OptiStruct Optimization90 Folien

12/18/2008
Altair OptiStruct
Concept Design with Topology and Topography Optimization
Altair Engineering
Altair Proprietary and Confidential Information
Copyright 2008 Altair Engineering, Inc. All rights reserved.
WHAT IS ALTAIR HYPERWORKS?

A World Class Suite of CAE Tools
HyperMesh
HyperView HyperWeb HyperView Player
HyperViewPlayer HyperWeb HyperGraph HyperStudy HyperView MotionView OptiStruct MotionSolve HyperForm Altair HyperWorks HyperMesh
HyperGraph HyperStudy
HyperForm MotionView Altair Proprietary and Confidential Information MotionSolve
OptiStruct
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What is OptiStruct
An Optimizer with a Finite Element and Multi-body dynamics solver integrated Used for the design, analysis and optimization of structures and mechanical systems OptiStruct Structural Optimization solutions:
Topology Topography Shape and Size Free Size and Free Shape
Optimization Definitions:
Topology: is a mathematical technique that optimized the material distribution for a
structure within a given package space
Free Size: is a mathematical technique that produces an optimized thickness

distribution per element for a 2D structure.
Topography: Topography optimization is an advanced form of shape optimization

in which a design region for a given part is defined and a pattern of shape variablebased reinforcements within that region is generated using OptiStruct .
Shape: is an automated way to modify the structure shape based on a predefined

shape variables to find the optimal shape.
Size: is an automated way to modify the structure parameters (Thickness, 1D

properties, material properties, etc) to find the optimal shape.
Free Shape: is an automated way to modify the structure shape based on set of
nodes that can move totally free on the boundary to find the optimal shape.
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Optimization Terminology:
Design Variables: System parameters that are varied to optimize system performance. Design Space: selected parts which are designable during optimization process. For example, material in the design space of a topology optimization Response: Measurement of system performance. Objective Function: Any response function of the system to be optimized. The response is a function of the design variables. Ex. Mass, Stress, Displacement, Moment of Inertia, Frequency, Center of Gravity, Buckling factor, and etc. Constraint Functions: Bounds on response functions of the system that need to be satisfied for the design to be acceptable. Feasible Design: One that satisfies all the constraints. Infeasible Design: One that violates one or more constraint functions. Optimum Design: Set of design variables along with the minimized (or maximized) objective function that satisfy all the constraints.
Altair Proprietary and Confidential Information Copyright 2008 Altair Engineering, Inc. All rights reserved.
Structural Optimization Concepts

The Optimization Problem Statement: Objective (What do I want?) min f(x) also min [max f(x)] Design Variables (What can I change?) XiL Xi XiU i =1,2,3,N Design Constraints (What performance targets must be met?) gj(x) 0 j = 1, 2, 3, , M
Note: The functions f(x), gi(x), can be linear, non-linear, implicit or explicit, and are continuous Example: Explicit y(x) = x2 2x Implicit y3 y2x + yx - x = 0
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Optimization Problem Example

A cantilever beam is modeled with 1D beam elements and loaded with force F=2400 N. Width and height of cross-section are optimized to minimize weight such that stresses do not exceed yield. Further the height h should not be larger than twice the width b.

Objective
Weight: min m(b,h)
Design Variables
Width: Height: bL < b < bU, hL < h < hU, 20 < b < 40 30 < h < 90
Design Region:
All beam elements
Design Constraints:
(b,h) max, with max = 160 MPa (b,h) max, with max = 60 MPa
h 2*b
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Mathematical Design Space
Beam height, h (mm)
Beam width, b (mm)
Interpreting the Results

Objective
Did we reach our objective? How much did the objective improve?
Design Variables
Values of variables for the improved design
Constraints
Did we violate any constraints?
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Interpreting the results

What can go wrong? Local minimum vs. global minimum Solution might not be available with the given objective, constraints and design variables over constrained Efficiency of Optimization Relation between constraints and design variables wrt their numbers Unconstrained Optimization Problem Optimization problem setup is not appropriate Issues related to FEA modeling Stress constraints on nodes connected to rigids
How Structural Optimization Cuts Development Time

Most of the product cost is determined at the concept design stage
Problem: minimum knowledge, but maximum freedom
Need: effective concept design tools to minimize downstream redesign costs and time-tomarket
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Optimization in Practice: Altair Bus
System Level Requirements (Loads analysis and packaging)
Package Space and Loads
Altair OptiStruct
Structural Design Altair-Bus

