OptiStruct 12.0 Tutorials PDF

OptiStruct 12.
0
Tutorials
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OptiStruct 12.0 Tutorials
OptiStruct
........................................................................................................................................... 1
Topology Optimization
............................................................................................................................................... 2
OS-2000: Design Concept for a Structural C-clip
................................................................................................................................... 3
OS-2005: Design Concept for a Structural C-clip with Minimum Member Size
Control................................................................................................................................... 18
OS-2010: Design Concept for an Automotive Control Arm
................................................................................................................................... 22
OS-2020: Increasing Natural Frequencies of an Automotive Splash Shield with
Ribs ................................................................................................................................... 37
OS-2030: Control Arm Topology Optimization with Draw Direction Constraints
................................................................................................................................... 53
OS-2040: Spot Weld Reduction using CWELD and 1-D Topology Optimization
................................................................................................................................... 62
OS-2050: Pattern Repetition using Topology Optimization
................................................................................................................................... 67
OS-2060: Symmetry and Draw Direction Applied Simultaneously in Topology
Optimization
................................................................................................................................... 77
OS-2070: Topology Optimization of a Reduced Model using DMIG
................................................................................................................................... 84
OS-2080: Topology Optimization of a Hook with Stress Constraints
................................................................................................................................... 98
OS-2090: Topology Optimization with Extrusion Constraints
................................................................................................................................... 106
OS-2095: Frequency Response Optimization of a Rectangular Plate
................................................................................................................................... 113
OS-2098: Topology Optimization of an Excavator Arm Model
................................................................................................................................... 134
Topography Optimization
............................................................................................................................................... 142
OS-3000: Topography Optimization of a Plate Under Torsion
................................................................................................................................... 143
OS-3010: Topography Optimization of an L-bracket
................................................................................................................................... 155
OS-3020: Automatic Recognition of Bead Results from Topography Optimization of
an L-bracket
................................................................................................................................... 164
OS-3030: Random Response Optimization
................................................................................................................................... 170
Combination Optimization
............................................................................................................................................... 177
OS-3100: Combined Topology and Topography Optimization of a Slider
Suspension
................................................................................................................................... 178
OS-3200: Optimization-driven Design of a Composite Aircraft Underbelly Fairing
................................................................................................................................... 186
Size Optimization
............................................................................................................................................... 207
OS-4000: 3-D Size Optimization of a Rail Joint
................................................................................................................................... 208
OS-4010: Size Optimization of a Welded Bracket
................................................................................................................................... 219
OS-4020: Composite Bike Frame Optimization
................................................................................................................................... 228
OS-4030: Discrete Size Optimization of a Welded Bracket
................................................................................................................................... 239
OS-4040: Size Optimization of a Shredder
................................................................................................................................... 248
OS-4050: Optimization of a Horizontal Tail Plane
................................................................................................................................... 261
OS-4070: Free-sizing Nonlinear Gap Optimization on an Airplane Wing Rib
................................................................................................................................... 292
OS-4080: Minimization of the Maximum Stress of a Rotating Bar: A Size
Optimization
................................................................................................................................... 303
Altair Engineering OptiStruct 12.0 Tutorials i
Proprietary Information of Altair Engineering

OS-4090: Manufacturing Constraints in a Free-size Optimization of a Composite
Structure
................................................................................................................................... 311
OS-4095: Size Optimization using External Responses (DRESP3) through
HyperMath
................................................................................................................................... 321
Shape Optimization
............................................................................................................................................... 328
OS-5000: 2-D Shape Optimization of a Cantilever Beam
................................................................................................................................... 329
OS-5010: Cantilever L-beam Shape Optimization
................................................................................................................................... 340
OS-5020: Shape Optimization of a 3-D Bracket Model using the Free-shape
Method
................................................................................................................................... 349
OS-5030: Buckling Optimization of a Structural Rail
................................................................................................................................... 362
OS-5040: Shape Optimization of a Rail Joint
................................................................................................................................... 373
OS-5050: Shape Optimization of a 4 Bar Linkage
................................................................................................................................... 393
OS-5060: Shape Optimization of a 3-D Model using the Free-shape Method with
Manufacturing Constraints
................................................................................................................................... 406
OS-5070: Fatigue Optimization of a Torque Control Arm
................................................................................................................................... 414
OS-5080: Global Search Optimization
................................................................................................................................... 430
OS-5090: Thermal Optimization on Aluminum Fins
................................................................................................................................... 436
ii OptiStruct 12.0 Tutorials Altair Engineering

OptiStruct
Size Optimization
Shape Optimization
Altair Engineering OptiStruct 12.0 Tutorials 1

