the set and click select.
Notice that 6 nodes at the end side of the wing are selected.
6. Choose dof3.
7. Click create to create the displacement response for the selected nodes.
8. Similarly, create another response with the name mass and a response type: of mass, with
total for the option.
9. Click create to create the mass response.
10. Click return.

In this step, the upper and lower bound constraint criteria for the analysis are set.
2. Click constraint= and enter disp_constr.
5. Select response= and set it to disp.
6. Click loadsteps.
7. Check the boxes next to SubCase1 and SubCase2.
8. Click select.
9. Click create.

1. Click objective.
4. Click create.
5. Click return twice to exit the optimization panel.

2. Click save as, enter Wing_FreeSize_with_PLYPCT.fem as the file name, and click Save.
OptiStruct also reports error messages if any exist. The file Wing_FreeSize_with_PLYPCT.out
can be opened in a text editor to find details regarding any errors. This file is written to the
same directory as the .fem file.
5. Close the Solver View window.
Post-processing the Free-size Optimization Results
OptiStruct provides element thickness, ply thickness information for all iterations, and also writes
out displacement and von Mises stress results for the linear static analysis. This section describes
how to view the results in HyperView.
Step 10: View a Contour Plot of Element and Ply Thicknesses

This starts a new HyperView session. All of the result files in .h3d format are automatically
loaded into HyperView. A message window appears with information about the model and
result files loaded into HyperView.
2. From the Results menu, activate the menu over Plot and click Contour. Choose Element
thicknesses as the Result type; then choose the drop-down menu below and select
Thickness.
3. Click Apply. This shows the contour of total laminate thickness for the selected iteration.
4. In the left top portion of the GUI, click in the area circled below to open the Iteration selection
pull-down and select the last design iteration result. The contoured thickness is the optimal
laminate thickness distribution for the current design.

Step 11: View Contour Plot Ply Thicknesses
Since only the TopSkin and BottomSkin components are in the free-size design space and the
thickness of only these two components are changing, it is convenient to view only these two
components. Also, for easy visualization purposes, it is convenient to move the two surfaces
apart as they are very close to each other.
1. Click Iso and click Apply to display the isometric view of the model.
2. In the Model browser, click the Component view icon .
3. Click the Isolate Shown icon and then click BottomSkin and TopSkin in the component
tree.
This leaves only these two components displayed.
4. Click the Exploded View icon, .

5. Click Add to add a new explosion view.
6. Click one of the components in the graphics area to select it for translating.
7. Select X Axis for the Direction option under Translate:. Leave the default value of 5 in the
Distance field.
8. Click the plus icon to move the selected component in the positive X direction and repeat until
the component is moved enough to view both the components.

Laminate optimized thickness contour
9. From the Results menu, activate the menu over Plot and click Contour. Choose Ply
Thickness as the Result type and leave Thickness selected.
10. For Entity with Layer:, select 1, and click Apply.
This shows the first ply thickness contour. You can repeat these steps to plot the thickness for
Ply 2, Ply 3, and Ply 4 or Max, etc.

First ply optimized thickness contour
11. Verify if all the manufacturing constraints (ply percentage, balance and minimum laminate
thickness) are satisfied. Additionally, open the Wing_FreeSize_with_PLYPCT.out file in a text
editor and verify that the displacement constraints are satisfied in the last iteration.

OS-4095: Size Optimization using External Responses
(DRESP3) through HyperMath
In this tutorial, the standard responses available in OptiStruct are passed to a HyperMath script
and the newly created responses from the script are used as optimization constraints. Since
HyperMath is an interpreter, users can build custom responses without having to compile their
HyperMath script.
The structural model shown above is loaded to HyperMesh. The materials, shell properties, loads
and boundary conditions are already defined in this model. The thicknesses of the three
components are identified as design variables. The von Mises stress of element numbers 58 and
59 (elements located on the circumference of the hole) are defined as responses, and a total
volume response is defined as well.
The von Mises stress of elements 58 and 59 are passed as inputs to the HyperMath script which
in turn, returns two values: the sum of the two von Mises stresses, and the average value of the
two elemental von Mises stresses.

Objective: Minimize volume
Constraints: Constraints on the sum of the von Mises stresses and the average von Mises
stress
Design Gauges of the three parts

variables:

 Examine the HyperMath script to calculate external responses
 Setup external responses using DRESP3
 Run the optimization using OptiStruct
Exercise
Step 1: Launch HyperMath and HyperMesh Desktop, Set User Profile, and
Retrieve the File
1. Launch HyperMath.
2. Under the File menu, select open and select the dresp3_simple_h.hml file you saved to
your working directory from the optistruct.zip file. Refer to Accessing the Model Files.
Examine the HyperMath script to calculate external responses.

Notice the HyperMath script identified with the function MYSUM takes two inputs, rparam[1]
and rparam[2], and returns two responses, rresp[1] – sum of the two inputs, and rresp[2]
– average value of the two inputs. The calculated responses rresp[1] and rresp[2] are sent
back to OptiStruct for use in the optimization. The script above will be linked to the DRESP3
related cards in the OptiStruct input file, which will pass the two inputs to this script and then
receive two outputs from this script.
Note: In this script, it is possible to assign any name to the

function, like MYSUM, myresponses, sumandavg, etc.
However, the argument names to the function such as
iparam, rresp, rparam, etc. cannot be changed.
External responses will now be set up using DRESP3.

4. Choose OptiStruct from the User Profiles dialog and click OK. This loads the OptiStruct user
the functionality of HyperMesh to what is relevant for generating models for OptiStruct.
5. From the File menu on the toolbar, select Import > Solver Deck.

6. Make sure the File type: is OptiStruct.
7. Load the dresp3_simple.fem file.
8. Click Import.
9. Click Close.
Step 2: Attach the HyperMath Script Library to OptiStruct

OptiStruct will need the location of the HyperMath script for it to pass and receive the necessary
inputs and outputs respectively. This is achieved using the LOADLIB card.
2. Click next.
3. Click LOADLIB and enter the following inputs:
Typ DRESP3
e:
GRO HLIB
UP:
PAT <location of the hml
H: file>
Example:
c:/temp/dresp3_simple_h
.hml
Note: There is a limited amount of space within the HyperMesh

Desktop GUI to enter the file path and name. If the full file
path with file name does not fit, exit the panel and edit the
rest in by hand in Step 5 of this exercise.
4. Click return.
5. Click prev.
Step 3: Create DRESP3 cards

The design variables for the thicknesses of the three components are already defined. The
responses for the total volume and the von Mises stress of elements 58 and 59 have also been
defined.
The DRESP3 bulk data entry is not supported in the current version of HyperMesh. Therefore,
these cards will be defined in the BULK_UNSUPPORTED_CARDS panel.
Note: A ‘$’ symbol indicates a comment and the following data will
not be read by the solver.

1. Click BULK_UNSUPPORTED_CARDS and enter in the following DRESP3 information:
This defines two external responses: the sum of the von Mises stresses of elements 58 and 59
(SUMH) and the average von Mises stress for elements 58 and 59 (AVGH).
The DRESP3 responses have different IDs from the DRESP1 responses and point to the library
called HLIB defined in Step 2. Also, the function MYSUM is the same function name in the
dresp3_simple_h.hml script.
This completes linking of the DRESP3 cards with the HyperMath Script.
Step 4: Create DCONSTR cards

Since the DRESP3 card is not supported in the current version of HyperMesh, the DCONSTR cards
cannot be assigned to the DRESP3 responses from the dconstraints panel either. The DCONSTR
cards are therefore also added using the BULK_UNSUPPORTED_CARDS panel.
1. With the BULK_UNSUPPORTED_CARDS dialog open, add the following constraint data
(DCONSTR and DCONADD) following the DRESP3 information:

2. Click OK.
3. Click return. This defines upper bound constraints of 50 and 25 on the SUMH response and the
AVGH response respectively.

1. From the File menu on the toolbar, select Export > Solver Deck.
2. Select the export directory for the solver file.
3. Click , select the file dresp3_simple.fem, and click Save.

4. Click Export. The .fem file name is used for OptiStruct input decks.
5. Open dresp3_simple.fem with a text editor.
6. Add the following under the subcase information section, towards the top of the file: DESSUB
= 10.
7. Save the file.
The DRESP3s created are subcase dependent responses and therefore are to be referenced
from within a subcase. The DESSUB command does this. This line has to be added manually
since the current version of HyperMesh does not support the DRESP3 bulk data entry.
8. Launch the OptiStruct solver GUI: start > All Programs > Altair HyperWorks 2017 >
OptiStruct.
9. Browse to the dresp3_simple.fem file saved above.
11. When the job is complete, post-process the results.
Note: The complete FEM deck, dresp3_simple_complete.fem, is

available and can be used as a reference.

Shape Optimization
OS-5000: 2D Shape Optimization of a Cantilever Beam

In this tutorial, a shape optimization on a cantilever beam modeled with shell elements will be
performed. The structural model with loads and constraints applied is shown in Figure 1. The
deflection at the lower right corner should be limited to 3mm. The optimal design would use as
little material as possible.
Figure 1. Cantilever beam, structural model.
The structural model, shown in Figure 1, is loaded into HyperMesh and is used to generate and
run a shape optimization of the cantilever beam. Shape perturbation vectors are generated using
HyperMorph, which is accessed, through the HyperMesh interface. The OptiStruct software
determines the optimal shape. The results are then reviewed in HyperView.
Constraints: Given maximum nodal displacement at the end of the beam < 3.0
mm.
Design variables: Shape variables defined with HyperMorph.

 Setup the shape optimization problem in HyperMesh

Exercise
Step 1: Load the OptiStruct User Profile and Retrieve the Geometry
3. From the File menu, select Open > Model.
4. Select the beamshape.hm file you saved to your working directory from the optistruct.zip
5. Click Open. The beamshape.hm is loaded into the current HyperMesh session, replacing any
The location of beamshape.hm displays in the file: field.
Setting Up the Shape Optimization Problem in HyperMesh
Step 2: Create Shapes using HyperMorph

This step makes use of HyperMorph. For a more detailed description of the functionality of
HyperMorph, refer to the HyperMorph section of the HyperMesh documentation.
2. Select the HyperMorph panel.
3. Select the domains panel.
4. Select the create subpanel using the radio buttons on the left side of the panel.
5. Change the switch subpanel to auto functions and keep the default settings.
6. Click generate. A number of domains and handles are created which will enable us to morph
the shape of the beam.
There are two types of handles: global handles, which are represented by larger red balls;
and local handles, which are represented by smaller yellow balls. Only local handles will be
covered in this tutorial.
7. Click return to return to the HyperMorph panel.
8. Select the morph panel.
9. Select the move handles subpanel.
10. Click the right-hand switch and select move to node from the pop-up menu.
11. If the handle button is not highlighted, click on it.
12. Select the top right local handle (where the force is applied) by clicking on it in the graphics
window. Figure 2 shows the node to be selected in black.

Figure 2. Selecting a local handle for morphing.
13. If the nodes button is not highlighted, click on it.

14. Select the node in the middle of the right-hand side of the beam.
The beam instantly changes shape, so that the handle you selected moved to the location of
the node you selected. See Figure 3 below. Note how the mesh adjusted to this change in
shape.
Figure 3. Morphed shape 1.
15. Select the save shape subpanel.

16. Click shape = and enter shape1.
17. You can select the color button and change the color of the shape vectors or leave the
default color set.
18. Set the toggle under shape = to as node perturbations.
19. Click save.
20. Click Yes. This shape has been saved, and can be associated with a design variable later.
21. Click undo all. The model returns to its original shape.
23. Select the handles panel.
25. Click name = and enter aux1.
26. Click domain and select the top edge domain by clicking on the top edge in the graphics
window.
27. To ensure that you select the top edge domain, hold down the left mouse button and move
the mouse over the top edge of the beam until the edge is highlighted (white), then release
the mouse button.
28. Set the toggle to by nodes.
29. Click nodes and select the node at the center of the top edge of the beam by clicking on it in
the graphics window.

30. Click create.
A new handle, 'aux1', is created at the center of the top edge of the beam, see Figure 4.
Figure 4. New handle added at the center of the top edge of the beam.

33. Select the move handles subpanel.
34. Click the switch beside move to node and select interactive from the pop-up menu.
35. The handles button should be highlighted. If not, click on it.
36. Select the yellow handle you just created by clicking on it in the graphics window.
37. A manipulator axis is created on the selected handle.
38. Left-click and hold down the mouse button on the manipulator axis pointing in the positive X
direction. While holding the mouse button down, pull the selected axis in the positive X
direction.
39. Pull down approximately until the center of the beam and release the mouse button. Note
how the mesh morphs interactively as the handle moves along the axis.
40. Select the set biasing subpanel using the radio buttons on the left-hand side of the panel.
41. Click handles.

42. Check the box next to aux1 and click select.
43. Verify that the box next to make retroactive is checked.
44. Switch the bias to screen edit.
45. Click screen edit. The number 1.000 appears next to the handle 'aux1'.
46. Click the number and hold the mouse button down.
If you move the mouse upwards the number increases, if you move the mouse downwards
the number decreases.
47. Move the mouse upwards until the value reads 1.500, then release the button and click
update.
48. Note how the curvature of the top edge has altered. See Figure 6.
49. Select the save shape subpanel using the radio buttons on the left-hand side of the panel.
50. Click shape = and enter shape2.
51. Select a color or leave the default.
52. Set the toggle under shape= to as node perturbations.
53. Click save.
54. Click Yes in the dialog box that prompts if you want to Save perturbations for nodes at
global and morph volume handles.
This shape is now saved, later it can be associate to a design variable.
56. Click return twice to return to the OptiStruct panel.
Step 3: Define the Shape Design Variables

1. Select the shape panel.
2. Select the desvar subpanel.
3. Switch the design variable option from single desvar to multiple desvars.
4. Click shapes.
5. Check the boxes next to shape1 and shape2 and click select.
6. Click create.
Two shape design variables are created using the shapes that were saved earlier.

Two responses are defined in this tutorial; a volume response for the objective function and a
displacement response for the constraint. A detailed description can be found in the OptiStruct
User's Guide under Responses.
2. Click response = and enter vol.
3. Click the response type switch and select Volume from the pop-up menu.
4. Click create. A response, vol, is defined for the total volume of the model.
5. Click response = and enter disp.
6. Click the response type switch and select static displacement from the pop-up menu.
7. Click nodes and select by id from the extended entity selection menu.
8. Enter 1115 and press ENTER.
9. Select dof1.
Dofs 1, 2, and 3 refer to translation in the X, Y, and Z directions.
Dofs 4, 5, and 6 refer to rotation about the X, Y, and Z axes.
10. Click create. A response, disp, is defined for the x-displacement of the node 1115.
Step 5: Define a Constraint

A constraint with upper bound is to be defined for the displacement response defined in the
previous section.
2. Click constraint = and enter constr.
3. Click response = and select disp from the list of responses. A loadstep button appears in the
panel.
4. Click loadstep.
5. Check the box next to Load and click select.
8. Click create. A constraint is defined on the response disp. The constraint is an upper bound
with a value of 3.0. The constraint applies to the subcase 'Load'.

In this step, the objective is to minimize the volume response defined in the previous section.
3. Click response = and select vol from the response list.
Step 7: Define the SHAPE Card

Only displacement and stress results are available in the _s#.h3d file by default. In order to look
at displacement/stress results on top of a shape change that was applied to the model in
HyperView, a SHAPE card needs to be defined.
2. Select SHAPE.
4. Set FORMAT to H3D. Set both TYPE and OPTION to ALL.

name for the model, beamshape.fem, in the File name: field. The .fem extension is
4. Click Save.
The name and location of the beamshape.fem file displays in the input file: field.
8. Click OptiStruct. This launches the OptiStruct job. If the job was successful, new results files
can be seen in the directory where the OptiStruct model file was written. The beamshape.out
file is a good place to look for error messages that will help to debug the input deck if any
errors are present. Make sure the process is complete before checking the results files.

Post-processing the Results in HyperView
This section describes how to view results in HyperView, which will be launched from within the
HyperView is a comprehensive post-processing and visualization environment for finite element
Step 9: View the Shape Results

2. The beamshape_des.h3d opens on page 1 and beamshape_s2.h3d opens on page 2 of
HyperView.
3. Use the navigations icons, seen in the figure below, to navigate to Design History (page 1), if
HyperView opens on page 2.
4. Select last iteration from Simulation using the drop-down selection, as seen in the figure
below.
5. Go to the Contour panel .

6. Set the Result type: to Shape change (v).
7. Select Mag.
8. Click Apply.

Shape optimization results applied to the model.
Step 10: View a Contour Plot of the Displacement on Top of the Shape
Optimized Model
1. Click the Next Page arrow to move to page 2 using the page navigation arrow icon.
2. Select the last iteration from Simulation using the drop-down selection, as seen in the image
below.
3. Go to the Deformed panel and set Result type: to Shape Change (v).
4. Click Apply. The optimized shape of the beam is shown on the screen now.
5. Go to the Contour panel and set Result type: to Displacement (v).
6. Select Mag using the toggle.

7. Click Apply.
8. Click the Measure panel toolbar icon .

9. Check the box in front of Static MinMax Result.
10. Notice that node 1115 has a displacement which is within the constraint value.

OS-5010: Cantilever L-beam Shape Optimization
This tutorial focuses on performing a shape optimization on an L-section cantilever beam
modeled with shell elements. A schematic is shown in the figure below. The vertical deflection at
point N should be limited to 2.0mm while minimizing the amount of material required.
Cantilever L-beam schematic
Objective: Minimize mass.
Constraints: A given maximum nodal displacement < 2 mm.
Design variables: Shape of each of the beam flanges.

 Set up the shape optimization problem in HyperMesh
Exercise
the File
4. Select the Lbeamshape.hm file you saved to your working directory from the optistruct.zip
5. Click Open.

Step 2: Create Shapes using HyperMorph

This section makes use of HyperMorph. For a more detailed description of the functionality of
HyperMorph, refer to the HyperMorph section of the HyperMesh documentation.
2. Select the HyperMorph panel.
3. Select the domains panel.
5. Click the switch next to global domain and select the auto functions from the pop-up
menu.
6. Click generate on the right side of the panel.
A number of domains and handles are created which will enable us to morph the shape of the
beam.
7. There are two types of handles; global handles, which are represented by larger red balls and
local handles, which are represented by smaller yellow balls. Only local handles are available
in this tutorial.
10. Select the move handles subpanel using the radio buttons on the left side of the panel.
11. Click the right-hand switch and select translate instead of interactive from the pop-up
menu.
12. If the handles button is not already highlighted, click on it.
13. Select the local handle that is located at the node where the load is applied by clicking on it in
the graphics window (local handles are indicated by a yellow ball).
14. Click y val = and enter -10.0.
15. Click morph. The beam changes shape so that the handle you selected moved -10.0 in the y-
direction. Note how the mesh adjusted to this change in shape.
16. Select the save shape subpanel using the radio buttons on the left side of the panel.
17. Click name = and enter shape1.
18. Click color and choose a color from the palette.
19. Set the toggle beneath shape = to as node perturbations.
20. Click save.

21. Select Yes to the message regarding the perturbations, as shown above.
This shape is saved as shape1. Later, you can associate it to a design variable.
Figure showing handles to be morphed
23. Repeat steps 9 through 22 for the local handles 3, 4 and 5. Referring to the figure above,
translate handles 3 and 4 by x=-10 and handle 5 by y=-10. Save the shapes after morphing
each handle as shape2, shape3 and shape4, respectively.
24. Click return twice to go to the optimization panel.
Step 3: Create Design Variables for Shape Optimization

1. On the Analysis page, in the optimization panel, select shape.
2. Select the desvar subpanel using the radio buttons on the left side of the panel.
3. Toggle the switch to multiple desvars from single desvar.
4. Click shapes, (the yellow button that appears).
5. Check the boxes next to shape1, shape2, shape3, and shape4 and click select.
6. Click create.
Four shape design variables are created using the shapes that were saved earlier.

A potential variation in shape of the vertical flange of the L-beam that could be achieved using the set up described.
Step 4: Create Mass and Static Displacement for Nodes as Responses

Two responses are defined in this tutorial, a mass response for the objective function and a
displacement response for the constraint. A detailed description can be found in the OptiStruct
User's Guide under Responses.
1. Select the responses panel (accessed through the optimization panel on the Analysis page).
5. Click response = and enter Disp.
Figure showing node to be selected while defining displacement response.
7. Select the response node by clicking on the node, shown in the above figure.

