SLIDE 1 COVER

Welcome to OptStruct training!

The instructor should describe the environment, rest room, kitchen, etc
The objective today is to introduce what is and how to use OptiStruct. This training will
give you too basic overview about optimiation too. We hope you enjoy these ! days and
take advantage o" this "abulous tool when you get back to your company.
#n"ormation about the class and instructor$
o %ame, company and position!
o What the attendee know about Optimiation and &yperWorks!
o Why he is attending this course!

On your computer there is a "older named training on your desktop, on this "older you
will "ind all electronic "iles you need$
o Manual$ 'older with the manual in pd" "ormat$
(ook with chapters and e)ercises.
o Model Files$ 'older with all model "iles that will be used during the e)ercises.
o Solved$ 'older with the "inal "iles "rom the e)ercises.
On your desk you should have a "older with a *+* that has all these "iles and the
,ower,oint printed as handouts to take notes during the e)position.
SLIDE 2 DAY 1 Agenda
Today we will cover the "irst part o" a product development, called Concept Design.
The idea is to give you an
1 I!"ROD#C"IO!
o - &yperWorks Overview
o &ow OptiStruct is integrated with the other &yperWorks solvers.
o -n OptiStruct overview
'.-,
/(* and
Optimiation.
o ! e)amples where OS was used to optimie a design.
2 "$EORE"ICAL %AC&'RO#!D
o Optimiation
a. *esign +ariable
b. 0esponse
c. Objective
d. 1onstraint
e. 'easible and un"easible
o 2radient3base method
o Sensitivity -nalysis
o /ove 4imit -djustment
o 1onstraint screening
o 0egions
o *iscrete *+
( O)"IMI*A"IO! I!"ERFACE A!D SE"#)
o /odel *e"inition Structure
a. Subcase #n"ormation Section
b. (ulk *ata Section
c. Optimiation 1ards
o O,T#/#5-T#O% 26#
a. Optimiation ,anel
b. Optimiation /enu
c. /odel (rowser
+ CO!CE)" DESI'!
o Topology
.)ercise$ step by step on a !* model
.)ercise$ - Solid 1ontrol arm.
o Topography
.)ercise$ *etermine the optimum hard drive disc slider suspension beads.
o 'ree3sie
.)ercise$ *etermine the optimum hard drive disc slider suspension beads.
SLIDE (, Da- 2 Agenda
On the second day we start with a review on what was learned mainly to record what
Concept Design was.
Then we start the new chapter 'ine Tuning
. Fine tuning Design
This chapter is called fine tuning because the techniques we will learned here
can be used to achieve very precise solution and at the same time dont permit in
almost all cases big changes on the design.
o Sie Optimiation
#n sie optimiation, the properties o" structural elements such as shell
thickness, beam cross3sectional properties, spring sti""ness, and mass are
modi"ied to solve the optimiation problem.
Si/e Opti0i/ation o1 a Rail 2oint 3Step 4- step5
o Shape Optimiation.
#n shape optimiation, the outer boundary o" the structure is modi"ied to
solve the optimiation problem. 6sing "inite element models, the shape
is de"ined by the grid point locations. &ence, shape modi"ications
change those locations.
Shape variables are de"ined in OptiStruct in a way very similar to that o"
other shape optimiation codes. .ach shape variable is de"ined by using
a DESVA bulk data entry.
S6ape Opti0i/ation o1 a Rail 2oint 3Step 4- step5
o 'ree3shape Optimiation
F7ee,s6ape optimiation uses a proprietary optimiation techni7ue
developed by -ltair .ngineering #nc., wherein the outer boundary o" a
structure is altered to meet with pre3de"ined objectives and constraints.
The essential idea o" "ree3shape optimiation, and where it di""ers "rom
other shape optimiation techni7ues, is that the allowable movement o"
the outer boundary is automatically determined, thus relieving users o"
the burden o" de"ining shape perturbations.
F7ee,s6ape design 7egions are de"ined through the DS!A"E bulk data
entry. *esign regions are identi"ied by the grids on the outer boundary
o" the structure 8the edge o" a shell structure or the sur"ace o" a solid
structure9. These grids are listed on the DS!A"E entry.
SLIDE + Int7oduction cove7
We will start the training with a small introduction describing:
What is HyperWorks?
and
What is OptiStruct?
SLIDE . $-pe78o79s Ove7vie:
HyperWorks Overview
A Platform for Innovation, is an enterprise simulation solution for rapid design
exploration and decision-making !sed for: Modeling, Analysis, Optimization,
Visualization, eporting, !er"ormance data management
HyperWorks #ool $escriptions
&yperWorks has a set o" tools some o" them that we will use during this training are$
HyperMesh: !niversal finite element pre- and post-processor
RADIOSS: "inite element solver for linear and non-linear problems
OptiStruct: #esign and optimi$ation software using finite elements and multi-
bod% d%namics
HyperView: &igh performance finite element and mechanical s%stem post-
processor, engineering plotter, and data anal%sis tool
HyperGraph: 'ngineering plotter and data anal%sis tool
(here are other tools that the user ma% need on future developments, to learn
about them go to the on-line help
SLIDE ; OptiSt7uct in $-pe78o79s
As we described before )pti*truct is part of the &%perWorks toolkit
)* is an optimi$er coupled with finite element and +,# solver
(he solvers consist of loosel% integrated executables -see picture. (o the user
the integration is seamless thru the run script provided %ased on the "ile naming