OS-2005: Design Concept for a Structural C-clip with Minimum Member Size Control
OS-2020: Increasing Natural Frequencies of an Automotive Splash Shield with Ribs
OS-2030: Control Arm Topology Optimization with Draw Direction Constraints
OS-2040: Spot Weld Reduction using CWELD and 1-D Topology Optimization
OS-2060: Symmetry and Draw Direction Applied Simultaneously in Topology Optimization
OS-2070: Topology Optimization of a Reduced Model using DMIG
OS-2080: Topology Optimization of a Hook with Stress Constraints
OS-2090: Topology Optimization with Extrusion Constraints
OS-2095: Frequency Response Optimization of a Rectangular Plate
OS-2098: Topology Optimization of an Excavator Arm Model
2 OptiStruct 12.0 Tutorials Altair Engineering

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 variables: The density of each element in the design space.
In this tutorial, you will:
Set up the model in HyperMesh
Analyze the baseline model
Set up 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 s ta rt menu.
The User Profiles dialog will appear by default.
2. Choose the O ptiStruct user profile by selecting the radio button beside it.
3. Click O K.
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 in Bulk Data Format for RADIOSS and OptiStruct.

Step 2: Open the cclip.hm File
1. From the File menu on the toolbar, select O pe n .
2. Select the cclip.hm file, located in the HyperWorks installation directory under
<install_directory>/tutorials/hwsolvers/optistruct/.
3. Click O pe n.
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.
1. Select the Model tab.
2. Right-click inside of the Model Browser window, activate the menu over Create, and
click M a te ria l.
When in this pop-up, do not press the ENTER key until you are done.
3. In the Name: field, type Steel.
4. Select M AT1 as Card image:.
5. Select the box for Card edit material upon creation and click C re a te .
The MAT1 card image opens.
6. For E, enter the value 2.1E5.
7. For Nu, enter the value 0.3.
8. For RHO, enter the value 7.9E-9.
9. Click re turn.
10. Right-click inside the Model Browser window, activate the menu over Create, and click
Pro pe rty .
11. In the Name: field, type prop_shell.
12. Select PSH E LL as the Card image:.
13. Select the Material tab and check the box for Assign material.
14. From the Name menu, select Ste e l as the material.
15. Select the Property tab and select the box for Card edit property upon creation, and
click C re a te .
The PSHELL card image appears. A new property has been created and the material
property (named Steel) is assigned to it. Look for the material ID under the MID1 field.

16. Activate the thickness field for the shell component by clicking [T].
This allows you to edit this field. Accept the default of 1.0.
17. Click re turn to go to the main menu.
18. To update the component collectors with the newly created properties, click on the
Components icon .
19. Select the update radio button and click on co m ps .
20. Check the box for comp_shell, and click s e le ct.
21. Toggle < no pro pe rty > to pro pe rty = .
22. Double-click on pro pe rty = and select pro p_s he ll.
23. Click upda te .
24. Click re turn.
Step 4: Create Load Collectors

Next we will create two load collectors (Constraints and Forces) and assign each a color.
Follow these steps for each load collector.
Lo a d C o lle cto r.
When in this popup, do not press ENTER on the keyboard until you are completely done.
2. In the Name: field, type Constraints.
3. Leave the Card image: field set to no ne .
4. Select a color from the palette.
5. Click C re a te .
6. Using the same method, create the second load collector, named Forces.
Step 5: Create Constraints

For the three nodes that show constraints in the following figure, we 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 C o ns tra ints , and click
on M a ke C urre nt.

2. From the Analysis page, enter the constraints panel.
3. Select nodes and corresponding dofs, and click on cre a te to create constraints, as shown
below.
Mesh showing the boundary conditions applied on the c-clip.
4. Click re turn.
Step 6: Create Forces

In this step, we 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, under (expanded) Load Collector, right-click on Fo rce s , and
click on M a ke C urre nt.
2. From Analysis page, enter the forces panel.
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 m a gnitude = , enter 100.0, and press E NTE R.
5. Set the switch below to y-axis.
6. Click cre a te .
An arrow, pointing up, should appear 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 m a gnitude = , type -100.0, and press E NTE R.
9. Verify that the y-axis is selected.
10. Click cre a te .
An arrow, pointing down, should appear at the node on the screen.
11. To provide a separation between the arrows, select uniform size=, type 7, and press

E NTE R.
12. Click re turn 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, enter the lo a ds te ps panel.
2. Click na m e = , type opposing forces, and press E NTE R.
3. Set type to line a r s ta tic.
4. Check the box preceding SPC.
An entry field appears to the right of SPC.
5. Click on the entry field and select C o ns tra ints from the list of load collectors.
6. Check the box preceding LOAD and select Fo rce s from the list of load collectors.
7. Click cre a te .
Analyze the Baseline Model
Step 8: Run the Analysis

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.
1. From the Analysis page, enter the R AD IO SS panel.
2. Click s a v e a s following the input file: field.
3. Select the directory where you would like to write the OptiStruct model file and enter the
name for the model, cclip.fem, in the File name: field.
.fem is the recommended extension for Bulk Data Format input decks.
4. Click Sa v e .
Note the name and location of the cclip.fem file displays in the input file: field.
5. Set the export options: toggle to a ll.
6. Click the run options: switch and select a na ly s is .
7. Set the memory options: toggle to m e m o ry de fa ult.