8. Select dof 2.
Dofs 1, 2, and 3 refer to translation in the X, Y, and Z directions.
Dofs 4, 5, and 6 refer to rotation about the X, Y, and Z axes.
9. Click create. A response, Disp, is defined for the y-displacement of the node selected.
Step 5: Define Minimize Mass as Objective Function

In this step, the objective is to minimize the mass response defined in the previous section.
1. Select the objective panel (accessed from the optimization panel on the Analysis page).
3. Click response = and select mass from the response list.
Step 6: Apply Design Constraint on Static Displacement Response

A response defined as the objective cannot be constrained (volume, in this case).
A lower bound constraint is to be defined for the displacement response defined in the previous
section.
1. Select the dconstraints panel (accessed from the optimization panel on the Analysis page).
2. Click constraint = and enter Constr.
3. Click response = and select Disp from the list of responses. A loadsteps button appears in
the panel.
4. Click loadsteps.
5. Check the box next to load and click select.
6. Check the box next to lower bound =.
7. Click lower bound = and enter -2.0. Note this is a lower bound, as the response is negative.
8. Click create.
A constraint is defined on the response disp. The constraint is a lower bound with a value of -
2.0. The constraint applies to the subcase Load.
Step 7: Save the Database as an hm File

1. From the File menu, select Save as > Model. A Save As dialog opens.
2. For Name, enter lbeamshape_opt.hm.
3. Click Save.

name for the model, lbeamshape_opt.fem, in the File name: field. The .fem extension is
4. Click Save.
The name and location of the lbeamshape_opt.fem file displays in the input file: field.
5. Set the memory options: switch, located in the center of the panel, to memory default.
6. Click the run options: switch, located at the left of the panel, and select optimization.
7. Set the export options: switch to all.
This launches the OptiStruct job. If the job was successful, new results files can be seen in
the directory where the OptiStruct model file was written. The lbeamshape_opt.out file is a
good place to look for error messages that will help to debug the input deck if any errors are
present.
Shape contour information is output from OptiStruct for all iterations. In addition, displacement
and stress results are output for the first and last iterations by default. This section describes
how to view those results in HyperView.

It is helpful to view the deformed shape of a model to determine if the boundary conditions have
been defined correctly and also to check if the model is deforming as expected. In this section,
use the Deformed panel to review the deformed shape for the last design iteration and a scale
factor, and overlay the undeformed shape.
1. While still in the OptiStruct panel, click HyperView.
2. Close the Message Log window that details the result files loaded into HyperView.
In the HyperWorks Desktop, the loaded .h3d files contain optimization results on page 2 and
analysis results on page 3.
3. Use the navigations icons, seen in the figure below to navigate to Design History (page 2).

4. Select the last iteration (iteration 6) using the drop-down selection, as seen in the figure
below.

6. Under Result type:, select Shape change (v).
7. Click Apply. The final shape for the Iteration # can now be seen.
Step 10: View a Transient Animation of Shape contour changes

1. Click the Play icon to start the animation.
2. The seek slider and playback speed slider (top and bottom respectively) are located next to
the playback controls.
3. Move the speed slider to adjust the animation speed.
4. After reviewing the animation, click the Stop icon to stop the animation and move Current
time: back to 0.
Step 11: Plot a Contour of Displacements

1. Click the Next Page arrow to go to page 3, which contains the analysis results.
2. Click the Contour panel toolbar .
3. Under Result type:, select Displacement (v).
4. Next, select the Y component of the Displacement (since that is what was constrained).

5. Select the last iteration (iteration 6) using the drop-down selection, as seen in the image
below.
6. Click Apply.
A plot of the displacements on your final shape should be displayed. The maximum
displacements for the last Iteration #, is still below 2.0.

OS-5020: Shape Optimization of a 3D Bracket Model using the
Free-shape Method
In this tutorial, shape optimization on a solid bracket model will be performed using the Free
Shape optimization method. The objective of this optimization is to reduce the stress by changing
the geometry of the bracket model.
The essential idea of free-shape optimization, and where it differs from other shape optimization
techniques, is that the allowable movement of the outer boundary is automatically determined,
thus relieving users of the burden of defining shape perturbations.
Objective: Minimize (Max von Mises Stress)
Constraints: No Constraints
Design Grids move normal to the surface

variables:

 Setup a free-shape optimization
 Post-process the free-shape optimization results
 Setup a new free-shape optimization simulation with moving constraints
 Post-process the new free-shape optimization results

Exercise
Step 1: Set the User Profile and Retrieve the File

3. Select the Open Model toolbar icon .

4. Select the free_shape3D.hm file you saved to your working directory from the
5. Click Open. The free_shape3D.hm database is loaded into the current HyperMesh session,
The location of free_shape3D.hm file displays in the File: field.
Step 2: Create Free-shape Design Variables (DSHAPE Cards)

2. Select the free shape panel.
3. Click name= and enter shape.
4. Select nodes, as shown in the figure (select only the face nodes that are also on shells).

Free-shape design space
5. Click create.
Step 3: Define the Optimization Problem

1. Select responses panel.
2. For response=, enter Stress.
3. Set the response type to static stress.
4. Click prop and select the stress_faces component which contains skin shells.
5. Click on the button below von mises and select both surfaces.
6. Click create.
Step 4: Define the Objective Reference

2. For dobjref =, enter MAX_STR.
3. Check pos reference; this gives the value 1.0.
4. Click response and select stress.
5. Click create.

2. Click the left-most toggle and select minmax.
3. Click dobjrefs and select MAX_STR.
4. Click create.
5. Click return twice to go back to main menu.

at stress results on top of a shape change that was applied to the model in HyperView, a SHAPE
card needs to be defined.
2. Select SHAPE.
4. Set both TYPE and OPTION to ALL.

name for the model, Free_Shape3D.fem, in the File name: field.
4. Click Save.
The name and location of the Free_Shape3D.fem file displays in the input file: field.
8. Click OptiStruct. This launches an OptiStruct run in a separate solver GUI window.
If the optimization was successful, no error messages are reported in the GUI window. The
optimization is complete when the message Job completed appears in the window.
Post-processing the Free-shape Optimization Results

Step 8: View Shape Results
Note that the message window opens to indicate that Free_Shape3D_des.h3d and
Free_Shape3D.h3d are opened.
Free_Shape3D_des.h3d will be opened in page 2 and Free_Shape3D.h3d will be opened in
page 3 of HyperView.
3. Use the navigation icons, seen in the figure below to navigate to Design History (page 2).
4. Select the last iteration (Iteration 8) using the drop-down selection, seen in the image below.
5. Go to the Deformed panel .

6. Set the Result type: to Shape change.
7. Click Apply. Shape optimization results are applied to the model. The figure below shows the
results.

Step 9: View a Contour Plot of the Stress on Top of the Shape Optimized
Model
1. Use the navigation icons, seen in the figure below, to navigate to Subcase 1 - step (page 3).
2. Select the last iteration (iteration 8) using the drop-down selection, as seen in the image
below.
3. Go to the Contour panel and select Element Stresses [2D & 3D] as the Result type:.
4. For stress type, select von Mises.

5. Click Apply. The stress contour shows on top of the shape changes applied to the model.
Setting Up a New Free-shape Optimization Simulation with Moving

Constraints
In the previous run, no constraints were applied on the movement of the DSHAPE grids.
Therefore, grids are free to move and the part thickness increases, as shown in the figure.
Free-shape results without constraints
In practice, however, there will be some sort of constraints imposed upon the movement of grids
due to manufacturability. For this tutorial model, thickness must be unchanged to avoid any
interference with other parts.

The next step will describe how to define constraints on DSHAPE grids such that the thickness of
design space will remain unchanged.
Step 10: Add Constraints on DSHAPE Grids

The constraints on free-shape design grids will be created separately for curved and flat parts of
the design space. The parts of the design space that are grouped as curved and those grouped as
flat are illustrated in the figure below.
Design space on curved and flat part
The constraints on the curved part will be created using a local rectangular coordinate system
(the other constraints on the flat part do not need a local coordinate system). Therefore, a local
rectangular coordinate system (z-axis will point to normal to DSHAPE surface) needs to be
created first.
1. Use the page navigation controls to move back to Page 1 and the HyperMesh client.
2. Back in HyperMesh, click return and go to the 1D page.
3. Click systems.
4. Select the create by axis direction subpanel.
5. Click nodes and select node ID 20999 (See the following figure).
6. Click origin and select the same node (ID 20999) as nodes.
7. Click x-axis and select node ID 15989.
8. Click xy-plane and select node ID 19462.

Local coordinate system
9. Click create.
10. Click return.
12. Select the free shape panel.
13. Select the gridcon subpanel.
The constraints on the flat part will be created first without any coordinate system.
14. Click desvar= and select shape.
15. Select constraint type as planar.
16. Select nodes, shown in the following figure.

Constraints on Free Shape design space
17. Click the vector definition switch and select vectors.

18. Select N1, N2, and N3 as those three nodes on plane geometry (as shown in the figure).
Three nodes to defined the plane
19. Click add.

These nodes will move only on the specified plane above. Next, the constraints on the curved
part will be created using a local coordinate system.
20. Select constraint type as vector.

21. Click nodes.
22. Select nodes, shown in the following figure (select only the nodes that are on the curved
part).
Constraints on free-shape design space on curved part
23. Click direction selector and select local system.

24. Click the local coordinate system created in the previous step.
25. Click the vector definition switch and select vector.
26. Click the direction definition switch below vector, and select z-axis from the pop-up menu.
27. Click add.

name for the model, Free_Shape3D_const.fem, in the File name: field.
4. Click Save.
The name and location of the Free_Shape3D_const.fem file displays in the input file: field.

Post-processing the New Free-shape Optimization Results
Follow the previously described steps on how to post-process the results (optimization results
without constraints) using HyperView, and compare the final shape change and stress results.

OS-5030: Buckling Optimization of a Structural Rail
Structures are said to "buckle" when a certain combination of loads cause them to be unstable
and deflection occurs. When a particular loading is reached, the structure continues to deflect
without an increase in the magnitude of the load. The critical load at which buckling occurs is the
product of the critical buckling factor and the applied reference load. The buckling factor is an
eigenvalue and has no dimension. Generally speaking, the lowest buckling load is usually of the
most interest to engineers, since a structure will fail prior to reaching any higher buckling loads.
When using OptiStruct to solve a linear buckling problem, apply a reference load to the structure
and calculate the buckling factors based on linear static and normal mode analysis. Use
OptiStruct also to perform size and/or shape optimizations on the structure to optimize for linear
buckling. Neither yielding of a structure nor change of force can occur during the optimization
process.
In this tutorial, a size and shape optimization are performed on a structural rail to increase the
buckling factor, thereby increasing the load it can carry before buckling. The rail has external
forces applied at one end, and is constrained in all degrees of freedom at the other end. By
performing buckling optimization, the buckling factor can be increased and thereby increase
critical buckling force.
Buckling optimization needs be performed to minimize the maximum von Mises stress among
several elements. This is done using the minimized maximum problem setup. Use MINMAX or
MAXMIN statements to define the objective function of a minimize maximum or maximize
minimum problem. Many times you will need to minimize or maximize several responses;
minimizing the maximum von Mises stress among several elements, for example. In such
situations, using user-defined equations to minimize the maximum von Mises stress will not
achieve the expected result. Reducing the maximum stress in one element often results in
increased stress on another element.
This tutorial describes the steps involved in defining linear buckling and size optimization using
the gauge panel. Shape and size optimizations will both be applied to this structural optimization.
The shape optimization has been pre-defined in this model using HyperMorph, so you will not
need to set up the shapes and shape design variables. The size optimization is part of the
exercise. A reference value is given to the stress design objective, and the problem is formulated
as a minmax optimization problem. The resulting structure is thicker and wider to prevent
buckling.

Buckling optimization of a structural rail
Problem Statement
This problem will perform a size and shape optimization on a structural rail to prevent buckling in
the rail structure.
Objective function: Minimize maximum von Mises stress.
Constraints: 1) Increase first buckling factor above 30.

2) Regional volume of designable region is less than 800000.
Design variables: Element thickness and shape perturbation.

 Setup a buckling optimization simulation
 Post-process the results with HyperView

Exercise
Retrieve the File
4. Select the os_buckle_original.hm file you saved to your working directory from the
5. Click Open. The os_buckle_original.hm database is loaded into the current HyperMesh
session, replacing any existing data.
Setting Up a Buckling Optimization Simulation
Step 2: Review Previously Defined Shape Design Variables and

Animation of Shape Changes
The shape optimization is already pre-defined using HyperMorph in this model. You will review
the design variables and animation of the previously defined shape changes.
1. In the Model browser, click the Utility tab.
If the Utility tab is not visible on the left side of the GUI in HyperMesh, go to the View menu,
and select Browsers > HyperMesh > Utility.
2. On the Utility tab, select Opti (near the bottom).
3. Under Optimization Info:, click Design Variables. The Size and Shape Design Variables
dialog appears.
v1 and v2 are pre-defined with Initial Value = 0.0, Lower Bound = -2.0, and Upper
Bound = 2.0 (shown below).

4. Click Close to close the Size and Shape Design Variables window.
6. Click shape.
7. Set the radio button to desvar, and click animate.
8. Set simulation = to SHAPE - v1 (1).
9. Set data type = to Perturbation Vector.
10. Click linear and notice the animation of the first shape.
11. To review the second shape, repeat steps 7 through 9, setting change simulation = to
SHAPE - v2 (2).
12. Click return three times to go back to the Optimization panel.
Step 3: Define the Size Optimization Design Variable

The shape optimization setup is predefined in os_buckle_original.hm. Therefore, you only need
to define the size design variable for this buckling optimization problem.
1. From the Optimization panel, select the gauge panel.
2. Verify that the create subpanel is selected with the radio buttons on the left.
3. Set the type: switch to PSHELL-T and the toggle beneath to same desvar for all props.
4. Click desvar= and enter shells.
5. Click props.
6. Click both dom and shell_elements.
7. Click select.
8. For initial value =, enter a value of 6.0.
9. Click the first toggle and change from lower bound % = to lower bound = and enter a
value of 3.0.

10. Click the second toggle and change from upper bound % = to upper bound = and enter a
value of 9.0.
11. Click create.
Step 4: Create Eigenvalue Analysis (buckling) Load Collectors

A load collector to perform real eigenvalue analysis (buckling analysis) will be created.
2. For Name, enter Buckling.

5. Set V1 = 0.01, V2 = 100.0, and ND = 20.
OptiStruct will search for the three lowest eigenvalues below 100.
Step 5: Set up a Buckling Optimization Load Step

2. For Name, enter Buckling.
4. Click Analysis type and select Linear buckling from the drop-down menu.
5. For STATSUB, select the pre-existing LINEAR subcase.
6. For METHOD(STRUCT), select buckling from the list of load collectors.
Step 6: Define the Responses for Optimization

2. Click responses.
3. Create three responses with the following settings: Region ID is not required.
Response = Response type: Characteristics
Buckle buckling Mode Number: 1
Von static stress props: dom

Stress type: von mises/both surfaces
Vol volume by entity

props: dom
4. Click return.

Step 7: Define the Constraints for Optimization
1. From the optimization panel, click dconstraints.
2. For constraint =, enter the name BUCKLE.
3. Click the check box to the left of lower bound and assign a value of 30.
4. Click response = and click Buckle.
5. Click loadsteps, then click the box besides the Buckling and click select.
6. Click create.
7. Set constraint = VOL and response = Vol.
8. Uncheck lower bound and click the check box to the left of upper bound to assign a value
of 800000.
9. Click create.
Step 8: Define the Minimize Maximum Optimization Response

2. For dobjref =, enter the name MAX_STRESS.
3. Click the check box to the left of pos reference = and enter a value of 1.000.
4. Click response = and select Von.
5. Toggle all to loadsteps.
6. Click loadsteps.
7. Click the check box to the left of LINEAR, and click select.
8. Click create. This creates the minimized maximum optimization response.
9. Click return.
Step 9: Define the Objective for Optimization

1. Click objective.
2. Click the switch and set to minmax.
3. Click dobjrefs.
4. Check the box to the left of MAX_STRESS.
5. Click select.
6. Click create.
Step 10: Solve the Buckling Optimization Problem

2. Click save as.
3. Select the directory where you would like to write the OptiStruct model file and enter the file
name, os_buckle_optimization.fem, in the File name: field. .fem is the suggested
4. Click Save.
The name and location of the os_buckle_optimization.fem file displays in the input file:
field.
8. Click OptiStruct. This exports the OptiStruct input file and launches the OptiStruct job.
model file was written. The os_buckle_optimization.out file is a good place to look for error
9. At the end of the optimization run, close the dialog.
Post-processing the Results with HyperView
Step 11: View Animations in HyperView

1. Click HyperView in the OptiStruct panel.
2. Close the Message Log window.
3. Using the page selector arrows (shown below), navigate to the Design History page (page
2).

4. Select Iteration 3 using the drop-down selector in the Model browser, as shown below.

6. Under Result type:, select Shape Change (v) from the first drop-down list, and Mag from
the second.
7. Click Apply.
8. The seek slider and playback speed slider (top and bottom respectively) are located next to
the playback controls.
9. With the animation running, use the slider bar to adjust the speed of the animation.
10. Click the Animation Controls icon next to the seek slider and activate the Bounce option to
review a back and forth animation of the impact.
11. Stop the animation and use the Current time: slider bar to manually control the animation.
For complete details on the various options available in this panel, refer to the online help.

Step 12: View the Stresses on the Final Shape
1. Click the Next Page arrow to go to the next page (page 3 of 4), which contains the Linear
analysis results.
2. Click the Contour panel toolbar icon.
3. Under Result type:, select Element Stresses (2D&3D)(t) from the first drop-down list,
and vonMises from the second.
4. Select the final iteration (Iteration 3) using the drop-down selector in the Model browser as
shown in step 11.
5. Click Apply.
A plot of the stresses on your final shape should be displayed.

Step 13: View the Buckling Modes
1. Click the Next Page arrow to go to the next page (page 4 of 4), which contains the buckling
results.
2. Click the Deformed icon contained within the HyperView toolbar, as shown below. Set the
deformed shape parameters to the same as those below. This will improve the animation
visualization that will be performed in the next step.
3. Select the animation mode toolbar icon and go to Modal.

4. Click the Animation Controls toolbar icon.
5. With the animation running, use the speed slider bar to adjust the animation.
Increase the scale to better see the buckling mode shape.
6. Activate the Bounce option to review animation of the impact.
7. The animation can also be manually controlled using the time slide to manually control the
animation.

OS-5040: Shape Optimization of a Rail Joint
Shape optimization requires you to have knowledge of the kind of shape you would like to change
in the structure. This may include finding the optimum shape to reduce stress concentrations to
changing the cross-sections to meet specific design requirements. Therefore, you need to define
the shape modifications and the nodal movements to reflect the shape changes. Shape
optimization requires the use of two cards DESVAR and DVGRID. They can be defined using
HyperMorph. Then these cards are included in the OptiStruct input file along with the objective
function and constraints to run the shape optimization.
In this exercise you perform a shape optimization on a rail-joint. The rail-joint is made of shell
elements and has one load case. The shape of the joint is modified to satisfy stress constraints
while minimizing mass.
Rail joint
Problem Statement
Objective: Minimize mass
Constraint: Maximum von Mises stress of the joint < 200 MPa
Design variables: Shape variables

 Perform an analysis of the initial design
 Post-process the initial design results in HyperView
 Setup a shape optimization problem in HyperMesh

Exercise
Step 1: Launch HyperMesh Desktop, Set the User Profile and Retrieve the
File
4. Select the rail_joint_original.hm file you saved to your working directory from the
Performing an Analysis of the Initial Design
Step 2: Run the Baseline Analysis

2. Click save as, enter rail_joint_original.fem as the file name, and click Save.
6. The options: field may be blank.
The message Processing complete appears in the window at the completion of the job. The
file rail_joint_original.out can be opened in a text editor to find details regarding any
errors. This file is written to the same directory as the .fem file.
Post-processing Baseline Results in HyperView
Step 3: View the Maximum von Mises Stress


click the HyperView button.
HyperView will launch and the results will be loaded. A message window appears to inform
about the successful loading of the model and result files into HyperView.
3D] (t).
5. Select the second drop-down and select von Mises.
6. Click Apply.
von Mises stress for the intial design.
7. Take note of the Maximum von Mises Stress of the joint and use the Delete Page icon to
delete the page with the HyperView client.
This should return you to Page 1 and the HyperMesh client.
8. Back in HyperMesh, click return to exit the panel.
Step 4: Display Node Numbers

1. From Tool page, select numbers panel.
2. Click nodes and select by sets.
3. Select node set by clicking the check box to the left of node.
4. Click select. Sixteen (16) nodes are highlighted on screen.
5. Click on to display node IDs.
6. Click return.

Step 5: Build 2D Domains on the Rail
1. In the Model browser, expand the Component list.
2. Right-click on the component PSHELL and click Isolate. All other components are turned off
for ease of visualization.
4. Go to the HyperMorph panel and select domains.
5. Select the radio button on the left of partitioning.
6. Verify that domain angle = 50.
7. Verify that curve tolerance = 8.0000.
8. Toggle back the radio button to create.
9. Click the switch (small triangle) and select 2D domains.
10. Toggle all elements to elems.
11. Click elems and select by sets from the pop-up window.
12. Check the boxes for rail_set1 and rail_set2.
13. Click select.
14. Click create.
Rail domains
Step 6: Split the Circular Edge Domains Around the Opening of the Rail
The following steps show the procedure to split each of the two circular domains (as seen in the
previous figure) into four curved edge domains.