CAD model with generic elements
Final Design Size and Shape Optimization

Parametric Shape Vectors
Finite Element Modeling
OptiStruct vs. HyperStudy: When to Use Which Tool?
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OptiStruct Features: Input decks

Nastran Style ASCII Input Format Elements 3D Shell: TRIA3/6, QUAD4/8 3D Solid: TETRA4, TETRA10, PENTA6, PENTA15, PYRA5, PYRA13, HEXA8, HEX20 1-D Elastic: ROD, TUBE, BAR, BEAM, ELAS1, ELAS2, BUSH 1-D Rigid: RROD,RBAR,RBE2, RBE3 Concentrated Mass : CONM, CMASS CWELD, CVISC, CDAMP, CGAP (Non-Linear gap element), CGAPG (node-patch nonlinear gap element) Composite Material Properties (PCOMP(G)) Load Types Forces, Pressures, Moments, Enforced Displacements, Thermal Loads, Radial Loads, Gravity Loads, Distributed Loads on 1D Dynamic loads
OptiStruct Features: Results

Output Displacements, Rotations, Velocity, Acceleration Stresses Von mises, Normal, Shear, Principal, Grid Point, Corner stress Strains Von mises, Normal, Shear, Principal Element Strain Energy and Strain Energy Density Element Densities Topology optimization Shape Changes Shape/Topography optimization Element Thickness Size/Free-Size optimization SPC (Reaction-) Forces, MPC Force, Grid Point Forces, Element Forces Sensitivity Analysis output HyperMesh Binary Format (Default) (.res) Altair H3D format (Default) (HyperView and HyperViewPlayer) OptiStruct ASCII Format NASTRAN Punch file Format (.pch) NASTRAN OP2 Format (.op2) PATRAN ASCII Format
Output Result Formats
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OptiStruct Features: Optimization Responses

Compliance, strain energy (COMP) Total and Regional Weighted Compliance (WCOMP) Natural Frequency (FREQ) Inverse of Weighted Eigenvalues (WFREQ) Combination of Weighted Compliance and Weighted Inverse Eigenvalues (COMB) Mass (MASS), Volume (VOLUME) Total and Regional Mass Fraction (MASSFRAC), Volume Fraction (VOLFRAC) Total and Regional, only used in topology optimization Nodal Displacements (DISP) Stress (STRESS) Buckling Mode (LAMA) Center of Gravity (COG) Force (FORCE) Mass Moments of Inertia (INERTIA) Strain (STRAIN) Composite stress, strain, failure (CSTRESS, CSTRAIN, CFAILURE) Frequency response displacements, velocity, acceleration (FRDISP, FRVELO, FRACCL) Frequency response stress (FRSTRE), strain (FRSTRA) Frequency response force (FRFORC)
OptiStruct Input - optimization

I/O Option Section Case Control Section Define Load Cases (Sub Cases, Load Steps) Definition of Objective and Constraint Reference Bulk Data Section Optimization Problem Design Variables Responses Constraints Optimization parameters (DOPTPRM) Finite Element Model
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Response Definition
DRESP1 Simple response definition Mass, mass fraction, volume, volume fraction, compliance, frequency, displacement, stress, strain, force, composite responses, weighted compliance, weighted frequency, and compliance index, frequency response analysis responses
DRESP2 Response definition using a user defined function Defines responses as function of design variables, grid location, table entries, responses, and generic properties Example: Average displacement of two nodes:
F ( x1, x 2) =
DRESP3
x1 + x 2 2
Where x1, x2 are nodal displacements
Response definition using a user defined external function External function may be written in C (C++) or Fortran
Constraint and Objective definition

DCONSTR Defines Responses as optimization constraints. Relates response to lower and/or upper bound DCONADD Adds constraints under same id DESSUB, DESGLB Load case dependent, and independent reference in Case Control Section DESOBJ Load case dependent, and independent reference in Case Control Section Min/max
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Constraint and Objective Definition: Load Case Reference

Objective and design constraints need to be defined load case dependent if the response is a reaction to a load Load case dependent Compliance, frequency, displacement, stress, strain, force, composite responses Functions using these responses w/o load case assignment Load case in-dependent (global) Mass, mass fraction, volume, volume fraction, center of gravity, moments of inertia, weighted compliance, weighted frequency, compliance index Functions using these responses Functions using compliance, frequency, displacement, stress, strain, force, composite responses with load case assignment
Optimization Tools:
DEQATN Defines an equation Linked to DVPREL2, DRESP2 for user defined property or response. DTABLE Defines constants used in DEQATN Linked to DVPREL2, DRESP2 DSCREEN Constraint screening definition DOPTPRM Optimization parameter definitions Max number of iterations, minimum member size control, moving limits, tolerances
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Optimization Setup in HyperMesh