8. Set the options: field to blank.
9. Click R a dio s s .
Upon successful completion of the analysis, the message ANALYSIS COMPLETED will
appear in the command window.
Step 9: View Displacement Contour

1. From the RADIOSS panel, click on H y pe rVie w.
HyperView launches the cclip.mvw file which loads the model and the results files.
2. From the Results menu, click on Plo t and then click on C o nto ur.
3. Choose D is pla ce m e nt 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. Use the page delete button contained within the page control toolbar to delete the
HyperView page, as seen in the figure below.
7. Back in HyperMesh, click re turn 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, we need to track the
displacements (which represents 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, we 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, enter the o ptim iz a tio n panel.
2. Select to po lo gy .
3. Make sure the create subpanel is selected using the radio buttons on the left-hand side
of the panel.
4. Click de s v a r= , type d_shell, and press E NTE R.
5. Click pro ps and select pro p_s he ll from the list of props;
click s e le ct.
6. Choose type: PSH E LL.
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 cre a te .
9. Click re turn to go back to the optimization panel.
Step 11: Create a Volume Response

1. Enter the responses panel.
2. Click re s po ns e = and type volfrac.
3. Click the switch below response type switch and select v o lum e fra c from the pop-up
menu.
4. Click cre a te .
Step 12: Create a Displacement Response

To create a displacement as a response, you will need to supply a meaningful name for the

response, set the response type to dis pla ce m e nt, select the node for the response, and
select the type of displacement (dof).
1. Click re s po ns e s .
2. Click re s po ns e = and type upperdis.
3. Change the response type: to s ta tic dis pla ce m e nt.
4. Click the node labeled A (upper opening of the c-clip) as shown in the figure to select it.
5. Choose do f2 for the node.
6. Click cre a te .
7. Click re s po ns e = and type lowerdis.
8. The response type: should still be s ta tic dis pla ce m e nt.
9. Click the node labeled B (lower opening of the c-clip) as shown in the figure to select it.
10. Select do f2 and cre a te the response.
Step 13: Create Constraints on Displacement Responses

In this step we set the upper and lower bound constraint criteria for this analysis.
1. Select the dco ns tra ints panel.
2. Click co ns tra int= and enter c_upper.
3. Check the box for upper bound only.
4. Click uppe r bo und= and enter 0.07.
5. Select re s po ns e = and set it to uppe rdis .
6. Click lo a ds te ps .
7. Check the box next to opposing forces.
8. Click s e le ct.
9. Click cre a te .
10. Click co ns tra int= and enter c_lower.
11. Check the box for lower bound only.
12. Click lo we r bo und= and enter -0.07.
13. Select re s po ns e = and set it to lo we rdis .
15. Check the box next to opposing forces.
Step 14: Define the Objective Function

1. Click o bje ctiv e .
2. The switch on the left should be set to m in.
3. Click re s po ns e = and select v o lfra c.
4. Click cre a te .
5. Click re turn twice to exit the optimization panel.
Step 15: Run the Optimization Problem

1. From the Analysis page, click on co ntro l ca rds .
2. Click ne xt twice.
3. Click on SC R E E N and re turn.
This will make OptiStruct output the optimization iterations to the output window.

4. From the Analysis page, select O ptiStruct.
5. Click s a v e a s , enter cclip_complete.fem as the file name, and click Sa v e .
6. Click the run options: switch and select o ptim iz a tio n.
7. Click O ptiStruct 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. Close the OptiStruct solver GUI window.
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. HyperMesh command file used to organize elements into

comp.cmf 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, 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 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. The

user may edit the parameters in the file to obtain the desired
results.
cclip_complete_hist. Contains the iteration history of the objective, constraints,

mvw 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 the H y pe rVie w button.
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 D e s ign under the load case section and the la s t ite ra tio n listed.
4. From Results menu, click on Plo t > Is o .
5. In the panel area at the bottom of the GUI, choose Element Densities as the Result

type.
6. Set the Current Value: to 0.3.
7. Click on To p view orientation to set the correct view.
8. Click Apply .
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 on the Next Page arrow toolbar button 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 on the Top view orientation to set the correct view .