1. Select the radio button to edit edges subpanel.
2. Verify the top selector is split.
3. Click domain and select the circular edge-domain passing through nodes 1300, 1305, 1311,
and 1316.
4. Click node and select node 1311 from the display. Refer to the previous figure.
5. Click split.
The circular domain is split at Node 1311 and a new handle is created at node 1311.
6. Select the circular edge between node 1311 and the other handle. The edge is highlighted.
7. Click node 1316 to split the domain.
8. Similarly (as in step 6.7), split the curved edge at nodes 1305 and 1300, respectively. Refer
to the previous figure.
A similar process is followed to split the circular domain using the four nodes on the other side
of the rail.
9. Click domain and select the circular domain passing through nodes 931, 926, 937 and 942.
10. Click node and select node 931 on screen.
11. Click split.
12. Select the circular edge between node 931 and the other handle. The edge is highlighted.
13. Click node 926 to split the domain.
14. Similarly (as in steps 6.11 to 6.14), split the curved edge at nodes 937 and 942, respectively.
The following figure shows the image after the circular edge domains are split.
Rail domains after the circular edge have been split

Step 7: Merge Edge Domains
Each circular domain on the rail has been split at four nodes and four new handles have been
added to each circular domain. This operation results in five curved edge domains on each
circular edge on the rail. The objective is to have only four domains. The following steps show the
procedure to merge domains.
1. Toggle the left switch and select to merge edges.
2. Click the left domain, below merge and select the outer red curve from node 926 to pre-
existing handle (refer to previous figure).
3. Click the right domain and select the outer red curve from pre-existing handle to node 942.
4. Verify that retain handles is unchecked.
5. Click merge. Notice the pre-existing handle is removed.
6. Repeat steps 7.1 through 7.5 to merge two edge domains between node 1316 and node 1300
on the other side of the rail.
Rail domains after few domains are merged
Step 8: Build 2D Domains on the Tube

1. In the Model browser, expand the Component list.
2. Right-click on the component PSHELL.1 and click Show.
3. Select the radio button create.
4. Make sure the switch (small triangle) is selected to 2D domains.
5. Click elems and select by sets from the pop-up window.

6. Check the boxes for elem_set1.
7. Click select.
8. Click create.
9. Repeat steps 8.5 through 8.8 to create three more 2D domains for elements in sets
elem_set2, elem_set3, and elem_set4, respectively.
10. Click return and go back to the HyperMorph module.
Domains on Rail and Tube Joint
Step 9: Create Shapes

In this step, three shapes using the created domains and handles are created.
1. Click morph.
Use the alter dimensions feature in HyperMorph to modify the curvatures of selected edge
domains.
2. Toggle to alter dimensions.
3. Toggle the right switch and select curvature.
4. Toggle center calculation and change the setting to by edges.
5. Toggle the switch below and select hold ends.
Holding two ends of a selected edge domain allows a change of curvature of the selected edge
without altering its end points.
6. Leave the other settings with the defaults.
7. Under edges only, click domains and select red edge-domains, as shown in the following
figure. You might need to zoom in for easier picking operation.
8. Verify that a total of eight edge domains are selected and highlighted on screen.

Morph edge domains
9. Click curve ratio = and enter 20.

10. Click morph. A new curvature is applied to the selected eight edge domains. See the
following figure below.
11. Select the radio button to save shape.
12. Click shape =, enter the name sh1.
13. Toggle as handle perturbation to as node perturbation.
14. Click color and change the color of the shape vectors or leave the default color.
15. Click save. Shape vectors (arrows) are created of the selected color.
16. Click undo all to prepare for the generation of the next shape.
17. In the Model browser, right-click Shape and select Hide.

First shape variable, sh1.
18. Select the radio button alter dimensions.
19. Under edges only, click reset . This will clean up previous selection from buffer.
20. Click domains and select the red edge curves, as shown the following figure.
Morph edge domains for the second shape.
21. Click morph. A new curvature is applied to the selected eight edge domains. See the
following figure below.
22. Select the radio button save shape.
23. Click shape =, enter the name sh2.

24. Toggle as handle perturbation to as node perturbation.
25. Click color and change the color of the shape vectors or leave the default color.
26. Click save. Shape vectors (arrows) are created of the selected color.
27. Click undo all to prepare for the generation of the next shape.
Refer to the following figure for the new shape changes.
Second shape variable, sh2.
29. Select the radio button apply shapes. In HyperMorph, a new shape can be created as a
linear combination of existing shapes.
30. Click shapes and select both sh1 and sh2.
31. Click Select.
32. Verify that the multiplier is 1.0.
33. Click apply.
34. Select the radio button save shapes.
35. Click shape = and enter sh3.
36. Make sure that the toggle is set to node perturbations. The new shape sh3 includes
influences from both sh1 and sh2 shapes, as shown in the next figure.
37. Click save.
Do NOT click undo all at this moment, because one more shape based on this third shape
change will be created.

The third shape variable, sh3, converts the tube to a square cross-section
An additional shape variable is created using the shape created in the previous step.
39. In the Model browser, right-click on the component PSHELL and click Hide. These
components are turned off for ease of visualization.
40. Toggle the radio button to alter dimensions.
41. Under edges only, click reset . This will clean up previous selection from buffer.
42. Switch the top selector from curve ratio to distance =. This feature allows you to shorten
the distance between selected domains.
43. Switch the end a: selector from two handles to nodes and handles.
44. Click node a and pick node, as shown in the next figure.
45. Click node b and pick node, as shown in the next figure.

Setup for the fourth shape variable, sh4
Once nodes a and b are selected, the distance between node a and node b is measured
automatically and appears in distance = field.
The distance between node a and node b is about 43.
46. Click handles under node a and select the 8 handles shown by the downward pointing
arrows in the previous figure.
To select, click the handles on the screen until they are highlighted.
47. Click handles under node b and similarly as in the previous step, select the 8 handles near
the opposite face of the tube.
48. Toggle the bottom selector and select hold middle. These components are turned on for ease
of visualization
49. Click distance = and enter 20.
50. Click morph. A rectangular shape appears to the joint, as shown in the next figure.
51. Toggle the button to save shape.
52. Click shape = and enter sh4.
53. Make sure that the toggle is set to node perturbations.
54. Click save.
55. Click undo all to restore the mesh to the baseline configuration.
57. Click return three times to go the main menu.

Fourth shape variable, sh4
Step 10: Define the Shape Design Variables and Review by Animation
2. Click the shape panel.
3. Make sure the radio button is set to desvar and create.
4. Toggle the switch to select multiple desvars.
5. Click shape = and select sh1, sh2, sh3 and sh4.
6. Click select.
8. Click lower bound = and enter -1.0.
10. Click create.
This creates four design variables with the same initial value, lower bound, and upper bound.
HyperMesh automatically links the design variables to each shape, respectively and assigns
names to each design variable the same as its associated shapes.
11. Click animate.
12. Click simulation = SHAPE – sh1 (1).
13. Make sure that data type = is set to Perturbation vector.
14. Click modal to animate the first shape variable.

15. Click next and then animate to see the next shape variable, and so forth.
16. Click return three times to go back to the optimization panel.
Step 11: Create the Mass and Static Stress Response

7. Click the response type switch and select static stress from the pop-up menu.
8. Click props and select the PSHELL.1 component which contains skin shells.
9. Do NOT select any element under excluding:.
10. Make sure that the toggle is selected to von Mises.
11. Toggle the bottom switch to select both surfaces.
12. Click create. A response, Stress, is defined for the model.

3. Click response= and select Mass.
4. Click create.
5. Click return to exit the optimization panel.
Step 13: Create Constraints on Stress Response

In this step, the upper and lower bound constraint criteria for this analysis will be set.
2. Click constraint= and enter con.
4. Click upper bound= and enter 200.
5. Select response= and set it to Stress.

6. Click loadsteps and check STEP.
7. Click select.
8. Click create.
9. Click return to the main menu.
Step 14: Define Control Cards Required for Shape Optimization

Without this control card defined, optimization gets terminated by quality check and you do not
get the converged results.
1. From the Analysis page, click the control cards panel.
2. Click next twice and choose the PARAM card.
3. Check the box next to CHECKEL.
4. Click YES under CHECKEL_V1 and change to NO.

2. Click save as, enter rail_joint_opt.fem as the file name, and click Save.
3. Set the export options: toggle to All.
OptiStruct also reports error messages if any exist. The file carm_complete.out can be
7. Close the DOS window or shell.
Step 16: Review the Shape Optimization Results

click HyperView. The HyperView client is launched and the results are loaded into a new
page.
files into HyperView. Notice that all three .h3d files get loaded, each in a different page of
HyperView.

2. Click Close to close the message window. Rail_joint_opt_des.h3d will be opened in page 2
and Rail_joint_opt.h3d will be opened in page 3 of HyperView.
3. Click the Contour toolbar icon.
Note the Result type: is Shape Change [v]; this should be the only results type in the
“file_name”_des.h3d file. The second drop-down menu select mag.
4. Click Apply to display the shape change.
Note the contour is all blue this is because your results are on the first design step or
Iteration 0.
5. At the bottom of the GUI, click the name Design <> Iteration 0 to activate the Load Case
and Simulation Selection dialog.
6. Select the last iteration by double-clicking on the last Iteration listed.
Shape optimization results are applied to the model.
Shape change converged (Scale 2x)

Step 17: View a Contour Plot of the Stress on Top of the Shape
Optimized Model
1. Click the Next arrow to move to page 2.
The Result type: is Element Stresses [2D & 3D] [t]. The second drop-down menu shows
von Mises.
3. At the bottom of the GUI, click the name Subcase 1 (STEP) <> Model Step to activate the
Load Case and Simulation Selection dialog.
4. Select the last iteration by double-clicking on the last Iteration listed.
5. Click Apply.
The stress contour shows on top of the shape changes applied to the model. Verify that this
value is around the constraint value specified.
von Mises stress for the last iteration (Max < 200 MPa)

Reviewing the Results
Is your design objective of minimizing the volume obtained? If not, can you explain why?
Are your design constraints satisfied?
Which shape has the most influence in this problem setup?
What is the percentage decrease in compliance?
Can size optimization be introduced to the joint?

OS-5050: Shape Optimization of a 4 Bar Linkage
This tutorial demonstrates how to set up the structural optimization problem of MBD systems
with HyperMesh, and how to run the shape optimization job in OptiStruct. The mass of the
system is to be minimized by controlling 12 shape design variables while the stress should be
less than an allowable value. Left link is a driving link whose angular velocity is 50 rad/sec. Units
(kg, N, cm, s).
4 bar linkage.
Objective: Minimize mass
Constraints: Upper bound on stress
Design variables: Shape design variables of the three flexible bodies

 Setup an MBD transient analysis
 Post-process MBD results in HyperView
 Setup an ESL MBD optimization problem in HyperMesh
 Post-process optimization results using HyperView

Exercise
the File
2. Choose OptiStruct in the User Profiles and click OK. This loads the user profile. It includes
the appropriate template, macro menu, and import reader, paring down the functionality of
4. Select the 4bar_design.hm file you saved to your working directory from the optistruct.zip
The 4bar_design.hm database is loaded into the current HyperMesh session.
Step 2: Define a Driving Motion

In this tutorial, the driving motion at a joint, MOTNJ is defined. However, MOTNJ is not currently
supported by HyperMesh, so the card needs to be entered manually.
2. Click BULK_UNSUPPORTED_CARDS.
3. Make sure the following card is there; if not, it needs to be entered.
Constant velocity (50 Rad/s) applied to the joint 66299.

4. Click OK.
5. Click return.
Step 3: Update Boundary Condition and MOTION in the Predefined MBD

Subcase
1. In the Model browser, select the SUBCASE1 load step.
2. Make sure that Analysis type is set to Multi-body dynamics.
3. For MBSIM, select MBSIM1 from the pop-out window and click OK.
4. Scroll down to the bottom of the load step entry, and click on the box next to
SUBCASE_UNSUPPORTED.
5. Click and enter MOTION = 1 in pop-out window.

6. Click OK.
Step 4: Submit the Transient MBD simulation in OptiStruct

name for the model, 4bar_design_analysis.fem, in the File name: field. For OptiStruct
input decks, .fem is the suggested extension.
7. Change the options: field so that it is blank.
appears.
If the analysis was successful, no error messages are reported to the shell. The analysis is
complete when the message Process complete successfully appears in the shell.

Post-processing the MBD Results in HyperView
Step 5: Post-process the Transient MBD Analysis

close the window.
2. Click HyperView from within the OptiStruct panel. This will automatically load the results for
the current run into HyperView.
files.
5. Select the first drop-down menu below Result type: and select Element Stresses (2D &
3D) (t).
6. Click Apply.
7. Click Edit Legend and change the Type: to Dynamic scale. Other properties can be
changed here to created the desired legend.
8. Click the Page Layout icon and change the page to 2 Vertical windows .
9. Click the empty window on the right side to make it current.
10. Click the Client Selector drop-down switch and select HyperGraph 2D .
11. Click in window 1 to make it current.
12. Click Measure .
13. In the Measure Groups list, check the box beside Dynamic MinMax Result.
14. Click Max at the list below Resolved in.
15. Click Create Curve, modify Place curve on: to Existing Plot. This will expose a list of plot
windows on this report.
16. Check the Live link box, select Window 2 and click Apply. This will plot the Maximum von
Mises stress (t). Now this file will be saved as a template to be applied on the optimized
result.

MBD Stress results (Max = 56996 N/cm2)
17. From the File menu, select Save As > Session and change the Save as type: to Report
definition (*.tpl).
18. Enter Stress_report.tpl click Save.
19. Use the page navigation icons to return to Page 1 and the HyperMesh client.
Setting Up the ESL Optimization Problem in HyperMesh
Step 6: Define Boundary Conditions for Structural Analysis in ESL

Optimization
Structural analysis and optimization of the flexible bodies of this model are performed in ESL
optimization. Thus, the boundary condition for the flexible bodies needs to be defined.
2. For Name, enter BCforOpt.
5. From the Preferences menu, select Graphics.
6. Make sure coincident picking is checked on.
7. Click return to go to main menu.

9. All of the dofs (1 through 6) should be fixed to remove the 6 rigid body motion of each
flexible body. Make sure that dof1 through dof6 are all checked in the constraints panel.
Nodes to be constrained to arrest rigid body motions.
10. From the graphics area, click the center of the lower spider of the component Left. You should
see two node numbers at one location; choose node number 288.
11. From the graphics area, click the center of the left spider of the component Middle and choose
node number 143.
12. From the graphics area, click the center of the lower spider of the component Right and
choose node number 441.
13. Make sure the Load Type= is set to SPC.
14. Click create.
Step 7: Update Boundary Condition and MOTION in the Predefined MBD

Subcase
1. In the Model browser, click on the SUBCASE1 load step.
2. Make sure that Analysis type is set to Multi-body dynamics.
3. For MBSIM, select MBSIM1 from the pop-out window and click OK.
4. For SPC, select BCforOpt from the pop-out window and click OK.

Step 8: Define Shape Variables
The shape perturbation vectors already have been created in this database. For more details
about creating shape perturbation vectors, refer to other tutorials related to HyperMorph. In this
section, you will define shape design variables with the predefined shape perturbation vectors.
2. Click shape.
3. Select the desvar subpanel using the radio buttons on the left side of the panel.
4. Click the switch next to single desvar and change it to multiple desvars.
5. Click shapes in the cyan border in the right upper corner, select all from the pop-up menu,
and click select.
6. Enter -1.0 for the lower bound and 1.2 for the upper bound.
7. Click create. 12 shape design variables are created.


Two responses are defined: a mass response for the objective function and stress for the
constraint.
1. You should already be in the optimization panel. Select the responses panel.
6. Click the response type switch and select static stress from the pop-up menu.
7. Click props in the cyan border and select Middle, Left, and Right.
8. Click select.
9. Make sure that stress type is von mises and for both surfaces.
10. Click create. A stress response is created.

Step 10: Define an Objective Function
The objective is to minimize the mass response defined in the previous section.
1. Select the objective panel (accessed from the optimization panel on the Analysis page).
3. Click response = and select Mass from the response list.
Step 11: Define Constraints on Stress Response

The upper bound constraint is to be defined for the stress response defined in the previous
section.
1. Select the dconstraints panel (accessed from the optimization panel on the Analysis page).
2. Click constraint = and enter Constr.
5. Click response = and select Stress from the list of responses. A loadsteps button appears in
the panel.
6. Click loadsteps.
7. Check the box next to SUBCASE1 and click select.
8. Click create. A constraint is defined on the response Stress. The constraint will force the
maximum stress on SUBCASE1 to be less than 30000.0 N/cm 2.

1. From the File menu, click Save As > Model.
2. Select the directory in which to save the file and, in File name:, enter 4bar_design_opt.hm.
3. Click Save.
Step 13: Submit the ESL Optimization Job in OptiStruct


name for the model, 4bar_design_opt.fem, in the File name: field. For OptiStruct input
decks .fem is the suggested extension.
7. Click Save.
appears.
was saved. In addition to ordinary output files, you can see a text file whose name is
4bar_design_user.eslout. This file is a good source to see the process of the ESL
optimization.
Post-processing Optimization Results using HyperView
Step 14: View Stress Results for the Last Iteration

close the DOS window.
2. Click HyperView from within the OptiStruct panel or open HyperView from the Start menu.
3. From the File menu, select Open > Report Template.
4. Browse for the report Stress_report.tpl and click Open.
5. For GRAPHIC_FILE_1 and RESULT_FILE_1, select 4bar_design_opt_mbd_0#.h3d from where
the optimization was run (the highest # should be the final iteration).
A message appears explaining that the Element Stresses (2D & 3D) results do not exist - this
is because the stress results on MBD simulations are just named Stress.
6. Close the Message Log window.
7. Click on window 1 to make it current.
9. Select the first drop-down menu below Result type: and select Stress (t).

10. Click the traffic light icon to start the animation.
von Mises stress contour (Max < 30000 N/cm2)
Step 15: Contour the Shape Change

1. Click to add a new page to the session.
2. Click the Load Results toolbar icon and open the last iteration (highest) number result file
of 4bar_design_opt_des_0#.h3d from where the optimization was run.
3. Click Apply.
5. Select the first drop-down menu below Result type: and select Shape Change (v).
6. Click Apply.

Shape changing contour
Open the file 4bar_design_opt.dsvar to see how OptiStruct changed the DVs during the
optimization process.
This will show that all DVs for the right and mid arms went to the limit of 1.2, showing that
minimizing the mass of these two arms are key to reducing the Stress.

OS-5060: Shape Optimization of a 3D Model using the Free-
shape Method with Manufacturing Constraints
In this tutorial, shape optimization on a solid model will be performed using the free-shape
optimization method along with manufacturing constraints, such as symmetry and mesh barrier
constraints. The objective of this optimization is to reduce the stress by changing the geometry
of the model.

 Setup a free-shape optimization problem with manufacturing constraints
 Post-process free-shape optimization results in HyperView
Exercise
Setting Up a Free-shape Optimization Problem with Manufacturing

Constraints
the Model
3. From the File menu, select Open > Model.

4. Select the freeshape3d_mfg.hm file you saved to your working directory from the
optistruct.zip file. Refer Accessing the Model Files.
5. Click Open. The freeshape3D_mfg.hm database is loaded into the current HyperMesh session,
The location of freeshape3D_mfg.hm displays in the file: field.

2. Click free shape.
3. In the create subpanel, click desvar=, and enter shape.
4. Click nodes and select the by sets check the box next to shape_nodes.
5. Click select.
Free-shape design space
6. Click create.
7. Click the parameters subpanel and select the direction as grow.
8. Set mvfactor= to 0.5.
9. Set nsmooth to 10 and click update.

Step 3: Convert Existing Shell Elements to Create the Barrier Mesh Face
(BMFACE)
1. Go to the 2D page.
2. Enter the elem types panel.
3. Click elems to get the extended entity list.
4. Select by collector.
5. Check the box next to barrier.
6. On the 2D & 3D subpanel, click CTRIA3 in the field next to tria3.
7. Select BMFACE from the list of options.
8. Click CQUAD4 in the field next to quad4.
9. Select BMFACE from the list of options.
10. Click update.
Step 4: Define the 1-Plane Symmetry Constraint

The manufacturing constraint options for free-shape are: (Draw direction constraint, Extrusion
constraint, Pattern grouping: 1-plane symmetry constraint, Maximum growing/shrinking distance
control, Side constraint, and Mesh barrier constraint).
2. Click free shape; make sure that the desvar selected is shape.
3. Click pattern grouping in the free shape panel.
4. Select the pattern type: 1-pln sym.
The 1-plane symmetry constraints in free-shape will produce symmetric designs regardless of
the initial mesh, boundary conditions or loads. The plane of symmetry is defined by specifying
the anchor and the first nodes. The plane of symmetry will then be perpendicular to the
vector from the anchor node to the first node and pass through the anchor node.
5. Click anchor node, input the node id= 1, and press ENTER. This selects the node with the
ID of 1.
6. Click first node and input the node id= 2. This selects the node with the ID of 2.
7. Click update to update the design variables. This completes the definition of the symmetry
constraint.

Defining 1-plane symmetry
Step 5: Define the Mesh Barrier (sidecon) Constraint

A mesh barrier constraint allows control on the total deformation extent of a design
boundary/surface; mesh barrier will constrain the design boundary/surface to deform within the
restricted design space and never penetrate the barrier.
The barrier should be constructed by shell elements with the smallest number of elements
possible.
For this exercise, the mesh barrier was already created and the component name is barrier.
1. Click sidecon in the free shape panel.
2. Click desvar = and select shape.
3. Click Barrier mesh: component= and select barrier from the list.
4. Click update.

Mesh barrier component
Step 6: Define Responses for Optimization

2. For response=, enter Stress.
3. Set the response type to static stress.
4. Switch from props to elems.
5. Click elems and click by sets.
6. Check the box next to stress and click select.
7. Choose von mises and click create.
8. Click response= and assign mass.
9. Set the response type to mass.
10. Click create.
Step 7: Define Constraints for Optimization

2. Click constraint= and enter the name stress.
3. Click response= select stress.
4. Activate upper bound = and assign a value 62.