convention the right executable or combination of executables is chosen
(he pre-processing for )pti*truct is made using HyperMesh and the post-
processing using HyperView and HyperGraph HyperStudy is another
HyperWorks tool that can be used with OptiStruct for /obust design, #)' and
)ptimi$ation
#uring the next exercises the &%perWorks integration with )pti*truct will be
showed in detail, and for more about it the user should go to our online documentation
SLIDE < OptiSt7uct Ove7vie: 3FEA5
OptiStruct is a finite element and multi-bod% d%namics optimi$er which can be
used to design and optimi$e structures and mechanical s%stems
The graphical interface for OptiStruct within HyperWorks allows you to perform
complete modeling, optimization problem setup, job submission, and post-processing
uickly and easily!
(he "inite 'lements Anal%sis includes: linear static, modal, linear &uckling and
thermal'stress analysis "or steady state
It support advanced anal%sis as "/" direct and modal, /andom response or P*#
anal%sis, (ransient direct and modal, 0ontact non-linear, acoustic with coupled fluid
and structure, fatigue anal%sis for high and low c%cle
SLIDE = OptiSt7uct Ove7vie: 3M%D5
&ine0atic
:inematics is the study o" the motion o" a system
with no consideration o" "orces
Static
Statics is the study o" systems in e7uilibrium
,er"ormed "or systems having *.O.' ;< =
System at rest or having constant velocity
2ives in"ormation about the e7uilibrium "orces
>uasi,static
>uasi3static simulation is a se7uence o" static
simulations where bodies are moving very slowly
,er"ormed "or systems having *.O.' ;< =
>uasi static simulation is a se7uence o" static
simulations
?ou must have a time dependent "orce or motion in
your model
>uasi means almost. So the results are valid only i"
things are moving su""iciently slowly
Met6od I Fo7ce I04alance Met6od
Met6od II M&EAM Met6od
D-na0ic
*ynamics deals with systems which are not in
e7uilibrium and are accelerating. #t studies motion,
taking into account "orces
SLIDE ? Optist7uct Opti0i/ation Ove7vie:
This training focus on #ptiStruct, but it is important for the user to understand all
optimization resource it is a"ailable on HyperWorks!
3 4et@s take a look on how &yperWorks can be used during the *esign ,rocess.
$%&$'
3 "opolog-$ Or the best material distribution. $%&$'
3 F7ee,si/e@ 6sed to determine the best thickness distribution, mainly used on
composite structures. $%&$'
3 "opog7ap6-@ 6sed on !* to determine the optimum topography o" a component.
$%&$'
3 F7ee,s6ape@ -s the name says is a shape optimiation where the shape variables
are determined automatically by the solver using the normal o" the elements.
$%&$'
3 S6ape@ -s we can see shape optimiation is the change on any geometric "eature
like a hole, thickness, radio, etc. $%&$'
3 Si/e$ This is known too as parametric optimiation, it is the change o" numerical
parameters, "or e)ample a plate thickness modeled with shell elements. $%&$'
3 On OptiStruct we can divide the optimiation in ! phases
3 $oncept Design 8That will be our chapter A9 $%&$'
3 Design #ptimi(ation or )ine Tuning 8this will be discussed in detail on
our chapter B9 $%&$'
3 -nd all these optimiations are available on OptiStruct. $%&$'
When we use HyperWorks there is another tool called HyperStudy that can
complement and impro"e the optimization and the study of our design!
With HST is possible to do #ultidisciplinar optimization, $O%, and stochastic
studies with any sol"er!
SLIDE 1A , Lig6t:eig6t S#V F7a0e Develop0ent
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SLIDE 11 , Opti0i/ation )7ocess 1o7 "o7sion Lin9s
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SLIDE 12 Cove7 "6eo7etical %ac9g7ound
We will now take some time to understand what )ptimi$ation means in the contest of
product design
We will introduce )ptimi$ation 0oncepts and #efinitions that will be ver% important to
%ou during the exercises, then if %ou have an% doubt here please feel free to ask at
an% time
SLIDE 1( , St7uctu7al Opti0i/ation Concepts
1ow that we had alread% learned based in an example how a function or response
can be optimi$ed in 2# graphical 3et4s define formall% a optimi$ation problem:
5 )b6ective is the functions7properties7responses that %ou want to maximi$e or
minimi$e
2 #8s7parameters are what %ou can change to achieve the ob6ective
9 0onstraints are again as the ob6ective responses7functions7properties that
need to be higher or lower then a target value
(hese function can be of an% t%pe, linear, non-linear, d%namic, implicit or explicit,
when working in )pti*truct we will work onl% with continuous functions
SLIDE 1+ , Opti0i/ation De1initions
5 (oplog% optimi$ation
SLIDE 1. Opti0i/ation De1initions
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SLIDE 1; , Opti0i/ation "e70inolog- DVB DS
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SLIDE 1< , Opti0i/ation "e70inolog- Response
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SLIDE 1= Opti0i/ation "e70inolog- O4CectiveB
Const7aint
SLIDE 1? , Opti0i/ation )7o4le0 EDa0ple
It is good to start with an example that ever% engineer knows the response
A cantilever beam with a constant length of 5, remember this is 6ust an example:::
We will consider that the beam theor% is valid for all the design space proposed