4. From the Results menu, select Plo t > C o nto ur.
5. Choose D is pla ce m e nt as the Result type, and set the menu below Displacement to Y .

6. Click Apply .
7. Click on the Deformed toolbar button .
8. On the Deformed shape panel, change the scale value to 100, the undeformed shape
to e dge s , and click Apply .
9. From Edit menu, click on C o py > W indo w, and then click on the empty window.
10. Again, from the Edit menu, click Pa s te > W indo w.
11. Switch the animation mode to Linear Static .
12. With the second window selected, choose Ite ra tio n 28.
13. From Edit menu, click C o py > Pa ge .
14. From the Edit menu again, click Pa s te > Pa ge .
This will create a third page on this report.
15. Now click on the first window and click on the Contour button .
16. Change the result type to E le m e nt Stre s s e s (2D & 3D ) (t).
17. For Averaging method:, select Sim ple and click Apply .
18. Click with the right button on the first window; choose Apply Sty le To , then C urre nt
Pa ge , and select C o nto ur.

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:
Importing the .fem file into HyperMesh
Setting up 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
1. Launch HyperMesh Desktop, choose the O ptiStruct user profile in the User Profiles
dialog, and click O K.
User Profiles can also be accessed from the Preferences menu on the toolbar.
2. Click the Import panel toolbar button .
The Import tab appears.
3. Set the Import type: to Im po rt FE M o de by clicking on the icon .
4. Set the File type: to O ptiStruct.
5. Use the file browser to select the cclip_complete.fem file, located in the HyperWorks
installation directory under <install_directory>/tutorials/hwsolvers/optistruct/
and click O pe n.

Notice that the location of the file is now displayed in the File: field.
6. Click Im po rt 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. Press F4 to bring up the distance panel.
2. Click the radio button to the left of two nodes to select it.
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 step 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.
6. Click re turn to go back to main menu.
7. Click Ana ly s is .
8. From the Analysis page, click o ptim iz a tio n.
9. Click to po lo gy .
10. Activate the parameters option.
11. Click re v ie w.
12. Select s he lls (1).
13. Click the toggle next to minmemb off to activate mindim= and set the value to 5.
14. Click upda te .
A minimum member size control has been applied on this topology optimization problem.
15. Click re turn twice to go back to Analysis page.
Step 3: Run the Optimization

2. Click s a v e a s , enter cclip_complete_min_member.fem as the file name, and click

Sa v e .
5. At the end of processing, close the OptiStruct solver GUI window.

6. Click re turn.
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

This will launch HyperView within HyperMesh Desktop and open 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 Plo t > Is o .
4. Choose E le m e nt D e ns itie s as the Result type.
5. Click Apply .
6. Set C urre nt v a lue : to 0.3.

Iso value plot of element densities.
7. Compare this image to the one we 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 we saw 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.
8. Click File > E xit from the menu to quit HyperView.

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 is used to determine 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.
The following exercises are included:
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
1. Launch HyperMesh Desktop.
2. Choose the OptiStruct User Profile and click O K.
models in Bulk Data Format for RADIOSS and OptiStruct. The User Profiles GUI can
also be accessed from the Preferences menu on the toolbar.
4. Select the carm.hm file, located in the HyperWorks installation directory under
5. Click O pe n.
Step 2: Create Materials and Properties and Assign to Proper

Components
1. Click the Model tab.
2. Right-click inside the Model Browser and, from the C re a te menu, select M a te ria l.
3. In the Name: field, type Steel.
4. For Card image:, choose M AT1 as the material type.
5. Select the box for Card edit material upon creation and click C re a te .
The MAT1 card image opens.
6. For E, enter the value 2.0E5.
7. For Nu, enter the value 0.3.
8. Click re turn.
9. Right-click inside the Model Browser and, from the C re a te menu, select Pro pe rty .
10. In the Name: field, type design_prop.
11. For Card image:, choose PSO LID as the property type.

12. Select the Material tab.
13. Check the box for Assign material and from the Name menu, select Ste e l as the
material.
14. Select the Property tab and click C re a te .
15. Right-click inside the Model Browser and, from the C re a te menu, select Pro pe rty .
16. In the Name: field, type nondesign_prop.
17. For Card image:, choose PSO LID as the property type.
18. Select the Material tab and check the box for Assign material.
19. From the Name menu, select Ste e l as the material.
21. Click on the Components icon to update the component collectors with the newly
created properties.
22. Select the assign radio button.
23. Click on co m ps , check the nondesign box, and then click s e le ct.
24. Click pro pe rty = and select no nde s ign_pro p.
25. Click a s s ign.
26. Repeat steps 21 24 to assign de s ign_pro p to the design component.
27. Click re turn.
Step 3: Create Load Collectors