5. Click loadsteps, activate ls2, and click select.
6. Click create.
7. Click return.

2. Click the left-most toggle and select min.
4. Click create.

at stress results on top of a shape change that was applied to the model in HyperView, a SHAPE
card needs to be defined.
2. Click next three times and select SHAPE.
3. Set format to h3d and both TYPE and OPTION to ALL.

name for the model, freeshape3d_mfgopt.fem, in the File name: field.
4. Click Save.
The name and location of the freeshape3d_mfgopt.fem file displays in the input file: field.
8. Click OptiStruct. This launches an OptiStruct run in a separate (DOS or UNIX) shell.

Post-processing Free-shape Optimization Results in HyperView
Step 11: View Shape Results

Note that the message window pops up to indicate that freeshape3d_mfgopt_des.h3d and
freeshape3d_mfgopt_s4.h3d are opened.
2. Click Close to close the window.
freeshape3d_mfgopt_des.h3d will be opened in page 1 and
freeshape3d_mfgopt_s4.h3d will be opened in page 2 of HyperView.
3. Click the arrow to move to page 2.
4. From the Graphics menu, click Select Load Case.
This opens the Load Case and Simulation Selection dialog which is also accessible from
the lower right portion of the status bar.
5. Select Iteration14 from beneath Simulation (load final iteration results).
6. Click OK.
7. Go to the Deformed panel .
8. Set the Result type: to Shape change(v).

9. Click Apply. Shape optimization results are applied to the model.
Step 12: View a Contour Plot of the Stress on Top of the Shape
Optimized Model
1. Go to the Contour panel and select Element Stresses (2D & 3D) (t) as the Result
type:.
2. Select von Mises as the stress type.
3. Click Elements, click By set, and select the set stress.
4. Click Add and close.
5. Click Apply.

von Mises stress contour on the final shape.

OS-5070: Fatigue Optimization of a Torque Control Arm
In this tutorial, free-shape fatigue optimization on a torque control arm will be performed. The
objective of this optimization is to increase the fatigue life of the control arm by changing the
geometry of the model.
The torque control arm is loaded by brake force and vertical force, as shown in Figure 1. Two
load time histories acquired for 279 seconds with 1HZ, as shown in Figures 2(a) and 2(b), are
applied. The material of the control arm is Steel, whose S - N curve is shown in Figure 3.
Figure 1. Model of control arm for Fatigue Optimization
Figure 2(a). Load time histories for vertical force Figure 2(b). Load time histories for braking force

Figure 3. S-N Curve of Steel

 Setup S-N Fatigue Problem using Fatigue Process Manager (FPM)
 Setup free-shape optimization problem in HyperMesh
 Post-process free-shape fatigue optimization results in HyperView
The three files found in the optistruct.zip file are required to perform this tutorial. Refer to
tarm_fatigue.fem
tarm_loadY.csv
tarm_loadX.csv
Exercise
Setting Up the S-N Fatigue Problem using Fatigue Process Manager

(FPM)
Step 1: Launch HyperMesh Desktop and Process Manager

2. Choose Optistruct in the User Profiles dialog and click OK.
3. From the Tools menu, select Fatigue Process, and select Create New.
4. Enter a New Session Name, select a working folder, and click Create. This creates a new
file to save the instance of the currently loaded fatigue process template.
When finished, the fatigue process tree shows in the Process Manager tab, with the Import
File task selected.

Step 2: Import Model
1. For Model file type:, select OptiStruct.
2. Click the Open Model file icon . An Open file browser window opens.
3. Select the tarm_fatigue.fem file you saved to your working directory from the
4. Click Import.
This loads the control arm model. It includes a whole definition of two static subcases,
elements sets, and material static properties, and so on.
5. Click Apply.
This guides you to the next task of the fatigue process tree, Fatigue Subcase.

Step 3: Create a Fatigue Subcase
1. Make sure the task Fatigue Subcase is selected in the fatigue process tree.
2. In the Create new fatigue subcase field, enter fatsub.
3. Click Create.
4. In the Select existing fatigue subcase field, select the newly created fatigue subcase,
fatsub.
fatsub is selected as the active fatigue subcase. Definitions in the following processes
(analysis parameters, fatigue elements and properties, loading sequences, etc.) will be for
this subcase.
5. Click Apply.
This saves the current definitions and guides you to the next task, Analysis Parameters, of the
fatigue process tree.

1. Make sure the task Analysis Parameters is selected in the fatigue process tree.

Analysis S-N
type:
Stress Abs. Max. Principal
combinatio
n method:
Mean stress GOODMAN
correction:
FEA stress MPA
unit:
Rainflow LOAD
type:
Gate: 0.0
Certainty of 0.5
survival:
4. Click Apply.
This saves the current definitions and guides you to the next task of the fatigue process tree,
Elements and Materials. For details, consult the HyperWorks online help.

1. Make sure the task Elements and Materials is selected in the fatigue process tree.

3. For Element entity type:, select Property-PSHELL.
4. For Element entity name:, select shells.
5. Make sure the Ultimate tensile strength (UTS) is selected to define the material data.
7. For Input method under Define SN Curve, select Estimate From UTS.
8. Click the Show SN curve definition icon . An SN Method description window introducing
how to generate the SN material parameter pops up.
9. Click Close.

10. For Material type:, select Steel and click Estimate. All the data for SN curve definition are
automatically estimated.
11. Click Plot SN Curve at the bottom of the window to show the SN curve.
12. Close the SN Curve plot window.
13. For Layer of stress results in shell elements, select TOP and BOTTOM.
17. Click Save to save the definition of the SN data for the selected elements.
18. Click Apply.
This saves the current definitions and guides you to the next task in the fatigue process tree,
Load-Time History.

1. Make sure the task Load-Time History is selected in the fatigue process tree.

3. For Load-time history name, enter hist_y.
4. For Load-time history type, select CSV from the drop-down menu.
6. Browse for tarm_loadY.csv.
7. Click Open.
8. Click Import.
12. Follow steps 2 - 11 to create another load-time history, hist_x, by importing the file
tarm_loadX.csv.
13. Click Apply.
This saves the current definitions and guides you to the next task, Loading Sequences, of the
fatigue process tree.

In this step, one event consisting of two load time history is created, in other words, the linear
1. Make sure that the task Loading Sequence is selected in the fatigue process tree.

3. For Select static loadcase, select loadx.
4. For Select load-time history, select hist_x from the drop-down menu.
7. Enter Event1 for the new created fatigue event name.
8. Click Save.
10. For Select static loadcase, select loady.
11. For Select load-time history, select hist_y.
13. Make sure Existing is selected using the radio buttons.
14. From Existing, select Event1.
15. Click Save.
16. Click Apply.
This completes the fatigue problem set-up. Next, you will set-up the optimization problem.

Free Shape Optimization Problem Set-up in HyperMesh
This section describes how to set-up the free-shape design variables, objective, and fatigue life
constraint.

2. Click free shape.
3. In the create subpanel, click desvar= and enter upper.
4. Click nodes and select the by sets and check the box next to node set upper.
5. Click select.
6. Click create.
7. Click the parameters subpanel.
8. Activate the options checkbox.
9. Set nsmooth = 10, and mvfactor = 0.25.

10. Click update.
11. Repeat steps 4 through 10 and create a new design variable named lower with the node set
lower.
Step 9: Define Responses for Optimization

2. Enter volume in the response= field.
3. Set the response type to volume.

4. Click create.
5. Click response= and enter life.
6. Set the response type to fatigue.
7. Click props and select the shells property.

8. Click create.
Step 10: Define Constraints for Optimization

2. Click constraint= and enter the name con_life.
3. Click response= and select life.
4. Activate lower bound= and assign a value 2.0E4.
5. Click loadsteps, activate fatsub, and click select.
6. Click create.
7. Click return.

2. Make sure the left-most toggle is selected to min.
3. Click response= and select volume.
4. Click create.

Only life and damage results are available in the _s#.h3d file by default. In order to look at life
results on top of a shape change that was applied to the model in HyperView, a SHAPE card
needs to be defined.
2. Click next twice and select SHAPE.
3. Set format to H3D and set both TYPE and OPTION to ALL.
Step 13: Submit Fatigue Optimization Job

1. Make sure the task Submit Analysis is selected in the fatigue process tree (click it to
activate).
2. Click the Save .fem file as icon . A Save file browser window opens.
3. Set the directory in which to save the file, and in File name, enter tarm_fatigue_opti.fem.
6. From Run Options:, select optimization.
7. Click Submit.
This launches the OptiStruct to run the fatigue optimization.


tarm_fatigue_opti.0.4.fa An ASCII format file which contains fatigue results of each

t fatigue subcase in iteration step.
tarm_fatigue_opti_s4.h3d Hyper 3D binary results file, with both static analysis results and
fatigue free-shape optimization results.
tarm_fatigue_opti.out OptiStruct output file containing specific information on the file

set up, the set up of your fatigue problem, compute time
information, etc. Review this file for warnings and errors.
tarm_fatigue_opti.stat Summary of analysis process, providing CPU information for

each step during analysis/optimization process.

1. Make sure the task Post-processing is selected in the fatigue process tree. When the fatigue
optimization is finished successfully, it will automatically go into this task.
2. Click Load H3D Results(HV).
This launches HyperView to load the tarm_fatigue_opti_s4.h3d results file for life results on
top of shape results.
3. Click on last iteration (Iteration 11) from the Simulation list of the Load Case and Simulation
Selection Manager.
4. Click the Start/Pause Animation icon to stop the animation.

5. Change the animation mode from Linear Static to Transient . This shows the Life Contour
on top of shape results.

7. Click Edit Legend and edit the legend (if you wish) to be the same as shown in the following
two images.
8. Click Exit to unload fatigue process manager.
Life contour of Iteration 0, volume = 4.674E+02, minimum Life = 2.053E+04.
Life contour of iteration 11, volume =3.78213E+02, minimum Life = 2.053E+04.

OS-5080: Global Search Optimization
In this tutorial, Global Search Optimization (GSO) will be performed with shape design variables.
A global search approach will be used to generate the multiple starting points. The structure,
consisting of one base panel and the cross shaped ribs (as shown in the following image), is
subjected to a frequency-varying unit load excitation using the modal method. The goal is to
achieve the best stiffened structure by changing the shapes of the ribs.
A regular shape optimization has been defined in the model. The formulation of this optimization
is listed below.
Objective: Minimize the maximum (minmax) displacement at the node where the
excitation load was applied.
Constraints: Mass < 2.0e-3
Design Shape design variables

variables:
3. From the File menu, select Import > Solver Deck.

6. Select the rib_opt.fem file you saved to your working directory from the optistruct.zip
7. Click Open. The location of rib_opt.fem displays in the file: field.
8. Click Import. rib_opt.fem database is imported into the current HyperMesh session.
Step 2: Review the model and optimization setup

The shape optimization of the frequency response model has been defined in the model.
1. Use the Model browser, located on the left side of the HyperMesh window (as shown below) to
review the model, loadstep, and optimization setup.
2. To review the shape design variables, click shape on the optimization panel.
3. Click animate and enter the Deformed Shape panel. One of the shapes should be displayed
in simulation=.
4. Click linear, you will see the animation of that shape.
5. The other shapes can be reviewed by clicking the next or prev icon.
6. Return to the optimization panel.

Step 3: Submit the job as is
The name and location of the rib_opt.fem file displays in the input file: field. The location
where the model and result files will be written can be modified.
3. After the running process completes, go to the working directory and open the rib_opt.out
file. Check the optimization history and the final optimal design.
4. Return back to the Analysis page.
Step 4: Define the DGLOBAL cards for global search

1. On the Analysis page, click control cards.
2. Click CASE_UNSUPPORTED_CARDS, and enter DGLOBAL=1.
3. Click BULK_UNSUPPORTED_CARDS, and enter DGLOBAL,1.
4. Click return. Both subcase and bulk data entries for global search are created with default
parameters.

1. On the Analysis page, select the OptiStruct panel.
2. Click save as, following the input file: field. A Save file browser window opens.
name for the model, rib_opt_global.fem, in the File name: field. The .fem filename
4. Click Save.
The name and location of the rib_opt_global.fem file displays in the input file: field.
model file was written. The rib_opt_global.out file is a good place to look for error
messages that will help to debug the input deck if any errors are present. Make sure the
process is complete before checking the results files.
Step 6: Post-process the results of GSO

Since the default parameters are used for GSO, OptiStruct determines the number of starting
points and number of groups of design variables automatically.
1. Open the rib_opt_global.out file.
A general summary of the GSO run is output at the end of the out file. This GSO run
completed with 20 starting points. Seventeen (17) unique designs were found, which means
three designs were repeated. The best design was found at starting point 3. The table of
unique designs and table of designs were also printed with the information of starting point,
objective function, constraint violation, times found, and directory suffix.

2. Compare the best design with the results from the regular optimization approach (step 3).
In the working directory, 17 directories with suffix ‘_GSO_V1_V2’ were created for the unique
designs. V1 is the number of the starting point, and V2 is the rank of this design among all
unique designs. The optimization results of each starting point can be found in the directory
respectively.
3. Open the Excel file, rib_opt_global_GSO.slk.
The tables for unique designs and all designs are printed in the Excel file. The best design
among the GSO runs was achieved with the 3rd starting point, and the results of this design
were saved in the directory, rib_opt_global_GSO_3_1, and this design was found three times
during the global search. In GSO search, if the difference between two designs is under the
unique design tolerance, they are considered identical; for example, the designs with starting
points 11 and 3. This information can be found in the table of all designs. The statistical
information and the optimal design variables for each run are also available.
Step 7: Post-process the best design in HyperView

The following steps demonstrate how to review the best design of GSO in HyperView.
1. Launch HyperView by clicking HyperView in the OptiStruct panel.
2. In the Load model and results panel, load the rib_opt_global_des.h3d file in the
directory /rib_opt_global_GSO_3_1.
3. Click Apply. The h3d file containing optimization results is loaded.
4. Make sure that Iteration 10 is selected in the Results browser.
5. Go to the Contour panel, select Shape Change (v) as the Results type, and click Apply.
The optimized shape at the final iteration is loaded as shown below.

Best optimized shape design from GSO

OS-5090: Thermal Optimization on Aluminum Fins
In this tutorial, shape optimization on an example of aluminum fins (as shown in the following
image) is performed. The base of the fins experiences a constant heat flux of q=8000 W/m2. The
temperature of the surrounding air is 10˚C with a corresponding heat transfer coefficient of H =
40 W/m2 • K. The heat conduction coefficient is K = 221 W/m • K. The temperature distribution
within the fins is determined by solving the heat conduction and convection load case.
Model review
The formulation of the optimization problem is listed below.
Objective: Minimize the temperature at the center of the base
Constraints: Volume < 1.0e-5 m2
Design Shape design variables

variables:
3. From the File menu, select Import > Solver Deck.

6. Select the fins.fem file you saved to your working directory from the optistruct.zip file.
7. Click Open. The location of fins.fem displays in the file: field.
8. Click Apply. The fins.fem database is loaded into the current HyperMesh session.
Step 2: Create shapes in HyperMorph

The Freehand module in HyperMorph creates the shapes. For a more detailed description of the
functionality of HyperMorph, refer to the HyperMorph section of the HyperMesh documentation.
2. Click HyperMorph.
3. Click Freehand.
4. Select the move nodes subpanel using the radio buttons on the left side of the panel.
5. Set the movement option as translate.
6. Input the translation distance in the basic coordinate system, x=0.03, y=0.0, z=0.0. You
only want to extend the fins in x-direction.
7. Select moving nodes.
8. Click the highlighted nodes and click by sets on the pop-up window.
9. Check the small box in front of node set sh1_move and click select. The selected moving
nodes are highlighted on the screen.
10. Select fixed nodes.
11. Click the highlighted nodes and click by sets on the pop-up window.
12. Check the small box in front of node set sh1_fix and click select. The selected fixed nodes
are highlighted on the screen.
13. Select affected elements.
14. Click the highlighted elems and click by sets on the pop-up window.
15. Check the small box in front of element set sh1_elem and click select. The selected
elements are highlighted on the screen.
16. Click morph. The fin is extended in the x direction.
17. Go to the save shape subpanel.
18. Input name= sh1 and toggle the option to as node perturbations.
19. Click save. The shape, shp1, for shape design variable is created.
20. Click undo all.
21. Repeat steps 5 through 16 to create shapes sh2 and sh3 on the original model. The
corresponding node sets (sh2_move/fix and sh3_move/fix) and element sets (sh2_elem and
sh3_elem) are predefined.
22. Click return twice back to the optimization panel.

Step 3: Create shape design variables
1. Select the shape panel.
2. Select the desvar subpanel.
3. Switch the design variable option from single desvar to multiple desvars.
4. Click the highlighted shapes.
5. Check the boxes next to sh1, sh2, and sh3 and click select.
6. Input initial value = 0.0, lower bound = -1.0, upper bound = 2.0.
7. Click create. Three shape design variables are created from the shapes created in the
previous step.
Step 4: Create design responses

A volume response is created and then defined as the constraint of the optimization problem.
1. Go to the responses panel.
2. Input response = volume.
3. Click the response type switch and select volume from the pop-up menu. Make sure the
total volume is selected.
4. Click create. The total volume of the fins is created as the response.
5. Input response = temperature.
6. Select temperature as the response type.
7. Click nodes and click by id, in the node ID field, enter 2450 and press ENTER.
8. Click create. The temperature response at node 2450 is created.
9. Click return twice and go back to the Analysis page.
Step 5: Define the optimization constraint

1. Go to the dconstraints panel.
2. Input constraint = vol.
3. Click response = and select volume.
4. Activate the upper bound and enter 1.0e-5.
5. Click create. A volume constraint with the upper bound of 1.0e-5 is created.

1. Go to objective panel.
2. Toggle the option to min.
3. Click response = and select temperature.
4. Click loadsteps and select heat transfer subcase.
5. Click create. The objective function of minimizing the temperature at node 2450 is created.

Step 7: Define the SHAPE card
Only the analysis results are available in the _s#.h3d file by default. In order to obtain analysis
results on top of the shape change that was applied to the model in HyperView, a SHAPE card
needs to be defined.
2. Click next to find SHAPE and click it.
3. Set format to h3d and set both TYPE and OPTION to ALL.

name for the model, fins_opt.fem, in the File name: field. The .fem file name extension is
the suggested extension for OptiStruct input decks.
4. Click Save.
The name and location of the fins_opt.fem file displays in the input file: field.
5. Set the memory toggle toggle to memory default.
7. Set the export options toggle to custom.
model file was written. The fins_opt.out file is a good place to look for error messages that
will help to debug the input deck if any errors are present. Make sure the process is complete
before checking the results files.
Step 9: Post-process the results in HyperView

The following steps demonstrate how to review the contour plot of the temperatures with the
optimized shape in HyperView.
1. Launch HyperView by clicking HyperView in the OptiStruct panel.
2. In the Load model and results panel, load the fins_opt_s1.h3d file in both model and
results fields.
3. Click Apply. The h3d file containing both the analysis and optimization results is loaded.
4. Make sure Iteration 0 is selected in the HyperView Results browser.
5. Go to the Contour panel.
6. Select Grid Temperatures (s) as the Result type and click Apply.
The initial temperature distribution contour in the aluminum fins is displayed.

8. In the Contour panel, select Shape Change (v) as the Results type and click Apply.
The optimized shape at final iteration is loaded.
9. Select Grid Temperatures (s) as the Result type and click Apply.
The contour plot of grid temperature is applied on top of the optimized shape now.
The following plot shows the temperature distributions of the original design and the
optimized design.

Examples
File Location The examples use model files that are located in the demos/ directory of
the software installation. In the examples, file paths are referenced as
<install_directory>/../. In order to locate the model files needed,
you will need to determine the path of the installation directory
<install_directory>. This path is dependent on the installation that
was performed at your site. To determine what this path is, follow these
instructions:
1. Launch the application.
2. From the Help menu, select Updates.
3. The HyperWorks Update Information dialog opens. The installation
directory path appears after Altair Home:.
The OptiStruct example model files are located in
<install_directory>/demos/hwsolvers/optistruct.
Downloading If you are using the examples via the Altair website, you will need to
Model Files download the model files before beginning. Access them by clicking:
http://www.altairhyperworks.com/hwhelp/Altair/hw2017/index.aspx
or via Altair Connect from here:

https://connect.altair.com/CP/downloads.html?suite=HyperWorks&tab=2
Please note that a User ID and password is required to access this area.
Follow the instructions provided to obtain the login information.

Example Problems for Structural Analysis
This section presents structural analysis examples generated using OptiStruct.

Normal Modes Analysis of a Compressor Wheel
Nonlinear Analysis of a Lap Joint
Nonlinear Analysis of Cantilever Beams with Follower Forces

Normal Modes Analysis of a Compressor Wheel
Summary
Altair OptiStruct was used to run a free-free normal modes analysis on a gas turbine compressor
wheel solid FE model.
Model
A solid hexa model of a gas turbine compressor wheel with fins was generated with Altair
HyperMesh. The model contained 44,369 grids and 31,022 solid hexa elements. A free-free
modal analysis was conducted using OptiStruct to find the first twelve natural frequencies.