Optimization Panel (Analysis page) Optimization problem set up OptiStruct Panel (Analysis page) Launch OptiStruct solution OSSmooth Panel (Post page) Generate geometry from topology results
Optimization Setup module in HyperMesh Definition of Design Variables Definition of Responses, Constraints and Objective Definition of Equations Optimization Control, Constraint Screening
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Altair OptiStruct
Topology and Topography Optimization training
Optimization Disciplines
Topology optimization Method to find the optimum material distribution in a given design space
Topology Topography
Topography optimization Method to evaluate the optimum stiffening pattern on a thin part
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Fundamental Procedure of Topology Optimization
old design
design proposal
Design Variables Topology Optimization What does OptiStruct change?

Density = 1
Density = 0
E/E0 1 (/0)p
/
0
Density Method
Very robust
Penalty Factor
More discrete design proposals
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OptiStruct Input: Topology Optimization

DTPL card Design Variable definition for topology optimization Shells - Property with base and total thickness defines topology design space Solids Properties define topology design space Composites (PCOMP) - Properties define topology design space Rod, Bar, Weld , Bush- Properties define topology design space Stress constraints bounds Manufacturing constraints definition HyperMesh Topology panel:
Topology optimization on PCOMP

Increase/decrease the thickness of given ply angle Ability to optimize the angle as well by creating phantom ply
0 90 - 45
y X
45 PCOMP
0 Optimized PCOMP
mat option on DTPL

Ply Homo ply based PCOMP (default) homogenized PSHELL
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Exercise 2.1 : Design Concept for a Structural C-clip

Import geometry into HyperMesh Define material and element properties Mesh the model Apply constraints and loads (boundary conditions) Run baseline analysis; check results Set up the optimization problem: Define the design space Create responses for volume and nodal displacements Set design constraints on the displacement responses Define the objective function
min(Vol ) d1 d ub d 2 d lb
OSSmooth: Geometry Extraction of Optimization Results A Geometry creation tool for Topology/Topography/Shap e Optimized models Supports different output formats (IGES, STL, H3D etc.) Advanced geometry smoothing options for smoother surfaces Surface reduction option to reduce the size of IGES and STL files Integrated into HyperMesh and is easy to use
IGES
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Optimization Example: Engine Mount Bracket

Six load cases: start backwards into pothole out of pothole attachment loads engine transport Optimization Problem: Minimize mass Maintain stiffness, strength
Courtesy Volkswagen AG, Wolfsburg
Engine Mount Bracket: Optimization Design Process
Design Space Loads
Topology Optimization Geometry Recovery
Final Design
Preliminary Design
Shape Optimization Sizing Optimization

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Engine Mount Bracket: Results

Topology Results Initial Design Concept

Engine Mount Bracket: Comparison

Original Design Optimized Design
Mass: 730g (-20%) Same stiffness, strength

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Topology Optimization Example: Radiator Bracket

Original bracket failed Reduce stress in bracket Single load case
Courtesy TECOSIM GmbH, Ruesselsheim


Topology Optimization results

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Interpretation of OSSmooth results in CAD

Original Design
Optimized Design
Max. v. Mises Stress
Max. Displ.
Mass

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Topology Optimization Example: Bulkhead Stiffeners
Task: Stiffening of a bulk head using ribs 2 load cases Hydrostatic load (fuel) Take-off Pressure load on blue part Clamped perimeter
Design space
2 man holes

Topology Results
Optimization between sheet thickness and rib hight
Stiffening
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Original layout
Max. Deflection: 100%
Optimized design
Max. Deflection: 85%
Exercise 2.2 : Design Concept for an Automotive Control Arm
Define three different load cases Define responses for volume and nodal displacements Set design constraints on nodal displacements for each load case Define the objective function: min(vol)
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Exercise 2.3 : Increasing Natural freq. of an Auto Splash Shield
Setup the normal modes analysis in HyperMesh Run the analysis and postprocess in HyperView Define the optimization problem Run the optimization and post-process Setup the final modes analysis in HyperMesh Run the analysis and postprocess in HyperView
Exercise 2.4: Sym. and Draw Dir. Constraints in a Top. Opt.
Set up the FE model in HyperMesh Define the symmetry and draw direction control parameters for optimization Submit the check job to OptiStruct Post-process the results
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Topology Optimization with stress Constraints