Next we will create four load collectors (SPC, Brake, Corner and Pothole) and assign each a
color. Follow these steps for each load collector.
1. Right-click inside the Model Browser and, from the C re a te menu, select Lo a dC o lle cto r.
2. In the Name: field, type SPC.
When in this popup, do not press the ENTER key on the keyboard until you are completely
done.
3. Leave the Card image: field set to No ne .
4. Select a suitable color.
6. Similarly, create load collectors called Brake, Corner, and Pothole.
Step 4: Apply Constraints

We need to create constraints and assign them to the SPC load collector, as outlined in the
following steps.
1. From the Model Browser, expand LoadCollectors, right-click on SPC , and click on M a ke
C urre nt.
2. From the Analysis page, enter the co ns tra ints panel.
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.
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.
7. Click cre a te .
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.
C onstraining 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.


the selected node. The number 23 is written beside the constraint symbol, indicating that
dof2 and dof3 are constrained.
C onstraining dof2 and dof3 at the other end of the bushing.
11. Click no de s and select by id from the extended entity selection window.
12. Type the value 3239 and press the E NTE R key.
13. This selects node ID 3239 (see the next figure), which corresponds to the shock absorber
mounting location.
14. Constrain only dof3.

the selected node. The number 3 is written beside the constraint symbol, indicating that
dof3 is constrained.

C onstraining dof3 on node ID 3239.
Step 5: Apply Forces for Brake, Corner, and Pothole Loadcases

1. From the Model Browser, expand LoadCollectors, right-click on B ra ke , and click on
M a ke C urre nt.
2. From Analysis page, select fo rce s panel.
3. Click no de s and select by id from the extended entity selection menu.
4. Type the node number 2699 and press the E NTE R key. This selects the node where the
force is being applied.
5. Click m a gnitude = , enter 1000.0 and press the E NTE R key.
6. Set the switch below to x- a xis .
7. Click cre a te .
An arrow, pointing the x direction, should appear at the node on the screen.
8. For better visualization of the arrows, select unifo rm s iz e = , type 100, and press E NTE R.
9. From the Model Browser, under the expanded LoadCollectors, right-click on C o rne r,
and click on M a ke C urre nt.
11. Type the node number 2699 and press E NTE R.
13. Set the switch below to y - a xis .
An arrow pointing in the Y direction should appear at the node on the screen.
15. From the Model Browser, under the expanded LoadCollectors, right-click on Po tho le ,
and click M a ke C urre nt.
17. Type the node number 2699 and press E NTE R.
19. Set the switch below to z - a xis .
An arrow, pointing in the Z direction, should appear 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.
1. From the Analysis page, enter the lo a ds te ps panel.
2. Click na m e = , enter Brake, and press E NTE R.
3. Select type as line a r s ta tic.
5. Click on the entry field and select SPC from the list of load collectors.
6. Check the box preceding Load and select B ra ke from the list of load collectors.
8. Similarly create the load cases Corner [by selecting the load collectors C o rne r and SPC ]
and Pothole [by selecting the load collectors Po tho le and SPC ].
Setting Up the Optimization in HyperMesh
Step 7: Define the Topology Design Variables

2. Enter the to po lo gy panel.
of the panel.
4. Click D E SVAR = , type design_prop, and press E NTE R.
5. Click props , choose de s ign_pro p from the list of props, and

click on s e le ct.
6. Choose type: PSO LID .
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.
Step 8: Create a Volume and Displacement Response

1. Enter the responses panel.
2. Click re s po ns e = and enter vol.
3. Click on the switch below response type and select v o lum e from the pop-up menu.
4. Ensure the regional selection is set to to ta l (this is the default).
5. Click cre a te .
A response, vol, is defined for the total volume of the model.
6. Click re s po ns e = and enter disp1.
7. Click on the switch below response type and select s ta tic dis pla ce m e nt from the pop-
up menu.
8. Click no de s and select by ID from the extended entity selection menu that pops up.
9. Type 2699 and press E NTE R.
The node where the three forces are applied is selected.
10. Select to ta l dis p from the radio options.
This is the vector sum of the x, y, and z translations.
A response, disp1, is defined for the total displacement of node 2699.

Step 9: Define the Objective
1. Enter the o bje ctiv e panel.
3. Click re s po ns e = and select Vo l.
4. Click cre a te .
5. Click re turn to exit the optimization panel.

1. Enter the dco ns tra ints panel.
2. Click co ns tra int= and enter constr1.
5. Select re s po ns e = and set it to dis p1.
7. Check the box next to Brake.
8. Click s e le ct.
9. Click cre a te .
15. Check the box next to Corner.