The first six frequencies found were rigid body modes and can be disregarded. The frequency
results can be found in the table below.
Mode # Frequency
7 2.46
8 2.46
9 3.33
10 3.62
11 3.62
12 3.83
File Location
<install_directory>/demos/hwsolvers/optistruct/compressor.fem

Nonlinear Analysis of a Lap Joint
Summary
Two overlapping plates (aluminum) are connected by a rivet (titanium) forming a lap joint. The
aluminum and titanium materials are both defined by piece-wise linear elasto-plastic law. The
plates and the rivet are meshed with solid elements. The free end of the bottom plate is
constrained and the free end of the top plate is pulled (by applying imposed displacement) to
shear the joint. An all inclusive contact is defined such that all the components in the model are
master and all nodes of the model are slave.
This example is considered a static problem and the nonlinear implicit solver is used.
Title
Lap joint
Number
40.1
Brief Description
A lap joint is fixed at one end and pulled at the other to shear the joint.
Keywords
 Nonlinear large displacement analysis (NLGEOM)
 Contact definition (CONTACT)
 Plasticity and Piece-wise linear elasto-plastic material (MATX36 and TABLES1)
OptiStruct Options
 Parameters for Geometric Nonlinear Implicit Static Analysis Control (NLPARMX)
 Boundary conditions (SPC)
 Imposed displacement (SPCD and NLOAD1)
 Solid element (PSOLIDX)
 Contact property for NLGEOM analysis (PCONTX)

Input File
Lap_joint: <install_directory>/demos/hwsolvers/optistruct/lap_joint.fem
Technical / Theoretical Level

Beginner
Overview
Aim of the Problem

The purpose of this example is to demonstrate a nonlinear large displacement implicit analysis
(NLGEOM) involving elasto-plastic material and contact using OptiStruct.
Physical Problem Description
The top and bottom plates have a length of 30mm, width of 20mm and height of 1.5mm. The
rivet is 8mm in diameter and 6mm in height. The geometry of the joint is shown in Figure 1. Due
to symmetry only half of the joint is modeled.
Fig 1: Geometry of the joint.
The material used for the aluminum plates have the following properties:
 Density: 1.2e-9 Mg/mm3
 Young’s modulus: 71700 MPa
 Poisson’s ratio: 0.33
 Yield stress: 350 MPa
The stress vs plastic strain plot for aluminum is shown in Figure 2.

Fig 2: Stress – plastic strain curve for aluminum
The material used for the titanium rivet has the following properties:
 Density: 7.8e-9 Mg/mm3
 Young’s modulus: 112000 MPa
 Yield stress: 907 MPa
The stress vs plastic strain plot for titanium is shown in Figure 3.

Fig 3: Stress – plastic strain curve for titanium
Analysis, Assumptions and Modeling Description
Geometric Linear (NLSTAT) or Geometric Nonlinear (NLGEOM) Analysis

In a geometric linear analysis all deformations and rotations are small – displacements of 5% of
the model dimension are considered small.
For this lap joint example, the final deformations and strains after shearing of the lap joint are
9.5% of the largest dimension of the model (30mm). So, the geometrically nonlinear static
NLSTAT analysis could not be considered for this example.
Modeling Methodology
The mesh is a regular solid mesh with the plates being around 1.5mm in dimension and the rivet
being around 0.5mm in dimension.
The plates and rivet have been modeled using first order fully-integrated solid elements.
PSOLID 4 1
PSOLIDX 4 14 222 VAR
The boundary conditions applied in the model are shown in Figure 4.

Fig 4: Boundary conditions
The imposed displacements are defined in FEM file using NLOAD1 card:
SPCD 3 572 1 2.5
………………
TABLED1 8 LINEAR LINEAR
+ 0.0 0.0 1.0 1.0ENDT
NLOAD1 7 3 DISP 8
OptiStruct Options Used

An all inclusive general purpose contact has been defined in the model. All the nodes of the
model are defined as slave and all components in the model are defined as the master.
SET 2 GRID LIST
+ 1 2 3 4 5 6 7 8
+ 9 10 11 12 13 14 15 16
………………………………
SET 7 ELEM PROP
+ 4 5 6
CONTACT 6 7 2 7 OPENGAP
A small physical gap of around 0.02mm has been introduced between the top and bottom plates
and also between the plates and the rivet. The minimum gap specified (0.022) for the contact is
slightly higher than the physical gap for contact to take effect. A static Coulomb friction of 0.05 is
defined for the interface.
PCONT 7 AUTO
PCONTX 7 0.05 0.022 0
+ CONST

+ 4
+
+ COUL STIFF
+
The plasticity and contact causes major nonlinearities; therefore, a static nonlinear analysis is
performed using the arc-length displacement strategy. The time step is determined by a
displacement norm control.
The nonlinear implicit parameters used are:
Implicit type: Static nonlinear
Nonlinear solver: BFGS Quasi-Newton method
Termination criteria: Relative residual in force
Tolerance: 0.01
Update of stiffness matrix: 5 iterations maximum
Time step control method: Arc-length
Initial time step: 0.01
Minimum time step: 1e-5
Maximum time step: 0.05
Line search method: AUTO
Special Residual force

computation with contact 0
interfaces present:
Desired convergence iteration 6

number:
Maximum convergence 20
iteration number:
Decreasing time step factor: 0.8
Maximum increasing time

step scale factor: 1.02
Arc-length: Automatic computation
Spring-back option: No.

A solver method is required to resolve Ax=b in each iteration of a nonlinear cycle. The linear
implicit options used are:
Linear solver: Direct (BCS)
Precondition methods: Factored approximate

Inverse
Maximum iterations System dimension

number: (NDOF)
Stop criteria: Relative residual of

preconditioned matrix
Tolerance for stop Machine precision

criteria:
The input nonlinear implicit options set in the FEM file are defined by NLPARMX:
NLPARM 9 100 P
+ 0.01
NLPARMX 9 0.0 0.1 0.01 -1 40
+ BFGS ARC 1e-5 0.05 AUTO
+ 6 1.02 20 0.8
Refer to the OptiStruct manual for more details about implicit options.
The nonlinear large deformation analysis has to be defined through a subcase. An NLPARM
statement, as well as ANALYSIS=NLGEOM has to be present in the subcase. The termination time
of 1.0s is defined through the TTERM entry.
SUBCASE 1
ANALYSIS NLGEOM
SPC = 10
NLPARM = 9
NLOAD = 7
TTERM = 1.000

Simulation Results and Conclusions
Animations
The displacement, stresses (mises) and plastic strain results after the shearing of the joint are
shown in the following figures.
Fig 5: Displacements (max = 2.84mm)
Fig 6: Stress (max = 1022 MPa)

Fig 7: Plastic strain in aluminum plates (max. = 23.86%).

Nonlinear Analysis of Cantilever Beams with Follower Forces

Summary
Four cantilever beams are analyzed. The objective is to evaluate the response of the beams
under (i) linear static analysis (small displacements) and (ii) geometric nonlinear analysis (large
displacements) with and without the application of follower forces.
Considering the example is a static problem, the nonlinear implicit solver is used.
Title
Follower Force
Number
41.1
Brief Description
Cantilever beams.
Keywords
 Nonlinear large displacement analysis (NLGEOM)
 Termination time (TTERM)
OptiStruct Options
 Parameters for Geometric Nonlinear Implicit Static Analysis Control (NLPARMX)
 Boundary conditions (SPC)
 Applied forces (FORCE, TABLED1, and NLOAD1)
 Default shell element parameters (XSHLPRM)
 Fixed coordinate system (CORD2R)
 Moving coordinate system (CORD3R)
Input File
Follower force: <install_directory>/demos/hwsolvers/optistruct/follow_force.fem
Technical / Theoretical Level

Beginner

Overview
Aim of the Problem

Follower forces imply that the direction of the load is assumed to rotate with the rotation at the
node (where the load is applied). The purpose of this example is to compare the deformation
characteristics of several cantilever beams – with and without the application of follower forces in
a geometrically nonlinear implicit analysis (NLGEOM) and that in a geometrically linear static
analysis.
Physical Problem Description
The four beams are all identical with a length of 100mm, width of 10mm and thickness of 1mm.
Fig 1: Geometry of the beams.
Small displacement (linear static) analysis is performed on beam 1. Large displacement

(NLGEOM) analysis is performed on beams 2, 3 and 4, as shown in Figure 1.
The material used is elastic with the following properties:
 Density: 7.9 e-9 Mg/mm3
 Young’s modulus: 2.1e+5 MPa
Analysis, Assumptions and Modeling Description
Modeling Methodology
The mesh is a regular shell mesh with average element size of 5mm.
The beams have been modeled using first order reduced integrated shell elements as specified in
the default definition of shell element properties (XSHLPRM):
PSHELL 1 11.0 1 1 0.0
XSHLPRM 24 2 VAR NEWT 5
The loads and boundary conditions applied in the model are shown in Figure 2.

Fig 2: Loads and Boundary conditions
The cantilever beams are constrained at one end and all dof and forces are applied at the other
end (15N are applied at the the two outer nodes as 30N is applied at the center node).
SPC 6 1 1234560.0
………………
For NLGEOM analysis, the loading is defined using NLOAD1 card:
TABLED1 8 LINEAR LINEAR
+ 0.0 0.0 1.0 1.0ENDT
NLOAD1 7 4 8
Force Type – Follower or Non-follower

For beams 1 and 4, the loading is defined in default global coordinate system, which is a fixed
coordinate system, signifying the definition of non-follower force on both the beams. Static
analysis is performed on beam 1, while geometric nonlinear analysis is performed on beam 4.
For beam 2, loading is defined with a fixed coordinate system (CORD2R) signifying the definition
of non-follower force on this beam as well. Geometric nonlinear analysis is performed on beam 2.
CORD2R 1 30.0 100.0 0.0 30.0 100.0 100.0
+ 130.0 100.0 0.0
FORCE 4 88 11.0 0.0 0.0 15.0
FORCE 4 89 11.0 0.0 0.0 30.0
FORCE 4 90 11.0 0.0 0.0 15.0

For beam 3, loading is defined with a moving coordinate system (CORD3R) signifying the follower
force on beam 3. Geometric nonlinear analysis is performed on beam 3.
CORD3R 3 151 150 178
FORCE 4 151 31.0 0.0 0.0 15.0
FORCE 4 152 31.0 0.0 0.0 30.0
FORCE 4 153 31.0 0.0 0.0 15.0
OptiStruct Options Used

As mentioned before, small displacement linear static analyses (for beam 1), as well as large
displacement nonlinear implicit analyses (for beams 2, 3 and 4) have been performed in this
example. The nonlinear analysis is performed using the arc-length displacement strategy. The
time step is determined by a displacement norm control.
The nonlinear implicit parameters used are:
Implicit type: Static nonlinear
Nonlinear solver: Modified Newton method
Termination criteria: Relative residual in force and

energy
Tolerance: 0.01
Update of stiffness matrix: 5 iterations maximum
Time step control method: Arc-length
Initial time step: 0.5
Minimum time step: 1e-5
Maximum time step: 1.5
Line search method: ENERGY
Desired convergence iteration 6

number:
Maximum convergence 20
iteration number:
Decreasing time step factor: 0.67
Maximum increasing time step

scale factor: 1.1
Arc-length: Automatic computation
Spring-back option: No.

A solver method is required to resolve Ax=b in each iteration of a nonlinear cycle. The linear
implicit options used are:
Linear solver: Direct (BCS)
Precondition Factored approximate Inverse

methods:
Maximum System dimension (NDOF)

iterations
number:
Stop criteria: Relative residual of

preconditioned matrix
Tolerance for Machine precision

stop criteria:
The input nonlinear implicit options set in the FEM file are defined by NLPARMX:
NLPARM 1 2
NLPARMX 1 0.0 0.1 0.01 -1 40
Refer to the OptiStruct manual for more details about implicit options.
The nonlinear large deformation analysis has to be defined through a subcase. An NLPARM
statement, as well as ANALYSIS=NLGEOM has to be present in the subcase. The termination time
of 1.0s is defined through the TTERM entry. The first subcase is linear static and the second
subcase is geometric nonlinear.
$HMNAME LOADSTEP 1"linstatic" 1
$
SUBCASE 1
SPC = 6
LOAD = 2
$
$HMNAME LOADSTEP 2"nlgeom" 15
$
SUBCASE 2
ANALYSIS NLGEOM
SPC = 6
NLPARM = 1
NLOAD = 7
TTERM = 1.0

Simulation Results and Conclusions
Animations
The displacement contour on the beams is shown in Figure 3. As expected, beam 1 for which
static analysis has been performed, shows the largest deformation. Beam 2 (for which loading
has been defined in a fixed coordinate system) and beam 4 (for which loading has been defined
in the default global coordinate system) show the exact same deformations. Beam 3 for which
NLGEOM analysis has been performed with follower forces, shows higher deformations than
beams 2 and 4, and the end where load is applied bulges out into a spherical shape.
Fig 3: Displacement contour of the four cantilever beams
Figure 4 shows the differences in deformation characteristics with and without the application of
follower forces for geometrically linear and geometrically nonlinear analyses.

Fig 4: Comparison of deformations for geometrically linear, geometrically nonlinear without application of follower force
and geometrically nonlinear analysis with follower force applied
Whether follower force should be applied or not depends on the application. For situations where
the applied force rotates with the rotation of the load application point, follower forces should be
defined for correct representation of the physical situation. In all other situations where the
direction of the force remains constant, follower forces do not need to be considered.

Example Problems for Topology Optimization
This section presents optimized topology examples generated using OptiStruct. Each example
uses a problem description, execution procedures, and results to demonstrate how OptiStruct is
used as a design concept tool.

Introductory Example of Topology Optimization
To develop a new design for a socket wrench, you are given:
 The design space
 The maximum forces that may develop during use
 A mass target
A finite element model representing the design space is created and the loads and boundary
conditions are applied.
Design Space.
FE model of design space with loads and constraints applied.

The end of the handle is assumed to be fixed. Forces simulating service conditions are applied at
the tip. The mass of the optimized design and other parameters are specified before topology
optimization. OptiStruct initializes the design space by distributing the available material evenly
to all elements.
OptiStruct uses an iterative process to determine the optimum distribution of material using the
Solid Isotropic Material with Penalization (SIMP) method. In the density method, the rho-mat is
used directly as the density design variable. The material density varies continuously between 0
and 1. These represent the void and solid states respectively for each element. The stiffness of
the material is assumed to be linearly dependent on its density.
Areas of intermediate density are fictitious when looked at from a practical standpoint. This is
due to the fact that the presence or absence of material at a particular region is deduced from
the density being either 1 or 0, respectively. All other values of density are practically
meaningless. Therefore, the intermediate densities are penalized to force the final design to be
represented by densities of only 0 or 1 for each element. Ideally, on convergence, the finite
element model is transformed into a structure with elements having either a density near 1.0
(representing material) or 0.0 (representing no material). The load paths in the structure are
prominently displayed at the end of the optimization.
Structure of the socket wrench after 22 iterations.
A design for the socket wrench is generated using the OptiStruct solution. The solution shows
major load paths running from the tip, which is loaded with a torque and surface pressure, to the
rigidly held areas farthest on the handle. Translators provided with OptiStruct can be used to
generate IGES surfaces which can be imported into any CAD system for developing a complete
design concept. A finite element model of the concept can also be developed for analysis and, if
necessary, further optimization using size and shape optimization methods can be performed.

Two-dimensional Michell-truss
The two-dimensional Michell-truss is an optimal topology structure generated under bending. The
design space for this problem consists of a rectangle with a single vertical load at the free end. A
circular cut-out is constrained in all translational degrees-of-freedom on the inside free edge. This
is a compliance minimization problem with a material volume fraction constraint of 20%.
CQUAD4 (4-noded isoparametric) elements are used in a design space defined by a rectangular
region with an aspect ratio approximately equal to one quarter of the short edge located closer to
the edge away from the load.
Subcase Section
The objective function (compliance) is a subcase dependent response, therefore the response
reference is part of the subcase definition. The constraint (volume fraction) is a global response,
therefore the reference is outside the subcase.
DESGLB = 2
$
SUBCASE 1
SPC = 1
LOAD = 2
DESOBJ = 1
Bulk Data Section

The responses and constraints are defined in the bulk data section. Two responses are defined
here, the compliance (which is referenced by the objective function), and the volume fraction,
referenced by the constraint statement to put up an upper bound of 0.2 (20% of the design
space volume). The constraint statement is then referenced as a global constraint in the subcase
section.
BEGIN BULK
$
DRESP1,1,comp,COMP
DRESP1,2,volfrac,VOLFRAC
DCONSTR,2,2,,0.2

Finite element mesh of the design space for the two-dimensional Michell-truss.
Execution
This example is analyzed using the one-file setup with the file, michell.fem. The OptiStruct
batch job is submitted using the command shell script, % optistruct michell.
Results
The optimization converges in 29 iterations. The results are requested in HyperMesh binary
format and written to the file, michell.res. The shape of the solution at the final iteration is
visualized by creating a contour plot of the density results at the 29th iteration in the HyperMesh
contour panel.

Contour plot of density results for the two-dimensional Michell-truss.
For the input file sample, see

<install_directory>/demos/hwsolvers/optistruct/michell.fem.

Suspension Bridge
The suspension bridge topology is an optimal structure generated under a distributed load. A fine
mesh is generated to simulate the design space and loads are applied. The distributed load forms
a single load case.
Subcase Section
therefore the reference is outside of the subcase.
DESGLB = 2
$
SUBCASE 1
SPC = 1
LOAD = 2
DESOBJ = 1
Bulk Data Section
here: the compliance, which is referenced by the objective function, and the volume fraction,
which is referenced by the constraint statement to put up an upper bound of 0.2 (20% of the
design space volume). The constraint statement is then referenced as a global constraint in the
subcase section.
BEGIN BULK
$
DRESP1,1,comp,COMP
DCONSTR,2,2,,0.2
Loads and constraints for suspension bridge.
Execution
This example is analyzed in the one-file setup with the file, bridge.fem. The OptiStruct batch job
is submitted using the command shell script, % optistruct bridge.
Results
The optimization converges in 24 iterations. The solution is well defined with discrete truss
members connecting the load carrying arch to the load applied points. The results are requested

in HyperMesh binary format and written to the file, bridge.res. The shape of the solution at the
final iteration is visualized by creating a contour plot of the density results at the 24th iteration in
the HyperMesh contour panel.
Design topology for suspension bridge with all loads weighted equally.

<install_directory>/demos/hwsolvers/optistruct/bridge.fem.

Cantilever Beam in Bending
This example demonstrates how OptiStruct creates optimized design concepts from a solid block
of material. The design space consists of a cantilever beam loaded at the mid-section of the free
end.
Subcase Section
therefore the reference is outside the subcase.
DESGLB = 2
$
SUBCASE 1
SPC = 1
LOAD = 2
DESOBJ = 1
Bulk Data Section
here: the compliance, which is referenced by the objective function, and the volume fraction,
which is referenced by the constraint statement to put up an upper bound of 0.25 (25% of the
design space volume). The constraint statement is then referenced as a global constraint in the
subcase section.
BEGIN BULK
$
DRESP1,1,comp,COMP
DCONSTR,2,2,,0.25
The volume fraction constraint is set to 25% of the total design material. In the beam.fem file,
the following PSOLID entry is used:
(1) (2) (3) (4) (5) (6) (7) (8) (9)
PSOLID 1 1 1
The 1 in the 9th field denotes that the component is designated as design material. The example
is run for 20 iterations.
By running the file, beam.HM.comp.cmf, as a command file in HyperMesh, the elements are
grouped into sets according to their final material density values. The set labeled "0.0 - 0.1"
contains all of the elements in which densities range from 0% to 10%. The set labeled "0.1 - 0.2"
contains all of the sets in which densities range from 10% to 20%. The elements in the sets that
have material densities less then 30% are masked so that the solution is easier to visualize. The
material densities of the remaining elements are plotted as shown.

Finite element model of a cantilever beam.
Execution
This example is analyzed in the one-file setup with the file, beam.fem. The OptiStruct batch job is
submitted using the command shell script, % optistruct beam.
Results
The optimization runs for 20 iterations. The results are requested in HyperMesh binary format
and written to the file, beam.res. The shape of the solution at the final iteration is visualized by
creating an assign plot of the density results at the 20th iteration in the HyperMesh contour
panel. By removing components labeled "0.1 - 0.2", "0.2 - 0.3", "0.3 - 0.4", and "0.4 - 0.5" from
the display, a concept of the optimized beam can be visualized.

OptiStruct results thresholds at 25%.
For the input file sample, see <install_directory>/demos/hwsolvers/optistruct/beam.fem.

Air Conditioner Bracket
The air conditioner bracket is an optimal topology structure generated under both linear static
stiffness and modal frequency response. Shell elements are used to ensure that the bracket is
manufacturable using a casting process.
A concentrated mass, M, is used to model the air conditioner unit connected to the mounting
bolts by beam elements. Shell elements close to the mounting bolt and engine bolt connections
(shown as darker elements) are moved to a nondesign component. The model is constrained at
two engine mounting bolts that are fixed for all displacements and rotations except for the
rotation perpendicular to the plane of the bracket. The belt tension load is applied at the node
representing the air conditioner bracket.
Subcase Section
Since the objective function (weighted combination of compliance and frequencies) is a global
response, the response reference is outside of the subcase definition. The constraint (volume
fraction) is a global response too, therefore the reference is outside the subcase. The weight
factors are defined within the load cases.
DESOBJ = 1
DESGLB = 2
$
SUBCASE 1
SPC = 1
LOAD = 2
$
WEIGHT = 1.0
$
SUBCASE 2
SPC = 2
METHOD = 2
$
MODEWEIGHT 1 1.0
MODEWEIGHT 2 1.0
MODEWEIGHT 3 1.0
$
NORM = 40000.0
Bulk Data Section

here, the weighted combination of compliance and reciprocal frequencies (referenced by the
objective function), and the volume fraction, which is referenced by the constraint statement to
put up an upper bound of 0.3 (30% of the design space volume). The constraint statement is
then referenced as a global constraint in the subcase section.
BEGIN BULK
$
DRESP1,1,freqstat,COMB
DCONSTR,2,2,,0.3
The same problem definition can also be achieved by using the equation utility DEQATN to define
the weighted combination.