Global von mises stress constraints Apply to entire model including non design space The reason is that it often creates an ill-posed optimization problem as elimination of the partial domain would remove all stress constraints This is for general stress level control Local stress should be taken care of by using shape/size Stress constraints for a partial domain of the structure are not allowed
Local stresses are still high
Stress < 50
Stress < 30
Topology Optimization with stress Constraints Common problem formulation when stress constraints are included
Minimize (total / regional) volume/ mass with stress constraints (displacement or frequency constraints can be combined)
Not recommended formulation

Minimize compliance with stress constraints + volume fraction
If the volume constraint is active, it prevents satisfaction of stress constraints !!

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Compliance Design : Load case 1 repeated 3 times

Stress Design: Load case 1 repeated 3 times
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Stress vs. Compliance Design

Set up in HyperMesh
Stress responses thru DRESP1 are for Size/Shape/Topology
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Exercise 2.5 : Topology Optimization of a Hook with Stress Constraints
Create design variable for topology optimization Create von mises stress constraints on DTPL card Create response Create the objective function: min(vol) Post-process the results
4 loading cases
Topology Optimization using Manufacturing Constraints
Manufacturing constraints for topology optimization helps generate practical design concepts Minimum member size control specifies the smallest dimension to be retained in topology design. Controls checker board effect and discreteness. Maximum member size control specifies the largest dimension allowed in the topology design. It prevents large formation of large members and large material concentrations are forced to more discrete forms. Pattern grouping / repetition can be applied to enforce a repeating pattern or symmetrical design even if the loads applied on the structure are unsymmetrical or non-repeating. Draw direction / extrusion constraints can be applied to obtain design suitable for casting or machining operations by preventing undercut or die-lock cavities.
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Manufacturing Constraints: Minimum Member Size Control

Input: approximate minimum diameter d in two dimensions Works in 2D and 3D Controls the size of small structural features Controls checkerboarding Easier interpretation of the resulting layout Higher computation cost
Without min member size Difficult to manufacture due to micro structures Results are mesh dependent
d= 60
d= 90
Manufacturing Constraints: Maximum Member Size Control
Definition of maximum allowable structural member size Eliminates material concentrations Mesh considerations Shell and solid elements Tetrahedral and hexhedral Min member > 3 X mesh size Max member > 2 X min size
Without Maximum Member size
With Maximum Member size

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Manufacturing Constraints: Pattern Repetition

Cyclic Repetition
Symmetry definitions Cyclic repetition of design features within a single domain User enters # of wedges Application: Cyclic structures with non symmetrical loadcases
Pattern Repetition
Application example: Airplane Wing Ribs
Goal: same topology on every rib Scaling factor to account for different sizes of design space
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Pattern Repetition
Application example: Airplane Wing Ribs
Without pattern repetition
With pattern repetition
Draw Direction Constraint

Define global casting direction Eliminates undercuts in design proposal Reduces interpretation effort Important if part shall be manufactured by Casting Injection molding Milling Draw type options Single Split
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Example: Determine Optimum Stiffeners in Torsion Loaded U-Profile
Initial Structure
Optimization Results
Without Draw Direction
Optimization Model With Draw Direction

Example: Optimum Rib Pattern of a Control Arm
Without Draw Direction

With Draw Direction

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Extrusion Constraint
Manufacturing control for constant cross sections
Package space
Design proposal without extrusion constraint
Design proposal with extrusion constraints
Combination of Manufacturing Constraints
Member Size Draw Direction Pattern Repetition Pattern Grouping Extrusion Constraint
Pattern Grouping (Symmetry)
Draw Direction
Any combination of manufacturing constraints is possible

Symmetry Draw Direction

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Applications of Topology Optimization

Determination of Optimum Rib Patterns for Reinforcement
Non design space represents general geometry concept Design space defines areas where ribs shall be introduced Manufacturing constraints crucial
Draw direction Minimum & maximum member size
Exercise 2.6: Topology Optimization with Extrusion Constraints
The use of HyperMesh to setup extrusion constraints The set up the design optimization problem responses, objective and constraints An examination of the results
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Common Topology Optimization Problems