(he section dimensions -b,h. of the beam are our #8s (he goal is to find the
minimum weight sub6ect to some constraint on stress
SLIDE 2A , Opti0i/ation )7o4le0 EDa0ple
We can state this problem as:
5 +inimi$e the weight that is a function of & and h(
2 where the parameters or design variables are & and h
9 (he #esign space is defined as all possible beams that can be generated
within the limits of & and h
; (he maximum bending stress -normal stress. can4t be higher than )*+ M!a
< And the maximum shear stress can4t be higher then *+ M!a
C. (here is another constraint applied directl% on the #8s, where the beam is
onl% valid if h ,-&
SLIDE 21 Opti0i/ation )7o4le0 EDa0ple
5 (his is the weight function level where each line represents a constant weight
value and these are decreasing when both b and h decrease CLICK
2 (his green line represents the max normal stress = 5>? +Pa and the region
below in pink is unfeasible because the stress is higher then it CLICK
9 (he blue line represents the shear stress = >? +Pa, as we can see it is
inactive because the non valid region is inside the other non-valid region and
will not change the results CLICK
; (his light blue line represents the h = 2b region and the pink region above it
is not valid because h @ 2b CLICK
< (hen we can plot the #8 limits using dot lines (his show that onl% the white
region is valid CLICK
> And based on the level curves we can see that the minimum weight is on the
left rand corner, where the constraints cross each other (his is a ver%
common situation for almost all 'ngineer problems CLICK
SLIDE 22 Opti0i/ation "e70inolog- Feasi4leB in1easi4le
and Opti0u0
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SLIDE 2( , Opti0i/ation "e70inolog- '7adient,4ased
Opti0i/ation
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SLIDE 2+ , Opti0i/ation "e70inolog- , Sensitivit- Anal-sis
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SLIDE 2. Inte7p7eting t6e Results

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SLIDE 2; Inte7p7eting t6e Results
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SLIDE 2< , Opti0i/ation Inte71ace and Setup 3cove75
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SLIDE 2= Opti0i/ation '#I
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SLIDE 2? Opti0i/ation Setup 0odule in $-pe7Mes6

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SLIDE (A , Opti0i/ation Setup 0odule in $-pe7Mes6