Finite element model of air conditioner bracket.
The OptiStruct output for the initial iteration appears as follows:
ITERATION 0
Subcase Weight Compliance Weight*Comp.

1 1.000E+00 2.573592E+01 2.573592E+01
----------------
Sum of Weight*Compliance 2.573592E+01
Subcase Mode Weight Frequency Eigenvalue Weight/Eigen

2 1 1.000E+00 3.129449E+00 3.866299E+02 2.586453E-03
2 2 1.000E+00 4.035579E+01 6.429414E+04 1.555352E-05
2 3 1.000E+00 8.710232E+01 2.995154E+05 3.338726E-06
2 4 0.000E+00 1.203149E+02 5.714770E+05 0.000000E+00
2 5 0.000E+00 1.513964E+02 9.048794E+05 0.000000E+00
-----------------
(Sum of Weight/Eigenvalue) / Sum of Weights 8.684483E-04

Mode Normalization Factor x 4.000E+04
-----------------
Eigenvalue total weight 3.473793E+01
Compliance total weight 2.573592E+01
-----------------
Objective Function 6.047386E+01

Execution
This example is analyzed in the one-file setup with the file, acbrack.fem. The OptiStruct batch
job is submitted using the command shell script, % optistruct acbrack.
Results
The optimization converges after 22 iterations. The results are requested in HyperMesh binary
format and written to the file, acbrack.res. The shape of the solution at the final iteration is
visualized by creating an assign plot of the density results at the 22nd iteration in the HyperMesh
contour panel.
Density plot of air conditioner bracket for combined eigenvalue and compliance objective.
Two thick ribs extend from the engine bolts to the lower air conditioner attachment and one thin
rib extends from the middle of the upper main rib to the upper air conditioner attachment. There
is webbing between the two main ribs and a wide, half-height rib running through the upper half
of the design space.
Many elements did not converge to either 100% dense or 0% dense. These elements can be
forced toward 0% and 100% by increasing the discreteness parameter. This solution is
acceptable because webbings and half-height ribs are manufacturable within a casting process.
Optimized models for linear static and frequency are analyzed separately.
The two main ribs from the combined solution are present in both solutions although they vary in
thickness between the cases. The third rib, which is full height in the combined load case,
appears only in the static solution and is thinner in the combined solution. The webbing between
the two main ribs appears as several discrete crossribs in both separate solutions. The upper rib
is half-height in the combined solution and appears in both the static and eigenvalue solutions.
This rib is in a different position in each analysis. The thicker half-height rib in the combined
solution is a compromise between the two.

Density plot for linear static load only.
Density plot for eigenvalue subcase only.

<install_directory>/demos/hwsolvers/optistruct/acbrack.fem.

Example Problems for Topology Optimization Using Minimum
Member Size Control
The examples in this section demonstrate how topology optimization is used with minimum
member size control.
Michell-truss Example
For a Michell-truss type solution, a point load is applied at the right hand tip, and nodes
along the circle are fixed. The upper half of the system is modeled because of the
symmetry (Dimension of the FE model = 100*30).
CHECKER,2.
MINMEMB,6.0,1.
MINMEMB,6.0,2.

MBB Beam Example
In this example, an MBB-Beam with a point load in the upper middle point and two roller
point supports at the two lower corners is used. The right half of the beam is modeled
(dimension of design domain = 900*300).
DOPTPRM CHECKER 2
DOPTPRM MINDIM 60.0 MINMETH 1


Arch Example
In this example, an arch with three single point loads as three individual load cases on the
lower edge is used. Two roller supports are placed at the two lower corners. The dimension
of the domain equals 500*250.
CHECKER, 2.
MINMEMB,40.0,1.

3D Bridge Model Example
In this example, a 3D bridge model with a fixed support at both ends is used. Three load
cases: a uniform load p=1 on the entire surface of the bridge and a uniform load p=0.3 on
the lanes in each direction separately. The dimension of the design domain:
length/width/depth = 500/100/100. Target volume fraction = 0.2.
CHECKER, 1.
MINMEMB, 20.0,1.
The reason for running CHECKER=1 in two stages with DISCRETE=1, and then 2, is that
after the convergence with DISCRETE = 1, the solution is far from DISCRETE. The two-
stage solution provides a fair comparison to results with minimum member control since
the latter contains an automatic increase of the DISCRETE value by an increment of 1.

Example Problems for Topography Optimization
The examples in this section demonstrate how topography optimization generates both bead
reinforcements in stamped plate structures and rib reinforcements for solid structures.

Plate in Torsion
The following example demonstrates the power of topography optimization.
For this example it is assumed that:
 A specific part of the structure is to be loaded in torsion (see Figure 1.1).
 The part is to be formed using a stamping process.
 Only the shape of the plate can be changed, the thickness cannot be changed.
Figure 1.1: Loads and Constraints.
Topography optimization divides the design region into smaller areas, each with its own shape
variable. OptiStruct performs this process using the parameters defined by the user. In this
example, the design space consists of the entire plate minus the areas near the loads and
constraints. The smaller areas can each move upward. The inner portions of these smaller areas
are shown fully deflected in Figure 1.2.

Figure 1.2: Inner portions of the shape variables for the plate.
The potential reinforcement pattern can be any combination of these variables deflected at any
height between zero and the user-defined maximum height. OptiStruct creates a reinforcement
pattern of any shape by manipulating the 174 discrete shape variables. The pattern could
resemble an X, an oval, a series of straight beads, or any number of the millions of potential
designs. By setting various parameters, the user can ensure that any design OptiStruct creates is
manufacturable.
Once OptiStruct generates the shape variables, it begins the optimization of the plate. The
objective in this example is simple, the stiffness of the plate under the given torsion load is to be
maximized. OptiStruct performs a series of analysis runs to evaluate the stiffness of the plate,
determines what variable value changes will improve the stiffness of the plate, and applies those
changes to the model. After much iteration, OptiStruct reaches the maximum design at a point
where the stiffness can no longer be improved. The solution is shown in Figure 1.3 where the
colors display the heights of the bead reinforcement patterns. A finite element model based on
that solution is shown in Figure 1.4. The symmetry of the solution is due to the use of an
OptiStruct design symmetry plane feature.
Figure 1.3: OptiStruct bead reinforcement pattern for a plate in torsion.

Figure 1.4: Finite element model built from OptiStruct results.
The face of the plate is covered with X-shaped cross-beads that work well in torsion. None of the
beads run completely across the plate in a straight line which would reduce their effectiveness.
Finite element analysis of the plate revealed a well distributed stress pattern and low deflection
at the load point.
The traditional method is to design a reinforcement pattern in the form of raised "beads" across
the surface of the plate, test the stiffness of the plate, and increase the stiffness of the plate until
it meets the design requirements. The efficiency of the plate in terms of cost and weight is
strongly dependent upon how good the reinforcement pattern is, so it is critical to generate a
good one. Two examples of conventional bead reinforcement patterns for the plate in twisting
model are shown in Figure 1.5. These patterns are ones which would commonly be found in
commercial products.
Figure 1.5: Common bead reinforcement patterns for a plate in torsion.
The plate generated by OptiStruct using topography optimization is far stiffer than both of the
conventional plates shown in Figure 1.5. Peak deflection for the topography plate is 0.83mm. For
the conventional plates, the peak deflections are 1.27mm for the one on the left and 6.47mm for
the one on the right. The plate developed with OptiStruct is 35% stiffer than a good conventional
design and far better than a poor one. The poor design, while following the conventional wisdom
of using an X-shaped reinforcement pattern, uses beads that run completely across the plate in a
straight line which are susceptible to kinking when loaded. Such design mistakes are caught and
corrected by OptiStruct during the optimization process allowing it to yield a superior design.
<install_directory>/demos/hwsolvers/optistruct/twistplate.fem.

Optimization of a Rectangular Pressure Vessel
This example involves a rectangular, thin-walled container used for storing fluid. The objective is
to minimize the outward bulging of the sides of the container caused by the pressure of its
contents. Additionally, the maximum outward displacement of the side panels must be below a
given value.
The model is constrained for displacement in all directions at the four lower corners, but is free to
rotate about those constraints. The loading is a distributed pressure through the area shown in
green. The pressure is higher at the bottom of the vessel.
Loads and constraints on rectangular pressure vessel.
The design domain includes the entire box with the exception of the filling hole on the top (shown
in red). All of the elements in the design domain are placed in the same component and
reference the same material property. The normal vectors for all of the elements in the design
domain are pointing outward. The topology variables are set up with the following DTPG card:
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10)
DTPG 1 PSHELL 1
+ 15.0 60.0 NO 4.5 NORM NONE
PATRN 10 7229 7209

The minimum bead width is set at 15.0mm, which is roughly the size of three elements. The
draw angle is set at 60 degrees, and the draw depth is set at 7.5mm. The shape variable draw
vectors are determined according to the element’s normal direction. No buffer zone has been
selected between the filling cap and the rest of the model. No grids are to be skipped. Therefore,
the nodes (where the constraints are applied) are associated with shape variables and are free to
move.
The third line of the DTPG card defines the pattern grouping option, in this case it is a plane of
symmetry. For this model, symmetry was enforced by dividing the box in half lengthwise. The
vector that defines the plane of symmetry was created pointing away from the side with the non-
design filler cap to prevent the absence of design variables from being reflected to the design
side.
Optimization objective function and constraints are set up as follows.
In the header, the following cards are added inside the subcase definition:
DESOBJ(MIN) 1
DESSUB 101
In the bulk data the following cards are added:

DRESP1 1 obj COMP
DRESP1 2 swall1 DISP 7 7332
DRESP1 3 swall2 DISP 7 9783
DRESP1 4 fwall DISP 7 9162
DRESP1 5 bwall DISP 7 8813
DRESP1 6 bottom DISP 7 11028
DCONSTR 101 2 10.0
DCONSTR 101 3 10.0
DCONSTR 101 4 1.0
DCONSTR 101 5 1.0
DCONSTR 101 6 5.0
The objective is to minimize compliance for the pressure load case, which is the same as
minimizing the strain energy of the entire model. The displacement of the center point of each of
the five loaded surfaces was constrained to be less than a given value.

OptiStruct generated the following solution for the problem:
OptiStruct topography solution for pressure vessel, front and rear views.
All of the optimization constraints are met for the model. The red areas represent the bead
reinforcements that OptiStruct created to increase the stiffness of the model. Circular or oval
reinforcement beads are generated for the large side panels and the bottom panel of the box.
Circular and oval beads are very effective in stiffening the panels against a distributed or central
load. This is due to the fact that bending in the central areas of the panels is occurring in two
directions, both vertically and horizontally. Straight beads provide stiffness for bending in one
direction, but would be vulnerable to kinking in the other. Round beads provide stiffness without
kinking. Bulbous beads are created at the eight corners of the model, anchoring the sides of the
box together and allowing each side of the box to gain support from the adjacent sides.
By changing the draw height on the DTPG card from 4.5 to –4.5, the direction of the beads can
be changed from outward to inward.
OptiStruct topography solution for pressure vessel, reversed bead directions.
The bead pattern for the inward bead model is almost a complete reflection of the one that
OptiStruct created for the outward bead model. The areas that are not pushed out in the outward
bead model are pushed in for the inward bead model, generating the same basic structure.
<install_directory>/demos/hwsolvers/optistruct/pressurebox.fem.

Optimization of a Two-Layer Stamped Control Arm
In this example, an automobile control arm is manufactured by using two stamped plates joined
at the seam. The shape of the bead reinforcements on the plates is optimized to withstand the
applied loads. The part is modeled as two layers of shell elements (green and blue) connected
with fringe elements (red), as shown in the figure below. The model is pinned, but is free to
rotate about an axis at the frame attachments. A vertical constraint is placed at the shock
absorber attachment point. This point is connected to the fringe elements with rigid bars.
Vertical, lateral, and twisting loads are applied to the spindle attachment.
Loads and constraints for the stamped control arm model.
The elements shown in green are included in the design space. The nodes in the top layer can
move upward and the nodes on the bottom layer can move downward. Symmetry is used to
force the bead pattern on the top to match the one on the bottom. The DTPG card is generated
as follows:
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10)
DTPG 2 DVGRID 1
+ 15.0 60.0 YES
PATRN 10 4184 1211
The plane of symmetry is normal to the vertical axis and is positioned running through the center
plane of the model.
The optimization objective function is simply defined as minimizing the sum of the weighted
compliance of all three load cases.
The solution for the model is shown in the figures below. The first figure shows the symmetry of
the solution about the vertical axis.

OptiStruct solution for the stamped control arm model, side view.
OptiStruct solution for the stamped control arm, top view.
The solution shows the importance of adding vertical bending stiffness in the area around the
shock absorber attachment point. OptiStruct creates a large bead running from the upper frame
attachment point, past the shock attachment, and up to the spindle attachment (second figure).
This bead supports most of the bending load. In addition, there is vertical bending which runs in
the perpendicular direction. OptiStruct creates a bead running from the shock attachment point
to the lower frame attachment (second figure). This second bead is not as pronounced because
there is less bending in that direction compared to the primary direction.
<install_directory>/demos/hwsolvers/optistruct/stampedarm.fem.

Eigenvalue Maximization with Topography Optimization
In this example, an irregularly shaped plate is optimized to increase its natural frequencies. The
plate is supported at ten bolt locations around its perimeter. The edge of the plate is turned
downward to add stiffness.
Cover plate model with constraints shown.
The red areas are excluded from the design domain. The blue area is open for OptiStruct to add a
bead reinforcement pattern. The bead is drawn upward with respect to the plate orientation. The
DTPG card used is as follows. Four different runs were made using different values for the draw
height. The first run was made with a draw height of 20mm, the second with 40mm, the third
with 60mm, and the fourth with 80mm.
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10)
DTPG 1 PSHELL 5
20.0 60.0 YES 65.0 NORM NONE
The optimization is set up to maximize the frequencies of the first six modes (minimizing the sum
of the weighted inverse eigenvalues) and to ensure that the first three modes were above certain
design constraints. This is accomplished by placing the following cards in the subcase definition:
DESOBJ(MIN) 1
DESSUB 101
The following cards are placed in the bulk data section:

DRESP1 11 freq1 FREQ 1
DRESP1 1 wfreq WFREQ

DCONSTR 101 11 400.0
DCONSTR 101 12 500.0
DCONSTR 101 13 600.0
DRESP2 1 wfreq 900
Setting constraints on the first three modes results in separations between the frequency values
of the modes and prevents OptiStruct from falling into local minimums when optimizing the
modes. This approach ensures that a minimum performance criterion is satisfied. Note that for
the 40mm, 60mm, and 80mm draw height runs, the constrained frequencies are higher than
those shown above.
The solutions generated for the plate runs are shown in the following figures:
Solution for plate with draw height equal to 20mm.

The reinforcement patterns have a similar shape, but runs with a higher maximum draw height
use more levels of draws throughout the plate. All of the solutions made good engineering sense,
connecting the weak areas of the plate with beads running primarily across the short span of the
plate. These beads were fluidly connected together across the long span of the plate allowing the
beads to reinforce each other.
<install_directory>/demos/hwsolvers/optistruct/eigenplate.fem.

Surface Optimization of a Control Arm
Topography optimization has applications beyond creating beads in shell surfaces. Since the basic
topography approach can be applied to any model containing large fields of shape variables, it
lends itself to solid model applications as well. In the following example, global shape
optimization of a solid part is performed by generating shape variables using the DTPG card.
The solid control arm model is based on the topology optimization results as shown in the figure
below. After a basic material layout is generated using topology optimization, the solution can be
refined to meet design specifications using shape optimization. However, it can be a very time
consuming procedure if done by hand. By automating the procedure of generating shape
variables over the entire surface of a solid part, OptiStruct allows users to quickly set up the
shape optimization model.
Loads and constraints for solid control arm.
To use topography optimization to optimize the surface of a solid model, the areas to be
optimized must first be covered with shell elements (see gray elements in figure below).
Solid control arm model partially covered in shell elements (gray areas).
The side surfaces of the structural members are optimized in this example.

Shells are attached to the sides of the members. Define the normal vectors of those elements to
point inward. Set the value of the draw height on the DTPG card so that the solid elements do
not get turned inside out during shape optimization. If this occurs, OptiStruct gives an error and
terminates the optimization. The lower bound on the DTPG card was set to –1.0 and the upper
bound was set to 1.0, which allows the control arm to become larger or smaller.
The objective was set as minimizing the weighted sum of the compliance of the load cases while
holding the mass of the part constant.
OptiStruct reduces the thickness of the rear crossbar and shapes the struts on either side to
resemble C-sections. The front member is tapered to be smaller the closer it is to the area of the
applied loads.
OptiStruct solution for surface optimized control arm, areas to be thinned are red.
OptiStruct undeformed model for surface optimized control arm, top view.

OptiStruct solution for surface optimized control arm, top view.

<install_directory>/demos/hwsolvers/optistruct/solidarm.fem.

Shape and Size Optimization of a Plate in Bending
Shape variables are used in this example to vary both the thickness and the shape of a plate
constructed from solid elements. Topography optimization allows discrete areas of the plate to
change thickness and/or height, providing a greater range of possible solutions than with shape
or size optimization alone.
A thin plate is built using two layers of solid elements. A uniform pressure is applied to the center
portion of the plate (gray area) and the plate is simply supported at the corners.
Loads and constraints for a plate to be optimized for both shape and size.
The design shape variables are generated externally to OptiStruct. Size variation is defined by
creating a single design variable that controls the thickness of the plate. Shape variation is
defined by creating a single design variable that controls the height of the plate relative to the
constrained nodes.
Models showing the size and shape variations at maximum thickness and height.
The two design variables are included in the finite element deck submitted to OptiStruct. Each
variable has a single DESVAR card and a DVGRID for each node in the model affected by that
variable. DTPG cards added to the deck reference the ID number of the DESVAR cards as follows:

DESVAR 1 DV001 0.25 0.0 0.25
DESVAR 2 DV002 0.75 0.0 0.75
DTPG 3 DVGRID 1
3.0 60.0 YES
DTPG 4 DVGRID 2
3.0 60.0 NO
DVGRID* 1 4 0 1.0
* 0.000000000E+00 9.9999999748E-07 5.0000000000E+00
DVGRID* 1 5 0 1.0
* 0.000000000E+00 9.9999999748E-07 5.0000000000E+00
Entries in fields 15 through 18 are not required because the draw vectors are already defined for
each node on the DVGRID cards. A buffer zone is requested for the shape variable that ensures a
smooth transition between the constraints and the rest of the structure. Lengthwise symmetry is
enforced (the left side of the plate mirrors the right side).
The compliance of the part was minimized with the mass of the part constrained to be below a
given value.
The solution is shown in the figures below.
OptiStruct solution for shape and size optimization of plate in bending, top view.

OptiStruct solution for shape and size optimization of plate in bending, bottom view.
OptiStruct creates a thick rib around the perimeter of the plate, providing a solid foundation for
the attachment of the remaining design features. The highest degree of bending occurs at the
center of the part, with the largest bending component running in the longitudinal direction. The
plate is stiffened in this direction when OptiStruct creates a central rib and a W-shaped
reinforcement pattern by raising the thick areas of the plate and lowering the thin areas of the
plate. This shape employs the entire structure, not just the parts with ribs.
Cross-sections of the optimized shape and size of the plate in bending.

<install_directory>/demos/hwsolvers/optistruct/sizeandshape.fem.

Example Problems for Topography Optimization Using Pattern
Grouping
The examples in this section demonstrate how topography optimization is used with pattern
grouping.
Cross-section Optimization of a Spot Welded Tube
Optimization of the Modal Frequencies of a Disc Using Constrained Beading Patterns
Multi-plane Symmetric Reinforcement Optimization for a Pressure Vessel
Shape Optimization of a Stamped Hat Section
Shape Optimization of a Solid Control Arm
Using Topography Optimization to Forge a Design Concept Out of a Solid Block

Cross-section Optimization of a Spot Welded Tube
A tube made of two sheet metal pieces is intended to carry a load in both bending and torsion.
The cross-section of the tube may be of any shape, but due to manufacturing requirements, it
must remain constant through the entire length. Conventional shape optimization can be used to
optimize the cross-section, but setting up the variables is time consuming. With topography
optimization and pattern grouping, cross-section shape optimization can be performed in a
fraction of the set up time. All optimization set up is done using the optimization panel and its
subpanels in HyperMesh.
The loads and constraints are applied to the flanges at the ends of the tube, and are shown in
Figure 1.1. Spot welds connect the two pieces of the tube along the flanges at regular intervals.
Figure 1.1: Loads and constraints for the spot welded tube.
The initial cross-section of the tube is arbitrarily chosen to be roughly circular. Two similar
topography variables are defined to allow the shape of the tube to change. The two variables
assign the blue and green pieces to be in the design domain while the flanges remain in their
original shape. The topography variables are in the bulk data section using the DTPG card as
shown below.
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10)
DTPG 1 PSHELL 1
+ 2.5 85.0 NO 5.0 NORM NONE
+ PATRN 1 0.0 0.0 0.0 1.0 0.0 0.0
The draw height of 5.0, combined with the upper and lower bounds of 2.0 and –2.0, allow a bead
height of 10.0 model units in both directions (inward and outward) and a bead growth direction
normal to the surface of the tube. A linear type pattern grouping is applied for this problem. This
means that the beads formed during the topology optimization will be constant along a line
parallel to the direction defined -- the central axis (X-axis) of the tube, in this case. By setting
this pattern grouping option, the cross-section of the tube will be allowed to change, but will
remain constant through the length of the tube.

