HTC2012 HyperStudy Training

Model Calibration using Altair HyperStudy Fatma Koer Altair Engineering May, 2012
Innovation Intelligence
Copyright 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
HyperStudy is:
Solver Neutral Design of Experiment, Multi-Disciplinary Optimization and Stochastic Simulation Engine. Automates processes for parametric study, optimization and robustness assessment Integrated with HyperWorks thru HyperMesh, MotionView and direct solver interfaces
HyperStudy: Business Benefits
Design high-performance products Reduce cost and development cycle Increase the return on CAE investments Cost effective and innovative licensing model
HyperStudy: User Benefits
Streamlined design exploration, study and optimization process Solver-neutral, multi-disciplinary Advanced data-mining capabilities State-of-the-art optimization engine HyperWorks integration: Morphing, Direct parametrization, Results Readers
Unilever Corp. (UK) Optimal Comfort Softener Bottle Design

Challenge: Increase collapse load and stiffness of a softener bottle while minimizing the mass Solution: DOE to screen design variables: Fractional Factorial Method 7 design variables are selected DOE to create Approximate Model: Box Behnken Method Optimization using the Approximate Model: ARSM Results: Buckling capacity increased over 20% Mass reduced over 5%
HyperStudy provides potential for reducing design cycle times, through facilitating definition of strong design concepts early in the design process, which require fewer down-stream modifications. Richard McNabb, Design Analysis and Technology Manager, Lever Faberg, Unilever Corporation
Capabilities Overview
Next Generation
UserCalilbration Interface Model
HyperStudy: Architecture Schema
Model Variant Variant Variant Variant Variant Simulation Simulation Simulation Simulation Simulation Results Results Results Results Results
Creation
Study Engine:
DOE Fit Optimization Stochastics
Job Management
Extraction
Study Results Optimal parameters Sensitivities Model Robustness
HyperStudy: Study Types
DOE
Approximation
Optimization
Stochastic
Parameters Screening System Performance Study Response Surface Evaluation Optimum Design Variation Analysis Robust Design Reliability Design
HyperStudy: Key Differentiators
Shape Optimization
Seamless integration with HyperMorph
Direct Parameterization
Automatic transfer of modal parameters from HyperMesh, MotionView, HyperForm
Direct Results Access

Direct result access to most Solvers: Abaqus, Ansys, Madymo, etc.
Data Mining
Correlations, SnakeView, PCA, RDA, etc.
Technology
State-of-the-art exploration, approximation and optimization methods
Next Generation HyperStudy
Next Generation
UserCalilbration Interface Model
Next Generation HyperStudy

Differentiators of HyperStudy are kept tree-based process navigation in the study pages Changes in user interface data in tables extended edition features dedicated wizards Enhanced Task Management orchestration live monitoring and control Improved Post-Processing multiple plots richer charting Reporting messaging study report
Model Calibration using HyperStudy
Next Generation
User Calibration Interface Model
Background
We need to model 6063 T7 Aluminum material in Radioss for the first time. 6063 T7 Aluminum has an isotropic elastic-plastic behavior which can be reproduced by a JohnsonCook model without damage as:
In Radioss Johnson-Cook model can be defined using the Law2 material card as:
Background
In this card, we do not know the values for five material properties: Youngs modulus, yield stress (a), hardening modulus (b), hardening exponent (n) , and maximum stress.
We have strain-stress curve from tensile testing of a a 6063 T7 Aluminum sample
Our objective is to find the five material property values of Radioss Law2 card such that Radioss simulation of the tensile test gives the same curve as the test. Then we can be confident in our material model for further simulations.
Background
We can model the tensile testing in Radioss as a quarter of a standard tensile test and using symmetry conditions. A traction is applied to the specimen via an imposed velocity at the left-end.
Thickness = 2.0 mm
We can then calculate the engineering strains are by dividing the node 1 displacement by the reference length (75 mm), and engineering stresses by dividing the section 1 force by its initial surface (12 mm2). Node 1 (displacement)
Section 1 (force)
Results from the Initial Radioss Simulation

