Webinar

Optimizing Sheet Metal Structures g g from Design to Manufacturing with Altair Hyperworks
November 29, 2007 Fatma Kocer, Pradeep Srinivasan, , p , Altair Engineering

Agenda:

Challenges: Design f h t D i of sheet metal structures that t l t t th t • meet design requirements, • are not overweight, • are manufacturable f t bl in an

Solutions: • Concept Design and Optimization • Formability Analysis and Optimization • Mapping Forming Effects to Structural Model

• • • • •
platform

integrated, easy-to-use, robust, flexible open

Altair HyperWorks: integrated, easy-to-use, robust, flexible open

Copyright © 2006 Altair Engineering, Inc. All rights reserved.

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Hyperworks: A Platform to Design for Manufacturability

Design Optimization Altair Optistruct

Formability Simulation Altair HyperForm yp

Optimization of Formability Altair HyperStudy

Mapping Forming Effects to Structural Model HyperWorks Results Mapper
Copyright © 2006 Altair Engineering, Inc. All rights reserved.

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Concept Design and Optimization in HyperWorks for Sheet Metal Structures

Determination of optimal p p principal material distribution p

Determination of optimal bead patterns for shell structures

Determination of optimal shape of a given design

Determination of optimal model parameters

Copyright © 2006 Altair Engineering, Inc. All rights reserved.

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Topography Optimization Process

Definition of desired bead dimensions and optimization targets

OptiStruct proposal of optimized bead pattern

Interpretation of proposed bead pattern

Copyright © 2006 Altair Engineering, Inc. All rights reserved.

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Topography Optimization: Oil Pan

Initial Design

Altair OptiStruct

Optimized Design

Design Problem: Increase first mode from 60Hz to at least 200Hz

Copyright © 2006 Altair Engineering, Inc. All rights reserved.

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Cutting Harvester Maintenance Costs at CLAAS

Challenge

• Design an easy-to-disassemble harvester easy to disassemble
reel hub • Goal: bolted, two-component design • Innovative bead pattern needed to meet p stiffness requirements

Solution

• OptiStruct topography optimization to create
optimized bead pattern

Results

• Time to repair assembly significantly reduced • Cut in production costs: no welding needed
“OptiStruct’s topography optimization has become an integral part of our design process to find innovative p p bead patterns in sheet metal components.”
Stephan Diekhaus CAE Manager CLAAS GmbH, Germany
Copyright © 2006 Altair Engineering, Inc. All rights reserved.

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Bead Optimization of a Muffler Housing Cap

Design Problem
Increase Eigenfrequencies of a housing cap by introducing a bead pattern Target: Mode 1 > 255 Hz Baseline: Mode 1 = 63 Hz

Method Used
Shape optimization to find the optimum curvature Topography optimization to find the optimum bead pattern Combination of both disciplines

Copyright © 2006 Altair Engineering, Inc. All rights reserved.

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Bead Optimization of a Muffler Housing Cap

Optimized curvature

Topography optimization

Combined bead and shape optimization

313 Hz Target 184 Hz Base Base Target 217 Hz Target

Base

Copyright © 2006 Altair Engineering, Inc. All rights reserved.

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Topography Optimization Results
Problem Formulation: Maximize the first 10 frequencies q subjected to circular pattern constraints
Baseline Design

OptiStruct Proposal

Modes (hz) 1 2 3 4 5

Baseline 29 77 138 138 194

Optimum 50 196 265 267 313

Optimum Design
Copyright © 2006 Altair Engineering, Inc. All rights reserved.

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Formability for Initial Manufacturing Feasibility
Initial Model From Optimization Design Modification for Formability

Copyright © 2006 Altair Engineering, Inc. All rights reserved.

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Optimizing Formability

Copyright © 2006 Altair Engineering, Inc. All rights reserved.

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Results

Modes (hz)

Baseline

Optimum

Formed Part

1 2 3 4 5

29 77 138 138 194

50 196 265 267 313

51 169 233 237 297

The weighted frequency of the first 10 modes has improved by 43%

Copyright © 2006 Altair Engineering, Inc. All rights reserved.

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What does it take? HyperWorks Unit Chart

You only need 50 HyperWorks units to optimize sheet metal structures from design to manufacturing

Copyright © 2006 Altair Engineering, Inc. All rights reserved.

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Summary

Optimizing sheet metal structures from design to manufacturing can entirely be done with HyperWorks HyperWorks improves productivity through innovative methods such as concept design, optimization, and morphing. Third party solutions can be easily integrated with HyperWorks through its powerful interface system.

Copyright © 2006 Altair Engineering, Inc. All rights reserved.

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