22. Check the box next to Pothole.
24. Click re turn twice to return to the main menu.
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.
1. From the Analysis page, enter the O ptiStruct panel.
name for the model, carm_check.fem, in the File name: field.
The extension.fem is for OptiStruct input decks.
4. Click Sa v e .
5. Note the name and location of the carm_check.fem file displays in the input file: field.
7. Click the run options: switch and select che ck.
9. Click O ptiStruct.
This launches the OptiStruct check run.
Once the processing is complete (indicated in the solver GUI window which pops up), 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 Opt im iza t ion Proble m Pa ra m e t e rs
section of the carm_check.out file.
The objective function? See Opt im iza t ion Proble m Pa ra m e t e rs section of the
carm_check.out file.
The constraints? See Opt im iza t ion Proble m Pa ra m e t e rs section of the carm_check.out
file.
What is the recommended amount of RAM for an In-Core solution? See M e m ory
Est im a t ion Inform a t ion section of the carm_check.out file.
Is there enough disk space to run the optimization? See Disk Spa c e Est im a t ion
Inform a t ion section of the carm_check.out file.

2. Click s a v e a s , enter carm_complete.fem as the file name, and click Sa v e .
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
opened in a text editor to find details regarding any errors. This file is written to the same
directory as the .fem file.
5. At the end of process, close the OptiStruct solver GUI window.
The default files written to the directory are:
carm_complete.hgdata HyperGraph file containing data for the objective function,

percent constraint violations, and constraint for each iteration.
carm_complete. OptiStruct history file containing iteration number, objective

his_data function values and percent of constraint violation for each
iteration.
carm_complete.HM. HyperMesh command file used to organize elements into

comp.cmf components based on their density result values. This file is
only used with OptiStruct topology optimization runs.
carm_complete.HM. HyperMesh command file used to organize elements into entity

ent.cmf 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

problem formulation and the results from the final iteration.
carm_complete.oss OSSmooth file with a default density threshold of 0.3. The user
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
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 cclip_complete.fem file.

carm_complete.res HyperMesh binary results file.
carm_complete.sh Shape file for the final iteration. It contains the material
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

each step during analysis process.
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. Once you see the message O PTIM IZ ATIO N H AS C O NVE R G E D in the command window,
click the green H y pe rVie w button.
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.
2. Click C lo s e to close the message window.
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 button to move to the second page.
The second page has the results from the carm_complete_s1.h3d file. Note that the
name of the page is displayed as Subca s e 1 B ra ke to indicate that the results
correspond to subcase 1.
4. Select Linear Static as the animation mode .
5. Click the Contour toolbar button .
6. Select the first drop-down menu below Result type: and select D is pla ce m e nt [v ].

7. Select the second drop-down menu and select M a g.
8. Click Apply to display the displacement contour.
9. Click the Deformed toolbar button .
10. Set Result type: to D is pla ce m e nt (v ), Scale: to m o de l units , and Type: to Unifo rm .
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 W ire fra m e .
13. Click Apply .
A deformed plot of your model with displacement contour should be visible, overlaid on the
original undeformed mesh.
14. Click the Sta rt/ Pa us e Anim a tio n button 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?
Does the deformed shape look correct for the boundary conditions applied to the mesh?
15. Select Ite ra tio n 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 on the Next Page toolbar button to move to the third page.
The third page which has results loaded from carm_complete_s12.h3d file, is displayed.
Note that the name of the page is displayed as Subca s e 2 co rne r 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?
Does the deformed shape look correct for the boundary conditions applied to the mesh?
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 button 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 Sim ple .
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 Ite ra tio n 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 o pti co ntro l 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
This plot provides the information about the element density. Is o Va lue retains all of the
1. From the Results menu, click Plo t > Is o .
2. From the panel area (lower portion of the GUI), choose E le m e nt D e ns itie s 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 30% 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

The following file is needed to perform this tutorial:
sshield_opti.fem Original ASCII OptiStruct input deck.
This file can be found in <install_directory>/tutorials/hwsolvers/optistruct/ and

copied to your working directory.
Exercise
Setting Up the Normal Modes Analysis in HyperMesh
Step 1: Launch the HyperMesh Desktop, Load the User Profile, and
Retrieve a File
2. Choose O ptiStruct in the User Profiles dialog and click O K.
3. From the File menu on the toolbar, select Im po rt .
An Import tab is added to your tab menu.
4. Set the Import type: to Im po rt FE M o de by clicking on the icon .
5. For File type:, select O ptiStruct.
6. Click on the Select Files button .
7. Select the sshield_opti.fem file, located in the HyperWorks installation directory under
<install_directory>/tutorials/hwsolvers/optistruct/ and click O pe n.
8. Click Im po rt.
The sshield_opti.fem OptiStruct input file is loaded into the current HyperMesh session.
9. Click C lo s e to exit the Import tab menu.
Step 2: Create an EIGRL Load Collector

1. Right-click inside the Model Browser window (on the Model tab), select C re a te to
activate the extended menu and choose Lo a dC o lle cto r.
2. In the Name: field, type constraints.
3. Click C o lo r: and select a color from the palette.