Radioss simulation with initial guesses of Youngs modulus, yield stress (a), hardening modulus (b), hardening exponent (n) , and maximum stress values of 60400 MPa, 110 MPa, 120 MPa, 0.15, 280 MPa leads to significant differences between the test and simulation results as seen below
Objective
The objective is to find the values for the five material properties so that the simulation results match to tensile test results. We can achieve this if we minimized (ideally zero): 1. difference between Radioss and experimental stress (141MPa) at Strain equal 0.02 2. difference between Radioss and experimental stress (148MPa) at Necking point 3. difference between Radioss and experimental strain (0.08) at Necking point
Method
We will use optimization to achieve this objective. We will use a special optimization problem formulation called System Identification. System identification minimizes the sum of normalized error-squared. Error is the difference between the target values and simulation results.
f i Ti min T i
where fi(x) is the ith response obtained from analysis, Ti are the target value for the ith response. Note that, in HyperStudy we do not need to enter this equation manually. We can simply enter the target values for each response and use the System Identification objective.
Problem Formulation
where
Demonstration
DOE Results
32 Design Full Factorial
Youngs Modulus and SigMax are not significant so we will continue our study with three design variables.
First Optimization Results

Adaptive Response Surface Method (ARSM) is used for this case. In 5 iterations, we minimized the system identification objective function value from 0.158 to 0.06. In the optimum design, the DV values are: 99, 132, 0.165 The response values are: 140, 146, 0.06 (note that the targets were 141, 148 and 0.08; initial design values were 147, 150, 0.05)
We observe that all three design variables are at their lower or upper bounds. If we can relax those bounds; we may be able to get closer to the target values. We started a new optimization from the best result of the first optimization and with relaxed bounds.
Second Optimization Results

ARSM is used for this case. In 10 iterations, we minimized the system identification objective function value from 0.06 to 0.0. In the optimum design, the DV values are: 93, 157, 0.2. The response values are: 140, 149, 0.08 (note that the targets were 141, 148 and 0.08)
First two objectives are off by 1.0 from the target and last one is on target
Results
Initial Variables E a b n Sigma Responses Obj1 Obj2 Obj3 147 (Target 141) 150 (Target 148) 0.05 (Target 0.08) 140 146 0.06 140 149 0.08 60400 110 120 0.15 280 60400 99 (99-121) 132 (108-132) 0.165 (0.135-0.165) 280 60400 93 (50-150) 157 (100-200) 0.19 (0.1-0.3) 280 Opt 1 Opt 2
Results
Radioss results for the Initial Design vs. Test Results: There are significant differences between the two curves.
Radioss results for the Optimum Design vs. Test Results: The two curves are almost identical.
Conclusions
HyperStudy provides a user friendly GUI to easily set up design studies including system identification. Design Study methods in HyperStudy are efficient and effective in meeting design targets. HyperStudy is solver independent and can also work with applications running other solvers such as LS-Dyna, Abaqus, Ansys, Adams, etc.
Altair HyperStudy
Altair HyperStudy is a user-level, solver neutral, multi-disciplinary, exploration, study and optimization tool, helping engineers to design high-performance products, reduce cost and development cycle, increase the return on CAE investments with advanced optimization and data mining capabilities.
HyperStudy enabled us to efficiently implement DOE and optimization methods. The new automated process is able to cover different types of applications and can be used in various projects. Besides the technical advantages and the saved development time, Magna benefits from being an HyperWorks Partner Alliance member and therefore can use the needed software at no additional costs. Werner Reinalter, Teamleader, MBS Simulation, Magna Steyr

HTC2012 HyperStudy Training

Uploaded by

Document Information

Original Description:

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

HTC2012 HyperStudy Training

Uploaded by

Copyright:

Available Formats

Model Calibration using Altair HyperStudy Fatma Koer Altair Engineering May, 2012

HyperStudy: Business Benefits

HyperStudy: User Benefits

Unilever Corp. (UK) Optimal Comfort Softener Bottle Design

UserCalilbration Interface Model

HyperStudy: Architecture Schema

Study Results Optimal parameters Sensitivities Model Robustness

HyperStudy: Study Types

HyperStudy: Key Differentiators

Direct Results Access

Next Generation HyperStudy

UserCalilbration Interface Model

Next Generation HyperStudy

Model Calibration using HyperStudy

User Calibration Interface Model

We have strain-stress curve from tensile testing of a a 6063 T7 Aluminum sample

Results from the Initial Radioss Simulation

First Optimization Results

Second Optimization Results

You might also like