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SLIDE (1 , Opti0i/ation Setup 0odule in $-pe7Mes6
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SLIDE (2 Opti0i/ation Setup 0odule in $-pe7Mes6

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SLIDE (( Model De1inition St7uctu7e

o We will get a little deep on the model de"inition, the user don@t need to be
worry about understand all things here, the idea is more to put every one on
the same page.
o - description how we set up the problem will be done very 7uickly, i" some
one has di""iculty on "ollow the steps let me know.
o The mainly objective on the ne)t it is to leave with the user a basic recipe o"
how to set up optimiation.
SLIDE (+ , Model De1inition St7uctu7e
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SLIDE (. , Model De1inition St7uctu7e
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SLIDE (; Const7aint and O4Cective de1inition
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SLIDE (< , Opti0i/ation Ca7ds
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SLIDE (= , Const7aint and O4Cective De1inition@ Load Case
Re1e7ence
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SLIDE (? , Opti0i/ation Setup
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SLIDE +A , Opti0i/ation Setup
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SLIDE +1 , Opti0i/ation Setup
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SLIDE +2 , Opti0i/ation Setup
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SLIDE +( , Opti0i/ation Setup
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SLIDE ++ , Opti0i/ation Setup
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SLIDE +. , Opti0i/ation Setup
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SLIDE +; , Opti0i/ation Setup
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SLIDE +< , Concept Design 3Cove75
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SLIDE += $o: St7uctu7al Opti0i/ation Cuts
Develop0ent "i0e

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SLIDE +? ,"opolog- Opti0i/ation
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SLIDE .A , Design Va7ia4les "opolog- Opti0i/ation
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SLIDE .1 OptiSt7uct Input@ "opolog- Opti0i/ation
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SLIDE .2 , "opolog- opti0i/ation on )COM)
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SLIDE .( , "opolog- Opti0i/ation using Manu1actu7ing
Const7aints
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SLIDE .+ "opolog- Opti0i/ation using Manu1actu7ing
Const7aints
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SLIDE .. Manu1actu7ing Const7aints@ Mini0u0 Me04e7
Si/e Cont7ol

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SLIDE .; , Manu1actu7ing Const7aints@ MaDi0u0 Me04e7
Si/e Cont7ol

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SLIDE .< , Manu1actu7ing Const7aints@ )atte7n Repetition

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SLIDE .= )atte7n Repetition

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SLIDE .? , )atte7n Repetition
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SLIDE ;A , D7a: Di7ection Const7aint
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SLIDE ;1 D7a: Di7ection Const7aint
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SLIDE ;2 , D7a: Di7ection Const7aint
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SLIDE ;( , EDt7usion Const7aint
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SLIDE ;+ Co04ination o1 Manu1actu7ing Const7aints
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SLIDE ;. Applications o1 "opolog- Opti0i/ation

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SLIDE ;; , Co00on "opolog- Opti0i/ation )7o4le0s

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SLIDE ;< , Additional Opti0i/ation Conside7ations
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SLIDE ;= "opolog- Opti0i/ation :it6 st7ess Const7aints

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SLIDE ;? , EDe7cise +1@ "opolog- Opti0i/ation o1 a $oo9
:it6 St7ess Const7aints
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SLIDE <A , EDe7cise +1@ "opolog- Opti0i/ation o1 a $oo9
:it6 St7ess Const7aints 3 RES#L"S 5
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SLIDE <1 OSS0oot6@ 'eo0et7- EDt7action o1
Opti0i/ation Results
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SLIDE <2 , "opolog- Opti0i/ation EDa0ple@ %ul96ead
Sti11ene7s
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SLIDE <( , "opolog- Opti0i/ation EDa0ple@ %ul96ead
Sti11ene7s 3 Results 5
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SLIDE <+ , "opolog- Opti0i/ation EDa0ple@ %ul96ead
Sti11ene7s 3 )e71o70ance 5
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SLIDE <. EDe7cise +2@ "opologic Opti0i/ation o1 a
Cont7ol A70
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SLIDE <; EDe7cise +2@ "opologic Opti0i/ation o1 a
Cont7ol A70
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SLIDE << , "opog7ap6- Opti0i/ation

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SLIDE <= , Molded )7essu7e "an9
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SLIDE <? Molded )7essu7e "an9 3 S-00et7- 5