Minimize (weighted / total / regional) compliance with constrained (total / regional) volume / mass fraction Minimize (total / regional) volume/ mass fraction with constrained displacements Maximize (weighted) frequency with constrained (total / regional) volume / mass fraction Minimize (total / regional) volume / mass fraction with constrained frequencies Minimize combined compliance and frequencies with constrained (total / regional) volume / mass fraction Minimize (total / regional) volume/ mass fraction with stress constraints
Additional Optimization Considerations

Constraint Screening (DSCREEN) Screening - specify normalized threshold value
Temporarily ignores constraints which are less than the normalized threshold value during optimization
Regionalization - specify maximum number of constraints to be retained for a given region

Considers user specified number of most violated constraints for each load case and region id.
Essential in situations where there are many constraints

E.g. Stress constraints for shape/size optimization.
If too many constrained responses are screened, it may take considerably longer to reach a converged solution or, in the worst case, it may not be able to converge on a solution if the number of retained responses is less than the number of active constraints for the given problem.
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Free-Size Optimization
Topology optimization
Free size optimization
Design space = Total Base Thickness Design variable Density Poor bending representation of semi-dense elements Truss-like design concepts, no Total Base shear panels thickness thickness
Design variables - Thickness of each element Accurate bending representation Expandable to composites Shear panels possible if they Thickness represent the best concept
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Topology
Optimum mass
5,50 5,00 4,50 4,00 3,50 3,00 2,50 2,00 1,50 1,00 1 1,5 2 2,5 3 3,5 4 4,5 5
Truss Concept Plate Concept
Maximum dispacement
Free-Size
Concept by topology and Free-Size Followed by sizing with buckling and stress constraints in sizing
The solution will be discrete when it needs to be so as the optimum design
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Free-Size Optimization on PCOMP

Composite Free-Size Optimization
Each Ply within Each Element has Thickness Design Variable (PCOMP) Stiffness Effected by Laminate Family and Element Thickness in Optimization
45 90 PCOMP -45 0 sym T = Ply2 (nom) T = Ply1 (nom) 0 T = Ply1 (opti) T_0 After Optimization T = Ply4 (nom) T = Ply3 (nom) PCOMP -45 T = Ply2 (opti) T_Total 45 T = Lower T = Upper 90 T = Ply3 (opti) T = Ply4 (opti)
sym Laminate Family [T_0/T_Total, T_+-45/T_Total, T_90/T_Total]
Exercise 2.7 : Free-Size nonlinear gap optimization on Airplane wing rib
Create design variable for FreeSize optimization Define optimization responses, objective and constraints Run the same model with topology optimization Compare the results
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Chapter 3: Topography Optimization
Topography Optimization
Search for optimal distribution of beads (swages) in shell structures Conceptual design method
Plate under torsion
Design variable generation
Final Design
Final contour
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Molded Pressure Tank

Thin walled tank filled with fluid to be optimized for stiffness

Symmetry
Three orthogonal planes of symmetry are defined
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Results
Reinforcement pattern for pressure box
CONTOUR
FINAL RESULT

Performance
Max. Deflect: 7.54mm
Max. Deflect: 10.8mm
Max. Deflect: 13.9 mm
Notice that more ribs doesnt necessarily mean more stiffness

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Topography Optimization
Torsion Plate Example
Max. Deflection: 2.23 Max. Stress: 267
Topography Optimization Max. Deflection: 1.17 Max. Stress: 196


OptiStruct Input: Topography Optimization

DTPG card Design Variable definition for topography optimization Definition of Design Variables
Nodal movement (shape change) on shell component Each iteration generates new nodal positions Shell, and composite properties (components) can be defined as topography design space.
Shells Composites Pattern grouping
HyperMesh Topology panel:
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Topography Optimization Setup

Bead Parameters
Min. Bead width Max. Bead height
normal
global
Draw angle

Pattern Grouping
linear planar symmetry radial Circular Cyclical
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Bounds Beads into one direction Beads into two directions Initial Bead fraction
Bead discreteness control

Beadfrac response
Used as objective or constraint More discrete results will be achieved with lower beadfrac
More discrete results

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Combining Optimization Types