The objective was set to minimize the weighted compliance of both load cases. In this case, both
load cases were weighted equally. The mass of the tube was constrained to be below the initial
value. OptiStruct generated the following solution for the model. See Figure 1.2.
Figure 1.2: Optimized cross-section for the tube.
The solution is not completely smooth, but the basic shape of the tube is clear. The lower half of
the tube has been lowered to increase the bending stiffness of the section while the upper half of
the tube runs directly from one flange to the other to support the shear force generated by the
twist load. The cross-sections of the model before and after optimization are shown in Figure 1.3.
Figure 1.3: Cross-sections of the tube before and after optimization.

To verify the OptiStruct solution, a smooth model of the tube is built based upon the results. This
model is shown in Figures 1.4 and 1.5. Static analysis shows the optimized cross-section after
smoothing to have a 35% lower peak deflection for torsion and an 18% lower peak deflection for
bending. Additionally, the mass of the part was reduced by 2.2%.
Figure 1.4: Smoothed cross-section of the tube.
Figure 1.5: Finite element model of the smoothed optimized tube.
For the input file sample, see <install_directory>/demos/hwsolvers/optistruct/tube.fem.

Optimization of the Modal Frequencies of a Disc Using
Constrained Beading Patterns
Finding a good reinforcement pattern for a single modal frequency is difficult when dealing with
beaded plates since adding stiffness in one direction often reduces stiffness in another direction.
The problem posed by finding a good reinforcement pattern for four modal frequencies
simultaneously is more than four times more difficult. Add to that the difficulty constraints on the
variety of reinforcement patterns, and the problem becomes a formidable task. By implementing
topography optimization and pattern grouping, the task is greatly simplified and good quality
results are quickly generated. All optimization set up is done using the optimization panel and
its subpanels in HyperMesh.
The first four modal frequencies of a thin metal disc are to be optimized using bead
reinforcement patterns. A variety of different manufacturing methods are being considered which
place limitations on the bead reinforcement patterns allowed. The metal disc has a hole in the
center where it is constrained (see Figure 2.1).
Figure 2.1: Constraints on the disc model.
The objective for the model is to increase the sum of the frequencies of the first four normal
modes of the disc. This is achieved by using the WFREQ response type. The WFREQ response is
the sum of the inverse eigenvalues of the chosen frequencies. This is done in order to assign
higher weight to the earlier modes than the latter ones.
The first manufacturing method to be considered is turning the disc on a lathe. This restricts the
bead reinforcements to being circular. A circular pattern grouping type is define. The DTPG card
for this card is shown below.
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10)
DTPG 1 PSHELL 1
+ 5.0 60.0 YES 2.5 NORM SPC
+ PATRN 2 0.0 0.0 0.0 0.0 0.0 1.0

The anchor node is set at the center of the disc and the first vector points in the z direction. The
nodes in the center ring are removed from the design region by choosing "Spc" in the "Boundary
skip" option in the topography subpanel. No other additions to the finite element model were
required.
The solution for the circular reinforcement pattern method is shown in Figure 2.2. OptiStruct
generated a single wide circular bead running from the inner ring to about three-quarters of the
way to the outer edge of the disc. The bead is gently sloped throughout its width. This
reinforcement pattern more than doubled the frequencies of the first three modes and increased
the fourth and fifth modes by over 75%.
Figure 2.2: Solution for the circular bead pattern method.
The second manufacturing method to be considered is stamping with radial beads only. The
topography set up for this approach is almost identical to that of the one for the circular approach
with the only change being the radial pattern grouping type. The DTPG card for this configuration
is shown below.
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10)
DTPG 1 PSHELL 1
+ 5.0 60.0 YES 2.5 NORM SPC
+ PATRN 4 0.0 0.0 0.0 0.0 0.0 1.0
The solution for the radial reinforcement pattern is shown in Figure 2.3. OptiStruct generated a
series of eight evenly spaced wide radial beads. Note that the beads are not drawn to their full
height. This demonstrates that full height beads are not necessarily optimal. This reinforcement
pattern also doubled the frequencies of the first three modes and increased the fourth and fifth
frequencies by more than 70%, but was not quite as efficient as the circular pattern.

Figure 2.3: Solution for the radial bead pattern method.
The third manufacturing method to be considered was stamping with no constraints on the bead
shapes. No pattern grouping was defined for this approach. The DTPG card for this set up is
shown below.
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10)
DTPG 1 PSHELL 1
+ 5.0 60.0 YES 2.5 NORM SPC
The solution for this setting is shown in Figure 2.4. OptiStruct generated a reinforcement pattern
that appears to be a combination of the circular and radial reinforcement patterns. The inside of
the disc has a series of radial beads while the outside has a roughly circular reinforcement. This
reinforcement pattern had the best increases in the modal frequencies for all of the patterns
compared.
Figure 2.4: Solution for the default pattern method.
Since the default reinforcement pattern is almost symmetric, a cyclically symmetric pattern can
be used to clean up the solution. Choosing four wedges for cyclical symmetry appears to be very
close to the pattern created with the default settings. The cyclical symmetry pattern grouping
type is applied. The DTPG card for the cyclical symmetry method is shown below.

(1) (2) (3) (4) (5) (6) (7) (8) (9) (10)
DTPG 1 PSHELL 1
+ 5.0 60.0 YES 2.5 NORM SPC
+ PATRN 41 0.0 0.0 0.0 0.0 1.0 0.0
+ PATRN2 4 1.0 0.0 0.0
For cyclical symmetry, both the first vector (fields 12, 13, and 14) and second vector are defined
in the same plane as the disc. The anchor node is located at the center of the disc. This cyclical
pattern is set up to have four symmetric wedges with each wedge being symmetric about itself.
Figure 2.5: Cyclical symmetry pattern for 4 symmetric wedges.
The solution for the cyclical pattern grouping option is shown in Figure 2.6. OptiStruct generated
a reinforcement pattern very similar to the default pattern grouping pattern but with fourfold
symmetry. The modal frequencies were slightly less than those for the default pattern.

Figure 2.6: Solution for the cyclical pattern method with 4 symmetric wedges.
The frequency results (in Hz) for the first six normal modes for the baseline model and four
reinforcement patterns are shown in the following table:
Mode # Baseline Circular Radial Default Cyclical
1 18.7 47.3 45.3 51.1 50.4
2 18.7 47.3 45.4 52.7 50.4
3 20.1 73.0 43.8 69.1 68.5
4 34.8 61.5 60.2 66.3 66.7
5 34.8 61.5 60.6 68.4 67.5
6 74.4 113.0 93.0 115.0 117.0

<install_directory>/demos/hwsolvers/optistruct/disc_radial.fem and
<install_directory>/demos/hwsolvers/optistruct/disc_cyclic.fem.

Multi-plane Symmetric Reinforcement Optimization for a
Pressure Vessel
A rectangular thin-walled box is to be used to store fluid. The outward bulging of the sides of the
container (due to the pressure of the contents) is to be minimized. Additionally, the maximum
outward displacement of the side panels must be below a given value. The model is shown in
Figure 3.1. All optimization set up is done using the optimization panel and its subpanels in
HyperMesh.
The model is constrained for displacement in all directions at the four lower corners but is free to
rotate about those constraints. The loading is a distributed pressure through the area shown in
green. The pressure is higher at the bottom of the vessel.
Figure 3.1: Loads and constraints on rectangular pressure vessel.
The entire box is to be used as the design domain with the exception of the filling hole on the top
shown in red. All of the elements in the design domain are placed in the same component and
reference the same material property. The normal vectors for all of the elements in the design
domain are pointing outward. The topology variables are set up with the following DTPG card:
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10)
DTPG 1 PSHELL 1
+ 7.0 60.0 YES 5.0 NORM NONE
+ PATRN 30 50.0 100.0 75.0 0.0 1.0 0.0

(1) (2) (3) (4) (5) (6) (7) (8) (9) (10)
+ PATRN2 0 0.0 0.0 1.0
+ BOUNDS 0.0 1.0
Three orthogonal planes of symmetry are defined (see Figure 3.2). The anchor node is placed at
the center of the box. The first and second vectors are defined parallel to the X and Y axes. The
first vector is defined pointing away from the filler cap. This ensures that the automatically
generated variables will cover the entire surface of the box. If the first vector was pointing in the
other direction, the symmetry method would reflect the lack of variables in the area of the filler
cap across all three planes of symmetry.
Figure 3.2: Orthogonal symmetry planes for the pressure box.
The objective is to minimize compliance for the pressure load case, which is the same as
minimizing the strain energy of the entire model. The displacement of the center point of each of
the five loaded surfaces was constrained to be less than a given value.
OptiStruct generated the following solution for the pressure box shown in Figure 3.3.

Figure 3.3: OptiStruct solution for the pressure box.
The OptiStruct solution met all of the optimization constraints and yielded a good design. The
areas shown in red (In Figure 3.3) are the bead reinforcements that OptiStruct created to
increase the stiffness of the model. The solution is unconventional, but makes a good deal of
engineering sense. For the large side panels and the top and bottom panels of the box,
OptiStruct has generated large, rounded, centrally located reinforcement beads. These types of
beads are very effective in stiffening the panels against a distributed or central load. This is due
to the fact that bending in the central areas of the panels is occurring in two directions, both
vertically and horizontally. The rounded beads create stiffness in both directions and are weak in
neither. At the eight corners of the model, OptiStruct created beads that anchor the sides of the
box together allowing each side of the box to gain support from the neighboring sides.
A finite element model was created from this reinforcement pattern (see Figure 3.4).
Figure 3.4: Finite element model of the OptiStruct solution for the pressure box.

This pattern was compared to two other bead reinforcement designs shown in Figure 3.5.
Figure 3.5: Conventional reinforcement patterns for the pressure box.
The OptiStruct model is superior in stiffness to both of the two conventional models. The
maximum deflection of the OptiStruct model was 30% less than the lightly reinforced
conventional model (the one on the left), and 46% less than the heavily reinforced model (the
one on the right). The lightly reinforced model was stiffer than the heavily reinforced model,
which goes against the assumption that more reinforcements result in increased stiffness. With
bead type reinforcements that assumption is not always true, which demonstrates the
effectiveness of topography optimization. OptiStruct delivers an optimized first design,
eliminating the need to do a series of re-designs where the second, third, fourth, etc., model
does not always result in an improvement.
Manufacturing constraints can be accounted for in the pressure box model using other pattern
grouping options. The set up is done easily through the HyperMesh interface. In order to
manufacture the pressure box using a two piece die mold, bead reinforcements that run laterally
would need to be eliminated or else they would cause a die lock condition. Topography
optimization can be used to generate reinforcement beads on the sides of the box that run
vertically only. This is done by using separate topography variables for the side walls, front and
back panels, and the top and bottom panels. Topography variables with planar symmetry with
one plane symmetry grouping type are defined for the side panels and the front/back panels,
respectively. As in the earlier case, a three plane symmetry topography variable is assigned for
the top/bottom panels. The two cards are shown below and differ only in the direction of the first
vector.
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10)
DTPG 1 PSHELL 1
+ 7.5 60.0 YES 5.0 NORM NONE
+ PATRN 13 50.0 100.0 75.0 0.0 1.0 0.0
+ BOUNDS 0.0 1.0

(1) (2) (3) (4) (5) (6) (7) (8) (9) (10)
DTPG 1 PSHELL 1
+ 7.5 60.0 YES 5.0 NORM NONE
+ PATRN 13 50.0 100.0 75.0 1.0 0.0 0.0
+ BOUNDS 0.0 1.0
The planes for the planar pattern grouping run vertically and perpendicular to the Y-axis, which
causes OptiStruct to generate vertical beads. Because the planes run through both sides of the
box, there will be symmetry between opposing sides. Also, symmetry on either side of the anchor
node in the direction of the first vector (Y-axis) is forced with the one plane symmetry option
(pattern grouping option 13). See Figure 3.6.
Figure 3.6: Planar pattern grouping planes for sides of pressure box.
With planar symmetry enforced for the sides of the pressure box and three-plane symmetry
enforced on the top and bottom of the box, OptiStruct generated the solution shown in Figure
3.7. Even without the presence of lateral beads on the sides of the box, the OptiStruct solution
shown below had a maximum deflection 6% less than the lightly reinforced conventional model.

Figure 3.7: Pressure box solution for combined three-plane and planar symmetry options.

<install_directory>/demos/hwsolvers/optistruct/pressure.fem and
<install_directory>/demos/hwsolvers/optistruct/pressure13.fem.

Shape Optimization of a Stamped Hat Section
Pattern grouping and shape variables can be used to optimize stamped plates that are difficult to
deal with due to corners and sharp edges. Automatic generation of topography variables does not
take into account situations in which elements can be folded inside out when the variables are
fully perturbed. This limits the draw depth that can be used with that technique. The following
example demonstrates how this problem can be avoided with user-defined variables. All
optimization set up is done using the optimization panel and its subpanels in HyperMesh.
A hat section is centrally loaded, creating both bending and torsional loads (see Figure 4.1). The
hat section is constrained at either end by four bolts.
Figure 4.1: Loads and constraints for the stamped hat section.
It is preferable to have the size of the reinforcements able to run deeper than the height of a
single element. To ensure that this will not cause a problem with the element mesh, three shape
variables are created using HyperMesh and are added to the deck. The shape variables for the
face and top side of the hat are shown in Figure 4.2.

Figure 4.2: User-defined shape variables for the hat section.
Note in Figure 4.2 that the first three rows of elements adjacent to the elements being fully
deflected are a part of the user-defined shape variable for that side. Also, the draw depth is equal
to one and a half times the average element size.
It is desired to create this hat section using a stamping process which means that reinforcing
features on the sides of the hat must be constant (from top to bottom), or else a die lock
condition will occur. Pattern grouping can be used to create variables that ensure
manufacturability. For the three variables created for the hat section optimization, planar pattern
grouping was selected with the planes running perpendicular to the length of the section (X-axis).
The DTPG card and associated DESVAR card for one of the variables are shown below.
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10)
DTPG 4 DVGRID 1
+ 20.0 60.0 YES
+ PATRN 13 500.0 0.0 0.0 1.0 0.0 0.0
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10)
DESVAR 1 DV001 0.0 0.0 1.0
Additionally, a plane of symmetry was used to force both halves of the section to be the same.

Figure 4.3 shows the symmetry plane for the hat section.
Figure 4.3: Plane of symmetry for the hat section model.
OptiStruct generates variables which allow for great flexibility in the reinforcement possibilities,
but which prevent a die lock condition as shown in Figure 4.4. Note that the area where the load
is applied is left out of the face variable.
Figure 4.4: Variables generated for the hat section.
The objective is to minimize the compliance for the applied load. OptiStruct generated the shape
shown in Figure 4.5.

Figure 4.5: OptiStruct solution for the hat section optimization.
The solution generated by OptiStruct is manufacturable using a stamping process. Also, the
solution is very well behaved and needs little refinement to turn it into a production-ready
design.
The optimized hat section increases the stiffness of the part by more than eightfold from the
initial condition with no beads. The eight ‘square’ beads for the hat section, especially the four at
the ends of the beam, are the key to bolstering the beam against shear collapse. Those beads
also serve to prevent the flanges from folding under the bending load. OptiStruct has generated a
strong design that supports both torsion and bending with restricted reinforcement possibilities.
The shape and placement of the reinforcements are optimized resulting in a very efficient
solution.
For the input file sample, see <install_directory>/demos/hwsolvers/optistruct/hat.fem.

Shape Optimization of a Solid Control Arm
Topography optimization has applications beyond creating beads in shell surfaces. Since the basic
topography approach can be applied to any model containing large fields of shape variables, it
lends itself to solid model applications. The following example demonstrates how topography can
be used in conjunction with user-defined shape variables to do global shape optimization of a
solid part. All optimization set up is done using the optimization panel and its subpanels in
HyperMesh.
A solid control arm model is built based around OptiStruct topology optimization results (see
Figure 5.1). Topology optimization is very effective at generating a basic material layout, but the
solution is generally not well refined. Refining the solution to meet design specifications can be
done using shape optimization. The generation of shape variables over the entire surface of a
solid part can be a very time consuming procedure if done by hand. With OptiStruct, this
procedure is automated and the shape optimization model can be set up in minutes.
Figure 5.1: Loads and constraints for solid control arm.
The first step is to generate shape variables for the part. HyperMesh is an excellent tool for doing
this. For this model, four basic shape variables were created which control the sizes of the two
legs and rear beam of the control arm. These are shown below in Figures 5.2 and 5.3. Care was
taken to ensure that the final design would have no internal cavities which would prevent it from
being manufacturable.

Figure 5.2: Shape variables controlling the thickness and height of the control arm legs.
Figure 5.3: Shape variables controlling the thickness and height of the control arm rear beam.

Topography optimization will divide these shape variables into smaller variables that control the
height and thickness of sections of each leg. The type of pattern grouping selected for each
variable is used to control the way that the variables get divided. Pattern grouping enhances the
ability of topography optimization to affect the shape of solid models. Without pattern grouping,
the distance that a grid is allowed to move must be less than the distance to the neighboring grid
or else the elements will get turned inside out. With pattern grouping, the movement of several
grids can be linked together so that those grids can move far beyond their original positions while
still maintaining a reasonable element mesh (as demonstrated in this example problem).
Linear pattern grouping is applied to the first variable which links the movement of all of the
grids through the thickness of both legs together. This allows the thickness of the legs to change
at many points across the sides of the legs, which gives OptiStruct a high degree of flexibility in
influencing their shape without causing problems with the finite element mesh.
Planar pattern grouping is applied to the second variable which links the movement of all of the
grids through both the thickness and height of both legs together. This allows the height of entire
cross-sections of the legs of the control arm to change. One of these planes is shown in Figure
5.4 cutting through both legs of the control arm.
Figure 5.4: Pattern grouping plane for variable #2.
Figure 5.5 shows the variables created from the planar pattern grouping option. Note that Figure
5.5 only shows the deflections of the centers of the variables. Because of the way that
topography optimization works, if all three variables were fully deflected, the legs of the control
arm would be uniformly at the minimum height.

Figure 5.5: Planar variable dispersion pattern for the height of the legs of the control arm.
Planar variable pattern grouping was also used for the height and thickness of the rear beam. For
both variables cards, TYP = 13 was used to ensure a beam shape that was symmetric about the
center. The DTPG card for variable #4 (beam height) and the associated DESVAR card are shown
below.
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10)
DTPG 8 DVGRID 4
+ 15.0 60.0 NO
+ PATRN 13 0.0 0.0 0.0 1.0 0.0 0.0
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10)
DESVAR 4 DV004 0.0 -1.5 1.0
Since shape variables are being assigned to topography, the height and the bounds in the DTPG
card do not need to be defined, as they are controlled by the shape variable. Even if these values
are defined, OptiStruct will ignore them.
The objective for the optimization was to minimize the mean compliance of the control arm for all
three load cases combined. The mass of the control arm was constrained to be less than 10%
below its initial mass. OptiStruct generated the following solution (see Figure 5.6). The red shows
areas where material was added, the blue shows areas where material was removed.

Figure 5.6: Optimized control arm using topography and user-defined shape variables.
OptiStruct optimizes the shape of the legs by shifting mass from the centers to the top and
bottom, creating C-shaped sections. These sections add vertical bending stiffness while leaving
the shear and axial stiffness intact. Additionally, the height of the legs was increased along their
length to further increase the bending stiffness of the sections. OptiStruct greatly reduced the
size of the rear beam in both height and thickness, indicating that it was oversized or perhaps
even unnecessary. Overall, the maximum deflection for all three load cases was reduced by 5%
while the mass was reduced by 10%. Figure 5.7 shows a refined finite element model of the
OptiStruct solution.
Figure 5.7: Finite element model of the OptiStruct solution.

<install_directory>/demos/hwsolvers/optistruct/controlarm.fem.

Using Topography Optimization to Forge a Design Concept Out
of a Solid Block
Pattern grouping lends itself very well to applications where manufacturing conditions must be
met. In the following example, topography optimization is used to form a design concept out of a
solid block. Manufacturing the design concept using a casting method is preferable. All
optimization set up is done using the optimization panel and its subpanels in HyperMesh.
A solid rectangular block is fixed at both ends and loaded in the center (see Figure 6.1).
Figure 6.1: Loads and constraints for the solid block model.
Two shape variables are generated using HyperMesh to control the height and width of the block.
These are shown in Figures 6.2 and 6.3.
Figure 6.2: User-defined variable #1.