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SLIDE =A , Molded )7essu7e "an9 3 Results 5
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SLIDE =1 , Molded )7essu7e "an9 3 )e71o70ance5
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SLIDE =2 "opog7ap6- Opti0i/ation 3 "o7sion plate ,
pe71o70ance 5
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SLIDE =( , OptiSt7uct Input@ "opog7ap6- Opti0i/ation
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SLIDE =+ "opog7ap6- Opti0i/ation Setup
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SLIDE =. "opog7ap6- Opti0i/ation Setup

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SLIDE =; , "opog7ap6- Opti0i/ation Setup

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SLIDE =< , %ead disc7eteness cont7ol

A## 1)('*
SLIDE == Co04ining Opti0i/ation "-pes
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SLIDE =? , EDe7cise +(@ "opog7ap6- Opti0i/ation o1 a
Slide7 Suspension
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SLIDE ?A , EDe7cise +(@ "opog7ap6- Opti0i/ation o1 a
Slide7 Suspension 3 Results 5
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SLIDE ?1 F7ee,Si/e Opti0i/ation
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SLIDE ?2 , F7ee,Si/e Opti0i/ation
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SLIDE ?( , F7ee,Si/e Opti0i/ation
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SLIDE ?+ F7ee,Si/e Opti0i/ation on )COM)
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SLIDE ?. EDe7cise ++@ F7ee,si/e Opti0i/ation o1 Finite
)late :it6 $ole

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SLIDE ?; , EDe7cise ++@ F7ee,si/e Opti0i/ation o1 Finite
)late :it6 $ole 3 Results 5

A## 1)('*
SLIDE ?< , Fine "uning Design 3Cove75
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SLIDE ?= Si/e Opti0i/ation
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SLIDE ?? , Si/e Opti0i/ation
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SLIDE 1AA , Si/e Opti0i/ation
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SLIDE 1A1 Si/e Opti0i/ation
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SLIDE 1A2 , Si/e Opti0i/ation
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SLIDE 1A( , Si/e Opti0i/ation
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SLIDE 1A+ EDe7cise .1 Si/e Opti0i/ation o1 a Rail 2oint
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SLIDE 1A. EDe7cise .1 Si/e Opti0i/ation o1 a Rail 2oint
3 Results 5

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SLIDE 1A; , S6ape Opti0i/ation

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SLIDE 1A< , S6ape Opti0i/ation
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SLIDE 1A= S6ape Opti0i/ation

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SLIDE 1A? , S6ape Opti0i/ation
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SLIDE 11A , S6ape Opti0i/ation
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SLIDE 111 Mo7p6ing :it6 Do0ain and $andle
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SLIDE 112 , Mo7p6ing :it6 Do0ain and $andle
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SLIDE 11( , Mo7p6ing :it6 Do0ain and $andle
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SLIDE 11+ Mo7p6ing :it6 Do0ain and $andle
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SLIDE 11. Mo7p6ing :it6 Do0ain and $andle

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SLIDE 11; , Mo7p6ing :it6 Do0ain and $andle

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SLIDE 11< , S6ape de1inition 1o7 Opti0i/ation
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SLIDE 11= EDe7cise .2 S6ape Opti0i/ation o1 a Rail
2oint

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SLIDE 11? , EDe7cise .2 S6ape Opti0i/ation o1 a Rail
2oint 3 Result 5
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SLIDE 12A , F7ee S6ape Opti0i/ation
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SLIDE 121 F7ee S6ape Opti0i/ation
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SLIDE 122 , F7ee S6ape Opti0i/ation
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SLIDE 12( , F7ee S6ape Opti0i/ation
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SLIDE 12+ F7ee S6ape opti0i/ation
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SLIDE 12. F7ee S6ape opti0i/ation

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SLIDE 12; , F7ee S6ape opti0i/ation

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SLIDE 12< , F7ee S6ape opti0i/ation
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SLIDE 12= F7ee S6ape opti0i/ation

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SLIDE 12? , EDa0ple 2@ s6ape c6ange 6isto7-
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SLIDE 1(A , EDe7cise .( , F7ee,s6ape opti0i/ation
Co0p7esso7 %7ac9et
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SLIDE 1(1 EDe7cise .( , F7ee,s6ape opti0i/ation
Co0p7esso7 %7ac9et 3 Result 5