Optimization types can be combined Example: Topology + Topography
Topography
Shape Contour
Topology + Topography Topology
Exercise 3.1 : Topography Optimization of a Torsion Plate
Create design variable for topography optimization Define optimization responses, objective and constraints Run the optimization Post-Process the results
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Altair OptiStruct
Size and Shape Optimization training
Optimization Disciplines
Shape optimization Find optimum shape of given part
Size Shape
Size optimization Method to obtain optimum dimensions of structural parts
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Chapter 1: Size Optimization
Size Optimization
Properties are easily sizable
Shell Thickness, Beam Sections Masses, Spring Stiffness
Element (Shells and Beams) properties are a function of design variables Gauge Optimization
Simplified size optimization Shell thickness t = DV
p = C0 + C j DV j or
j
p = f (DV j ,C j )
Gauge panel in HyperMesh easy setup of thickness optimization for many components p - Element property C j - Constant
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Size Optimization
DESVAR
Design variable
DVPREL1
Simple Design Variable to Property RELationship Element property is linear combination of design variables
DVPREL2
User-defined function Design Variable to Property RELationship Defines properties as function of design variables, and table entries
Example: Moment of Inertia for a rectangular beam
bh 3 I (b, h) = 12
Where b and h are beam dimensions

Size Optimization
Example : Define Shell Thickness of Component ID 5 as a Size Variable. Initial Thickness: 1.0mm Thickness Range: 1.0 - 2.5
PID MID1 T MID2 12I/T3 MID3 TS/T NSM
PSHELL 5
204
ID
1.0
LABEL XINIT XLB XUB DELXV
DESVAR
1
ID
DV001 1.0
TYPE COEF1 PID DVID2
1.0
FID
2.5
C0
DVPREL1
88
DVID1
PSHELL 5 1
4
COEF2 Etc
0.0
1
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Size Optimization
Definition of Design Variables
Definition of initial value, lower bound, upper bound PROD (area) PBAR,PBEAM (Area, Moment of Inertia, etc.) PBARL,PBEAML (height, width, etc.) PELAS (stiffness) CONM (mass) PSHELL (thickness, etc.)
Size Optimization
Build relationship between design variables and properties
PROD (area) PBAR,PBEAM (Area, Moment of Inertia, etc.) PBARL,PBEAML (height, width, etc.) PELAS (stiffness) CONM2 (mass) PSHELL (thickness, etc.)
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Size Optimization
Build relationship between design variables and properties using functions
A = f (b,h) = b*h I1 = f (b,h) = 1/12*b*h^3 I2 = f (b,h) = 1/12*b^3*h J = f (b,h) = ...
Exercise 1.1: 3-D Size Optimization of a Rail Joint
Setting up the optimization problem in HyperMesh Submitting the job Post processing results in HyperView
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Exercise 1.2: 3-D Composite Optimization using OptiStruct Retrieving the HyperMesh database file Setting up the problem in HyperMesh Submitting the job Viewing the results
Chapter 2: Shape Optimization
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Shape Optimization
Modify geometry to achieve objective
Fillet Radii Rib Height Channel Depth / Width Solid Cross Sections
Shape Optimization
Initial design
Final design
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Shape Optimization
Single nodal movement due to single shape variable
x
x=x(0)+x x(0)
Original location:
( ( ( ( X (0) = { x10 ) , x20 ) x30) ,L, xn0) }
Perturbations (DVGRID): X = { x1 , x2 , x3 ,L, xn } Magnitude of perturbations (DESVAR): Mesh nodal movement:

n
= {1 , 2 ,3 ,L,n }
X = X ( 0 ) + j X j
j =1
Shape Optimization
DESVAR
Design variable Card Image
ID LABEL XINIT XLB XUB DELXV
DESVAR 1
DV001
0.0
-1.0
1.0
DVGRID
Unit mesh perturbations Total perturbation due to a single design variable is DESVAR * DVGRID Card Image
DVID GID CID COEFF X Y Z
DVGRID 1
1032
1.0
1.0
0.0
0.0
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Shape Optimization
Defining Shapes in HyperMesh
Shapes need to be defined first

Mesh morphing (HyperMorph) Perturbations
Define shapes
Mesh topology must be maintained Shapes are then assigned to design variables Perturbations are exported with the OptiStruct input deck
Assign DESVAR
Auto-generate DVGRID
Introduction to HyperMorph
What is HyperMorph
Mesh morphing module in HyperMesh. Allows you to morph an FE model in useful, logical, and intuitive ways which result in minimal element distortion.
Why use HyperMorph

Only nodal location is changed; node id, element id and any association such as contact groups remain unchanged Provides a quick and easy means of generating DVGRID card for shape optimization
Where can you find HyperMorph