Figure 6.3: User-defined variable #2.
It is preferable to manufacture the resulting part using a casting process. This can be
accomplished by using a linear pattern grouping in the casting draw direction and a planar
pattern grouping perpendicular to the draw. This will ensure that there are no cavities that would
create a die lock situation.
Thinking ahead, it is predictable that the cross-section of the solution will be roughly an I-shaped
section with the web running vertically. This prediction establishes the draw direction as being
horizontal, which corresponds to variable #1 (block width), thus variable #1 will be split using
linear pattern grouping and variable #2 will be split using planar pattern grouping. The DTPG
cards and associated DESVAR cards are shown below:
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10)
DTPG 3 DVGRID 1
+ 2.0 60.0 NO
+ PATRN 21 50.0 250.0 50.0 0.0 0.0 1.0
+ PATRN2 0.0 1.0 0.0
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10)
DESVAR 1 DV001 0.0 0.0 1.0
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10)
DTPG 4 DVGRID 2
+ 20.0 60.0 NO

+ PATRN 13 50.0 250.0 50.0 0.0 1.0 0.0
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10)
DESVAR 2 DV002 0.0 0.0 1.0
The linear variable dispersion pattern for variable #1 allows OptiStruct to control the thickness of
the block at numerous points across its side giving the solution a great deal of flexibility. The
planar variable dispersion pattern for variable #2 allows OptiStruct to control the height of the
cross-sections along the length of the block. The objective was to minimize the mean compliance
of the block under the given load. The mass was constrained to be below one fourth of the initial
mass of the block. OptiStruct generated the solution, shown in Figure 6.4.
Figure 6.4: OptiStruct solution for the solid block.
The cross-section of the block is roughly I shaped, concentrating the material at the top and
bottom of the end and center areas where the bending moment is the greatest. The design is flat
and tall in areas where shear is dominant. The solution is manufacturable by use of a casting
process since there are no cavities or die lock conditions. The efficiency of the solution can be
seen by looking at the stress contours. The nearly uniform stress distribution, shown in Figure
6.5, indicates that almost every part of the structure is being used to its fullest potential.
Figure 6.5: Stress contours for the OptiStruct solution.

The maximum dimensions of the block were reduced by 2.5 times and a second topography
optimization was performed. The solution OptiStruct produced is shown in Figure 6.6.
Figure 6.6: OptiStruct solution for solid block with 2.5 times smaller cross-section.
The basic shape of the block is the same in the reduced dimension model, but has more
pronounced features. The I shaped cross-sections in the center and at the ends have wider
flanges, and the shear carrying areas in between are thinner. This makes sense considering the
smaller dimensions increase the need for bending stiffness more than the need for shear
stiffness.
For the input file sample, see <install_directory>/demos/hwsolvers/optistruct/block.fem
and <install_directory>/demos/hwsolvers/optistruct/blocklong.fem.

Example Problems for Size Optimization
This section presents size optimization examples solved using OptiStruct. Each example uses a
problem description, execution procedures, and results to demonstrate how OptiStruct is used in
size optimization.
Introductory Example of Size Optimization
Size Optimization of a Ten Bar Truss
Size Optimization of a Cantilever Beam using Equations

Introductory Example of Size Optimization: Shell Cantilever
This example demonstrates how size optimization can be used.
For the cantilever beam below, a thickness distribution is sought that minimizes the structural
mass and allows a limited vertical deflection of the loading end. The displacement is limited to
2.0mm.
Structural Model
In this example, the thickness for each element is varied. Therefore, five variables are defined in
the analysis deck. The initial thickness of all elements is 2mm. All thickness variables have a
lower bound of 1mm and an upper bound of 3mm.
The optimization problem, objective and constraint functions, is defined in the same manner as
for the other types of structural optimization. OptiStruct then goes through an iteration process
to solve the optimization problem. OptiStruct converged after 3 iterations. The table below shows
the optimization results of the cantilever beam, which met the constraints and minimizes the
mass (decrease of 6.6%).
Element 1 Element 2 Element 3 Element 4 Element 5 Disp Volume
Initial 2.0mm 2.0mm 2.0mm 2.0mm 2.0mm 2.5mm 400.00mm3
Final 2.6mm 2.3mm 1.9mm 1.5mm 1.0mm 2.0mm 373.204mm3
The input file can be found in <install_directory>/demos/hwsolvers/optistruct/size1.fem.

Size Optimization of a Ten Bar Truss
This example demonstrates how size optimization can be used.
For the ten bar truss structure, a cross-sectional area distribution is sought that minimizes the
structural mass and allows limited stress values in the elements. The stress limit is 25000. The y
displacements are limited to 2.
Structural Model
In this example, the cross-sectional area for each element is varied. Therefore, 10 variables are
defined in the analysis deck. The initial cross-sectional area of all the elements is 20, with a lower
bound of 0.2 and an upper bound of 200.
for the other types of structural optimization. OptiStruct then goes through an iteration process
to solve the optimization problem. OptiStruct converged after thirteen iterations. The table below
shows the optimization results of the ten bar truss structure, which met the constraints and
minimizes the mass (decrease of 38.7%).
Bar1 Bar2 Bar3 Bar4 Bar5 Bar6 Bar7 Bar8 Bar9 Bar10 Volume
Initia 20 20 20 20 20 20 20 20 20 20 83929
l
Final 30.4 38.4 24.5 15.4 0.2 0.2 8.8 21.5 20.1 0.4 51448
The input file for this example can be found in

<install_directory>/demos/hwsolvers/optistruct/tenbar.fem.

Size Optimization of a Cantilever Beam using Equations
This example demonstrates how to use the equation utility to define cross-sectional properties in
a size optimization.
The structure is a cantilever beam of a length of 55 modeled with five CBAR elements. The cross-
section of the beam is a solid circle. In each element, the diameter of the section is the design
variable. Hence, there are five design variables. The cross-sectional properties such as area,
moment of inertia, and torsional constant are calculated using the explicit formulas for a circle. In
terms of the DEQATN card, they appear as:
$AREA
DEQATN,111,A(D)=PI(1)*D**2/4
$MOMENT OF INERTIA
DEQATN,122,I(D)=PI(1)*D**4/64
$TORSIONAL CONSTANT
DEQATN,133,J(D)=PI(1)*D**4/32
Using these equations, DVPREL2 statements are used to assign each design variable to the
respective PBAR property. The statements that assign the diameter of the first bar element to the
cross-sectional area of that element look like:
DESVAR,1,Diam1,10,1,20,0.5
DVPREL2,11,PBAR,1,4,,,111
+,DESVAR,1
The optimization problem to be solved is the minimization of the tip displacement with a volume
constraint of 4000. Convergence was achieved after four iterations.
The result is given in the following table.
Diameter 1 Diameter 2 Diameter 3 Diameter 4 Diameter 5 Tip-Displ
Initial 10.00 10.00 10.00 10.00 10.00 40.42
Final 12.48 11.49 10.28 8.70 6.29 26.51
The input file for this example can be found in

<install_directory>/demos/hwsolvers/optistruct/bar.fem.

Solving an Optimization Problem that is not defined by a Finite
Element Model
This example involves the optimization of a box defined entirely by equations (there is no finite
element model in the solution).
The optimization problem is defined as:
Objective: Maximize the volume of a cube AxBxC
Constraint: The surface of the cube should be between 2.0 and 3.0
Design Variables: A, B, C
The volume and surface are defined as equations using DRESP2 and DEQATN:
$
$ VOLUME
$
DEQATN 1 VOL(W,L,H)=W*L*H
$
$ SURFACE
$
DEQATN 2 AREA(W,L,H)=2.0*(W*H+L*H+W*L)
$
DRESP2 1 VOLUME 1
DESVAR 1 2 3
DRESP2 2 SURFACE 2
DESVAR 1 2 3
$
DESVAR 1 W 1.1 0.1 10.0
DESVAR 2 L 0.9 0.1 10.0
DESVAR 3 H 2.0 0.1 10.0
$
Then, in the optimization problem, the objective and constraint are global responses (for
example, DESOBJ and DESGLB are used outside of a SUBCASE).
To trick OptiStruct into solving this problem, a dummy finite element model must be provided.
Here, a single shell element with some load is used.
As expected, the solution yields a cube with even sides of about 0.707, a surface of 3.0, and a
volume of 3.53.
The input file can be found in <install_directory>/demos/hwsolvers/optistruct/box.fem.

Example Problems for Shape Optimization
This section presents shape optimization example problems, solved using OptiStruct. Each
example uses a problem description, execution procedures and results to demonstrate how
OptiStruct is used in shape optimization.
Introductory Example of Shape Optimization
Optimization of a Cantilever Beam Modeled with Solid Elements

Introductory Example of Shape Optimization
This example demonstrates how shape optimization can be used.
For the cantilever beam below, a shape is sought that minimizes the structural mass and allows a
limited vertical deflection at the lower right corner.
Structural Model.
The shape of the beam is defined using a linear combination of the two basis shapes below. The
linear factors are the design variables in the optimization problem.
Basis Shape 1.

Basis Shape 2.
The basis shapes are defined using shape basis vectors. These can be generated using AutoDV,
which is part of HyperMesh. The output file of AutoDV contains the definition of the DESVAR and
DVGRID cards. This file can then be included in the OptiStruct input file, bulk data section, via
the INCLUDE statement.
the other types of structural optimization. OptiStruct then goes through an iteration process to
solve the optimization problem. The figures below show the optimization result of the cantilever
beam.
Final Shape.

Final Shape, deformed with von Mises stresses.

<install_directory>/demos/hwsolvers/optistruct/shape1.fem.

Optimization of a Cantilever Beam Modeled with Solid
Elements
The objective of this example is to minimize the volume of a prismatic cantilever beam. The
maximum displacement at the beam tip is limited, and the 1st and 2nd eigen frequencies have a
lower bound. Two subcases are defined; subcase 1 is the static load case, subcase 2 is the
eigenmode analysis.
Figure 1: Cantilever beam. Loads and boundary conditions.
The design domain is subdivided into two design elements; the web and the flange. Six design
variables are defined using the design elements and vectors (Fig. 2). For shape optimization, the
shape of the beam is defined using the nodal positions of the original shape and a linear
combination of the six shape perturbations associated with the design variables.
The linear factors are the design variables in the optimization problem. The shape
of the beam appears as:
.
Figure 3 shows the shape of the beam perturbed by the first design variable, which is a linear
perturbation. Figure 4 shows the quadratic perturbation caused by design variable 4.
Figure 2: Cantilever beam. Design elements and design variables.

Figure 3: Cantilever beam. Perturbed shape number 1.
Figure 4: Cantilever beam. Perturbed shape number 4.
The perturbation vectors need to be provided in the format of the DVGRID cards
using AutoDV (part of HyperMesh). These cards can be generated automatically. The output of
AutoDV also includes the design variable definition DESVAR. The output file Beam_shape.dat can
be incorporated into the bulk data section of the OptiStruct input deck via an include statement.
The definition of the optimization problem is included in the case control section of the input
deck. Figure 5 shows the section of the OptiStruct input file that includes the definition of the
optimization problem and the inclusion of the AutoDV output.
All optimization constraints are met for the model. The final shape is shown in Figure 5.
Cantilever beam. input data

$-----------------------------------------------------------------
$
$ Case Control Cards
$
$-----------------------------------------------------------------
$
DESOBJ(MIN) = 1
$
$HMNAME LOADSTEPS 1Static
$
SUBCASE 1
LOAD = 2
SPC = 3
DESSUB = 101
$
$HMNAME LOADSTEPS 2Eigenvalues
$
SUBCASE 2
SPC = 3
METHOD = 4
DESSUB = 201
$
BEGIN BULK
INCLUDE Beam_shape.dat
$
$ LOAD cards
$
EIGRL, 4, , , 10
$
DRESP1, 1, vol, VOLUME
DRESP1, 2, disp, DISP,,,2,,29530
DCONSTR, 101, 2, -0.01
DRESP1, 3, f1, FREQ,,,1
DRESP1, 4, f2, FREQ,,,2
DCONSTR, 202, 3, 2600.0
DCONSTR, 203, 4, 3000.0
DCONADD, 201, 202, 203

Figure 5: Cantilever beam. Final shape.

<install_directory>/demos/hwsolvers/optistruct/beam_shape.fem.

Example Problems for Optimization with ESLM
The examples in this section demonstrate how the Equivalent Static Load Method (ESLM) can be
used for the optimization of flexible bodies in multi-body systems.
Rotating Bar Example
Connecting Rod of a Slider Crank Example
Rotating Shell Example
Optimization of MBD System Level Response Optimzation Example

Rotating Bar Example
This is an introductory example of the optimization of a multi-body dynamics system. The object
of the rotating bar problem is to minimize the maximum stress of the bar. The structure consists
of 5 bar elements. The driving motion has a velocity of sin(2t), which is applied to the left end of
the structure. Sections of the bar elements are solid circles. Design variables are the radii of the
sections. The mass of the structure should be less than 10kg.
Rotating bar
A portion of the input file:

DESGLB = 4
MINMAX = 14
STRESS = ALL
SUBCASE 1
MBSIM = 1
MOTION = 1
SPC = 10
:
:
$
DESVAR 1 RAD1 10.00 0.05 100.0
DESVAR 2 RAD2 10.00 0.05 100.0
DESVAR 3 RAD3 10.00 0.05 100.0
DESVAR 4 RAD4 10.00 0.05 100.0
DESVAR 5 RAD5 10.00 0.05 100.0
$
DVPREL1 10 PBARL 1 DIM1 0.0
+ 1 1.0
+ 2 1.0
+ 3 1.0
+ 4 1.0
+ 5 1.0
$
DRESP1 33 STRESS STRESS PBARL SNMAX 1
+ 2 3 4 5
DRESP1 100 MASS MASS
$
DOBJREF 14 33 1 -1.0 1.0
$
DCONSTR 4 100 2.5

:
:
SPC1 10 123456 1
:
:
ENDDATA
The input file is just like one for an ordinary min-max problem. The maximum normal stress of
the flexible body of the subcase 1 is to be minimized by using DOBJREF and MINMAX.
Notable points include:
 Because the stress in multi-body dynamics systems is a time variant quantity, the
minimization of stress in multi-body dynamics analysis subcases should be a min-max
problem.
 The SPC1 card fixes only 6 dof of node 1 of the flexible body in order to remove 6 rigid
body motions. If you fix more than 6 dof of the flexible body, the additional fixed dof
become constraints of the flexible body.
 Stress output request is placed above the first subcase. If you place output request inside
subcase, your output request will be ignored.
The input file can be found in
<install_directory>/demos/hwsolvers/optistruct/rotating_bar_design.fem.

Connecting Rod of a Slider Crank Example
This example involves the shape optimization of the connecting rod of a slider crank. The mass of
the connecting rod is to be minimized. Initial velocity is applied to the block of the model. The
stress of all connecting rod elements must be less than an allowable value.
Slider crank
Four design variables follow:
Input decks for the design are as follows.

SUBCASE 1
MBSIM = 1
INVEL = 2
DESSUB = 10
SPC = 10
$
BEGIN BULK
$
DESVAR 1 UPPER0.0 -1.0 2.0
DESVAR 2 LOWER0.0 -1.0 2.0
DESVAR 3LEFT_OUT0.0 -1.0 1.0
DESVAR 5RIGHT_OU0.0 -1.0 1.0
$
DRESP1 1 MASS MASS PSOLID 18

DRESP1 2 STRESS STRESS PSOLID SVM 18
$
DCONSTR 10 2 -100.E1 100.E1
DVGRID* 1 9925511 0 1.0

* -1.568286121E-02-3.884642199E-02-6.483015791E-10
:
:
The final design appears as follows:
The optimum design

<install_directory>/demos/hwsolvers/optistruct/sc_design.fem.

Rotating Shell Example
In some models, the rate of change for the response value with respect to time is very high, and
the response is dominant in the design process; this is the case in the following example. The
model is a rotating shell structure. A lumped mass is attached to the center of the right hole. The
mass of the structure is to be minimized. The driving motion is a rotational velocity at the center
of the left hole. Its profile is shown below. The movement of the structure is like the second hand
of a watch. Stress of all the elements must be less than an allowable value. Four shape design
variables are controllable.
Rotating shell
Profile of the driving motion.
After analyzing the initial model, the time history of stress using HyperView can be seen.
Analysis result of the initial design

According to the analysis result image shown above, the peaks of stress are at around 0.3
seconds. Since the values of these peaks are the largest, you can expect that the responses at
around 0.3 seconds will be dominant in the design process. It is a good practice to "zoom in" on
the time period around 0.3 seconds so that the optimization process can consider more precise
responses. General steps to address the process in this case follow:
1. Run an analysis model with reasonable number of steps in MBSIM card.
ANALYSIS
$
DESOBJ(MIN)=1
$
SUBCASE 1
MBSIM = 10
MOTION = 11
DESSUB = 11
SPC = 10
:
:
MBSIM 10 TRANS END 0.7 NSTEPS 100
Now you can find out the behavior of the structure as in the analysis result image.
2. According to the results post-processed by HyperView, the maximum stresses are developed
at around 0.3 seconds. Increase the number of time steps around 0.3 seconds. That is, divide
the time period of 0.28 seconds – 0.34 seconds into 200 steps. Increasing the number of time
steps in this period provides the optimizer with more information.
The element that has the maximum stress and the corresponding time can be changed as the
design changes. Thus, Step 2 does not always work. If the time when maximum stress is
developed and corresponding element are expected to change dramatically as the design
changes, it is best to consider the changed peak time and corresponding element as much as
possible.
3. Replace the previous single MBSIM card with multiple MBSIM cards as the following.
+ VSTIFF
+ VSTIFF
+ VSTIFF
+ VSTIFF
MBSEQ 10 1 2 3

4. Run the optimization problem by removing ANALYSIS command.
$ANALYSIS
DESOBJ(MIN)=1
$
SUBCASE 1
MBSIM = 10
MOTION = 11
DESSUB = 11
SPC = 10
:
:
+ VSTIFF
+ VSTIFF
+ VSTIFF
MBSEQ 10 1 2 3
Using the above steps, the design process convergence can be enhanced.
<install_directory>/demos/hwsolvers/optistruct/rotating_shell_design.fem.

Optimization of MBD System Level Response Optimization
Example
MBD system level responses can be displacement, velocity, acceleration, force, or some
predefined function of those four quantities. MBD system level responses can be
optimized/constrained along with other structural responses of flexible bodies in MBD systems.
The example shown here is intended to minimize the mass of a system. Constraints are imposed
on the stress of a flexible body and the velocity of a point. Notable points are shown below.
System Level Responses
In order for the system level responses to be made available to the optimization process,
MBREQE or MBREQM entries must be defined so that the MBD solver can generate the
appropriate output.
$------|--MID--|--GID--|
MARKER 55 9929617
$------|--RSID-|--RID--|--ITEM-|--MID--|
MBREQM 99 999 VEL 55
Then RID (999 in this case) must be referenced in DRESP1.

$------|-------|-------|-------|-------|-------|-------|-------|-------|
DRESP1 3 VELO MBVEL MBREQM TX MIN 999
It is not necessary to reference the requests defined by MBREQM/E in the subcase to make the
requested responses available for the optimization. RSID (99 in this case) of MBREQM can be an
arbitrary positive integer.
DVGRID Including Joint Location
Changing the length of a body is a common method of achieving desired system level responses.
This change in shape can be defined using DVGRIDs. In this case, the DVGRIDs need to be
defined carefully, as it is necessary to ensure that the joints remain in a valid configuration while
changing the length of the bodies.

A common mistake in defining shape change that involves change of joint locations
In the figure above, Nodes A and B must remain coincident after applying the shape
perturbation.
The correct configuration after applying shape perturbation vector should be:
Correct way of defining shape change that involves change of joint locations
The input file for this problem can be found at

<install_directory>/altair/demos/hwsolvers/optistruct/mbdsystemlvlopt.fem.
The optimization result should look like the following. The opaque orange was the base line
model and blue one is optimized model.


OptiStruct 2017 Tutorials and Examples

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Accessing the Model Files ........................................................................................................................... 4

Raasch Challenge - curved strip hook .......................................................................................................... 5

NAFEMS Test Problem (LE3) - Radial Point Load on a Hemisphere ............................................................... 7

NAFEMS Frequency Benchmarks ................................................................................................................. 9

Pin-ended Double Cross (Test No. FV2).................................................................................................... 9

Cantilever with Off-Center Point Masses (Test No. FV4) ........................................................................ 12

Deep Simply-Supported Beam (Test No. FV5) ........................................................................................ 14

Clamped Thin Rhombic Plate (Test No. FV15) ........................................................................................ 18

Clamped Thick Rhombic Plate (Test No. FV22) ....................................................................................... 20

Simply-Supported Solid Square Plate (Test No. FV52) ............................................................................ 24

MacNeal-Harder Test Problems................................................................................................................. 27

Straight Cantilever Beam ....................................................................................................................... 27

Curved Cantilever Beam ........................................................................................................................ 30

Twisted Cantilever Beam ....................................................................................................................... 32

Tutorials and Examples ................................................................................................................................. 36

Accessing the Model Files...................................................................................................................... 36

Basic Small Displacement Finite Element Analysis.................................................................................. 40

Advanced Small Displacement Finite Element Analysis ........................................................................ 176

Large Displacement Finite Element Analysis ........................................................................................ 398

Fluid-Structure Interaction Analysis ..................................................................................................... 430

Multi-body Dynamics Analysis ............................................................................................................. 445

Topology Optimization ........................................................................................................................ 513

Topography Optimization .................................................................................................................... 632

Combination Optimization .................................................................................................................. 663

Size Optimization ................................................................................................................................ 740

Shape Optimization ............................................................................................................................. 846

1 OptiStruct 2017 Tutorials Altair Engineering

Proprietary Information of Altair Engineering

Example Problems for Structural Analysis ............................................................................................ 948

Example Problems for Topology Optimization ..................................................................................... 967

Example Problems for Topography Optimization ................................................................................. 987

Example Problems for Size Optimization ........................................................................................... 1033