4. Under Card Image:, leave the Select type: field set to no ne .
A new load collector, constraints, is created.
Next, an eigenvalue load collector will be created.
6. Right-click inside the Model Browser again to select C re a te , and then Lo a dC o lle cto r.
7. In the Name: field, type EIGRL.
8. Click C o lo r: and select a different color from the palette.
9. Under Card Image:, set the field to E IG R L.
10. Select the box for Card edit loadcollector upon creation and click C re a te .
The EIGRL card image opens.
If a quantity in brackets does not have a value below it, it is off. To change this, click on
the quantity in brackets and an entry field will appear below it. Click in the entry field,
and a value can be entered.
11. For V2, enter the value 3000.000.
12. For ND, enter the value 2.
13. Click re turn to save changes to the card image.
We just created a load collector 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 Lo a dC o lle cto rs , right-click on co ns tra ints , and click
on M a ke C urre nt.
The load collector name changes to bold to signify that it is now the current load
collector.
2. From the Analysis page, enter the co ns tra ints panel.
of the panel.
4. Click the entity selection switch and select no de s from the pop-up menu.
5. Click the no de s button and select by id.
6. Enter the value 1075 (beside id=) and press E NTE R.
7. Enter the value 1076 and press E NTE R.
8. Constrain all dofs.

9. Click cre a te .
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)

1. From the Analysis page, enter the lo a ds te p panel.
2. Click na m e = and enter frequencies.
3. Click the type switch and choose no rm a l m o de s from the pop-up menu.
5. Click on the entry field and select co ns tra ints 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 e igrl from the list of load collectors.
8. Click cre a te .
A RADIOSS loadstep has been created which references the constraints in the load
collector spc and the eigenvalue extraction data in the load collector eigrl.

1. From the Analysis page, enter the R AD IO SS panel.
A Save file browser window opens.
3. Select the directory where you would like to write the RADIOSS model file and enter the
name for the model, sshield_analysis.fem, in the File name: field.
The .fem file name extension is the suggested extension for RADIOSS input decks.
4. Click Sa v e .
Note that the name and location of the sshield_analysis.fem file now displays in the

input file: field.
8. Let the options: field be blank.
This launches the RADIOSS job. If the job is successful, new results files can be seen in
the directory where the RADIOSS model file was written. The sshield_analysis.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:
sshield_analysis.html HTML report of the analysis, giving a summary of the

problem formulation and the analysis results.
sshield_analysis.out RADIOSS 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 each optimization iteration,
and compute time information. Review this file for
warnings and errors.
sshield_analysis.res HyperMesh binary results file.
sshield_analysis.stat Summary of analysis process, providing CPU information

for each step during analysis process.
sshield_analysis.h3d HyperView results file.
sshield_analysis.mvw HyperView session file.
sshield_analysis_frames. HTML file used to post-process the .h3d with HyperView

html Player using a browser. It is linked with the _menu.html
file.
sshield_analysis_menu. HTML file to post-process the .h3d with HyperView Player

html using a browser.
Post-processing the Initial Results in HyperView
Eige nv e c t or results are output from RADIOSS 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 Radioss panel, click the green H y pe rVie w button.
This button 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 C lo s e to exit the Message Log window.
3. Change the animation type from Tra ns ie nt to M o da l .
4. Click the drop-down menu, as shown in the following image of the Results Browser.
The window will appear showing the calculated first two natural frequencies between 0
and 3000Hz.
5. Click on M o de 1 to select those mode results.
7. Make or verify the following settings in the Deformed panel.
Result Type: E ige n m o de (v )
Scale: M o de l Units
Type: Unifo rm
Value: 10
8. Click Apply .
9. Click the Anim a tio n C o ntro ls toolbar button.
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 Angula r Incre m e nt: to refine your animation.
11. Click the Pla y / Pa us e Anim a tio n button to start the animation.
An animation of the mode shape should be seen for the first frequency.
12. Click the Pla y / Pa us e Anim a tio n icon again to stop the animation.
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 re turn to exit the Radioss panel.
4. Select the create subpanel using the radio buttons on the left-hand side of the panel.
5. Click de s v a r = and enter shield.
6. Click pro ps .
7. Check the box next to design and click s e le ct.
8. Set the type toggle to PSH E LL.
9. Click on ba s e thickne s s = and change the value to 0.300.
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).
We 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. Click the C a rd E dito r toolbar button .
13. Set the entity selection to pro ps using the down arrow next to the listed entity.
14. Click the yellow pro ps button and check the box next to de s ign.
15. Click s e le ct.
16. Select the ca rd im a ge = and select PSH E LL from the pop-up menu.
17. Click e dit.
The PSHELL card image for the design component collector pops up.
18. Replace 0.300 in the T field with 1.000.
19. Click re turn to save the changes to the card image.
20. Click re turn to exit the Card Editor panel.
21. Click re turn to get back to the optimization panel.
Step 8: Create Responses