HyperMorph is in HyperMesh Tool page HyperMorph panel Within the Analysis page HyperMorph From the top menu bar. Tools HyperMorph
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HyperMorph Tools
Morph constraints: Create/update/release constraints to morph a CAE model. Systems: Create, edit and update system Symmetry: Create, edit and update symmetry. Update domains/handles to symmetry Shapes: Create/apply/autoshape/convert shape into loads/save shape/apply the saved shape to another model. Morph Volume: Create/edit & update/save & export-import/convert HEXA into morph volume Domains: Create/edit/update domains and setup parameters Handles: Create/edit/update handles and dependency or save-to load-from a file Morph: morph the model and create shape entities. Map to geom: map domains and handles to geometric data. Freehand: Easy way of morphing. Good for quick change and bead creation.
HyperMorph 9.0: Highlights

Morph volumes:
A brand new highly flexible approach to morphing that enables rapid setup and morphing of complex FEA models with enforced tangency.
Freehand morphing
Enables direct morphing of the mesh without any morphing entities. Provides the ability to insert beads by mesh sculpting via tools with regular or arbitrary cross-sections.
Section morphing:
Enables rapid shape changes by mapping to profile lines corresponding to new design cross-sections.
Large domain solver:

Enables efficient morphing of very large 2D and 3D models by morphing edge domains followed by a final updating of the internal domains.
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HyperMorph 9.0: Highlights

Coupling of morphing and mesh smoothing followed by quality index (QI) based re-meshing in order to enforce mesh criteria for specific CAE applications. New constraints:
Limiting constraints to prevent mesh penetration Cluster constraints to manage rigid elements Model constraints to enforce length, area, volume, etc. All constraints can now be saved with model
Enhanced shapes capabilities:

Translate, position, reflect, animate shapes Convert node movements in any HM panel to shapes Covert loads to shapes and vice versa Portability of shapes between dissimilar meshes
Use of existing geometry for improved partitioning of local domains

HyperMorph Applications
Rapidly change shape of existing model Fit old model to new design data Map an existing mesh onto lines, surfaces, map to section etc Generate NURB surfaces using FE -> Surf feature in HyperMesh Generate and edit shape variables for optimization
Morphing example: Dart to a X-29 supersonic jet Before After
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HyperMorph Applications (MorphVolume)
Before
After
HyperMorph Applications (Bead insertion with Freehand)
Before
After
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HyperMorph Applications (Map to Geometry)
Before
After
Morphing with Domain and Handle
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Domain: a grouping of elements and nodes that are influenced together during morphing Global domain: a single domain which can influence every node in the model. Local domains: include1D domain, 2D domain, 3D domain and edge domain. A model can have multiple local domains for morphing example of local domain differentexampleareas. domain local of global
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Handle: control point used to alter the shape of a domain Handle Influence: describes how the movement of a handle relates to the nodes in the domain Global Handle: Handles affecting the global domain. Movement of a global handle affects every node within a model, allowing large scale shape changes Local Handle: Handle affecting local domains. Local handles can only influence the nodes contained within the domains they are associated with Types of Morphing:

Partitioning: Division of a 2-D morphing domain into smaller 2-D domains based on feature angle as specified by the angle and curve tolerance Domain Angle: The angle between the normals of 2 adjacent elements. When the value is exceeded, a partition break will be created with an edge between the two elements Curve Tolerance: A parameter used to determine if a mesh is curved or planar. Similar to the domain angle, a partition break will be created if the value is exceeded
Without partitioning partitioning

With
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Alter Dimensions / Radius and Curvature: Change the radius or curvatures of edge domains
Curvature is a scalar applied to the radius for edge domains with varying curvature Options control changes with respect to curve center, ends or midpoint
Shape definition for Optimization

Using HyperMorph
Set up the model for morphing
Use any of the four morphing methods Morph the model to the desired shape. Save the shape Undo the shape Save the HyperMesh session file. Create a desvar (design variable) Run Optimization.
Morph
Save shape
Undo morph
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Exercise 2.1 : Using HyperMorph to Create Shape Variables
Load the model Generate the Morph entities Edit Domains Modify the model using Morph.
Exercise 2.2 : Using Morph Volumes

Create Morph Volumes Edit the Morph Volumes Morph the Model global handles.
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Exercise 2.3 : Mapping a mesh to a new geometry Practice the morphing process:
Using HyperMorph to modify an existing model based on a new geometry
Exercise 2.4 : Creating Shapes Practice the morphing process:

Create a Shape Create a Design Variable with this shape
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Exercise 2.5 : Pre-processing the Shape Optimization of a Channel
Smooth edge Vary the radio of surface fillet Modify channel depth Modify channel width
Morphing Example: Shock Absorber Bracket
Radius to optimize
Shock Absorber
Stabilizer Bracket
Courtesy
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Morphing Example: Shock Absorber Bracket Initial Stress Distribution
Morphing Example: Shock Absorber Bracket Shape Variables
11 Design variables [-1...0.5]
Problem Statement
Objective: Min (Max Stress) Design variables: Grid points of domains
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Morphing Example: Shock Absorber Bracket Results

Initial
Final
Reduced maximum stress by 17 %

Morphing Example: Shock Absorber Bracket Optimized Shape

Initial Final
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Exercise 2.6 : Shape optimization of a Rail Joint

Run a baseline analysis Create shape changes using HyperMorph Create design variables from the shapes Define responses and objective Solve and post-process
Free Shape Optimization
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No user-defined shape perturbation vector is necessary
Reduce the effort to guess what would be the optimum shape
Free Shape optimization uses a proprietary optimization technique developed by Altair, wherein the outer boundary of a structure is altered to meet with pre-defined objectives and constraints Can be combined with any type of optimization e.g. w/ morphing based shape optimization
Optimum ?

DSHAPE card Format
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10)
DSHAPE
ID PERT DTYPE MVFACTOR NSMOOTH GRID GID1 GID8 GID2 GID9 GID3 . GID4 GID5 GID6 . GID7
Optional continuation line for grid constraints

(1) (2) (3) (4) (5) (6) (7) (8) (9)
GRIDCON GDID1 GDID2 .
CTYPE1 CTYPE2 ..
CID1 CID2
X1 X2
Y1 Y2
Z1 Z2
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DTYPE
BOTH (default)
Undeformed Deformed
GROW
SHRINK
NOTE : Its better to use BOTH, unless you are

required to constrain the design boundary to grow or shrink
(a) NSMOOTH = 5 Larger NSMOOTH
(b) NSMOOTH = 1
better in avoiding element distortion BUT slower;
NSMOOTH can be larger than the number of available layers. e.g., NSMOOTH = 100 will work fine in the above example.
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Free Shape optimization
Objective :
Minimize compliance
Subject to:
Volume < 4000.00
DSHAPE 2
DSHAPE 1
Select Free Shape design grids

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Move only on X-Z plane fix the height of the beam section
ITER 0 :
Compliance = 4.103E+00 Volume = 6.480E+03

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ITER 26 :
Compliance = 3.368E+00 Volume=3.994E+03 0.00%
Objective -17.91%, Max. constraint violation 62.00%

Example 2: shape change history
Shape history of the solid beam example
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Exercise 2.7 : Shape optimization of a 3-D bracket using Free-Shape
Create design variables for Free-Shape (DSHAPE) Define responses and objective, constraints Solve and post-process w/o GRIDCON Create GRIDCON Solve and post-process
72

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Altair Proprietary and Confidential Information

Copyright 2008 Altair Engineering, Inc. All rights reserved.

WHAT IS ALTAIR HYPERWORKS?

HyperView HyperWeb HyperView Player

HyperForm MotionView Altair Proprietary and Confidential Information MotionSolve

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Altair Proprietary and Confidential Information

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Free Size: is a mathematical technique that produces an optimized thickness

Topography: Topography optimization is an advanced form of shape optimization

Shape: is an automated way to modify the structure shape based on a predefined

Size: is an automated way to modify the structure parameters (Thickness, 1D

Altair Proprietary and Confidential Information

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Structural Optimization Concepts

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Optimization Problem Example

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Optimization Problem Example

All beam elements

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Optimization Problem Example

Beam height, h (mm)

Beam width, b (mm)

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Interpreting the Results

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Interpreting the results

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How Structural Optimization Cuts Development Time

Problem: minimum knowledge, but maximum freedom

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Optimization in Practice: Altair Bus

System Level Requirements (Loads analysis and packaging)

Package Space and Loads

Structural Design Altair-Bus

Final Design Size and Shape Optimization

Parametric Shape Vectors

Finite Element Modeling

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OptiStruct vs. HyperStudy: When to Use Which Tool?

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OptiStruct Features: Input decks

OptiStruct Features: Results

Output Result Formats

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OptiStruct Features: Optimization Responses

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OptiStruct Input - optimization

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Where x1, x2 are nodal displacements