A detailed description of the available responses can be found in the OptiStruct Use r's Guide ,
under Responses.
Two responses will be defined here: the first frequency that will be the objective function and
a volume fraction response that will be used as a constraint.
1. Select the re s po ns e s panel.
2. Click re s po ns e = and enter freq1.
3. Click on the switch below response type and select fre que ncy from the pop-up menu.
4. Click on M o de Num be r: and enter 1 (this is the default value).
5. Click cre a te .
A response, freq1, is defined for the frequency of the first mode extracted.
6. Click re s po ns e = and enter volfrac.
7. Click on the switch below response type and select v o lum e fra c from the pop-up menu.
8. Set the total/regional toggle to to ta l.
9. Click cre a te .
A response, volfrac, is defined for the volume fraction of the design space.
10. Click re turn to go to the Optimization Setup panel.

In this example, the objective is to maximize the response, 'freq1', which was defined in the
previous section.
1. Enter the o bje ctiv e panel from within the optimization panel.
2. Click on the switch in the upper left corner of the panel, and select m a x from the pop-up
menu.
3. Click re s po ns e = and select fre q1 from the list of responses.
4. Click lo a ds te p and select the fre que ncie s loadstep previously defined.
5. Click cre a te .
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 dco ns tra ints panel from the optimization panel.
2. Click co ns tra int= and enter volume_constr.
3. Check the box to the left of upper bound =.
4. Click uppe r bo und = and enter the value 0.40.
5. Click re s po ns e = and select v o lfra c from the response list.
6. Click cre a te .
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 exercise we are allowing the topology optimization to use
additional volume with which it can come with ribsvconstr.
7. Click re turn 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 Sa v e .
Note that the name and location of the sshield_optimization.fem file now displays in
the input file: field.
This launches the OptiStruct job. If the job is successful, new results files can be seen in
the directory where the OptiStruct model file was written. The sshield_optimization.
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_optimization.hgdata HyperGraph file containing data for the objective

function, percent constraint violations and constraint
for each iteration.
sshield_optimization. OptiStruct history file containing iteration number,

his_data objective function values, and percent of constraint
violation for each iteration.
sshield_optimization.HM. HyperMesh command file used to organize elements

comp.cmf into components based on their density result values.
This file is only used with OptiStruct topology
optimization runs.
sshield_optimization.HM. HyperMesh command file used to organize elements

ent.cmf into entity sets based on their density result values.
This file is only used with OptiStruct topology
optimization runs.
sshield_optimization.html HTML report of the optimization, giving a summary of

the problem formulation and the results from the final
iteration.
sshield_optimization.oss OSSmooth file with a default density threshold of 0.3.

The user may edit the parameters in the file to obtain
the desired results.
sshield_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 each
optimization iteration, and compute time information.
Review this file for warnings and errors.

sshield_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.
sshield_optimization.stat Summary of analysis process, providing CPU

information for each step during analysis process.
sshield_optimization.mvw HyperView session file.
sshield_optimization_frames HTML file used to post-process the .h3d with

.html HyperView Player using a browser. It is linked with
the _menu.html file.
sshield_optimization_menu. HTML file used to post-process the .h3d with

html HyperView Player using a browser.
sshield_optimization_des. HyperView binary results file that contains: Density

H3D results from topology optimizations, Shape results
from topography or shape optimizations and Thickness
results from size and topology optimizations.
sshield_optimization_s1.H3D HyperView binary results file that contains:

Displacement results from linear static analysis,
Element strain energy results from normal mode
analysis and Stress results from linear static analysis,
etc.
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 the green H y pe rVie w button.
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 button .
4. Set the Result type: to E le m e nt Thickne s s (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
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 o pti co ntro l 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?

C ontour plot of element densities at iteration 12 with all components except the designable component
turned off. (top view)
HyperView page, as seen in the figure below.
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
HyperWorks installation directory under <install_directory>/tutorials/hwsolvers/
optistruct/.
Step 13: Delete the Current Model

1. Once back in HyperMesh, click re turn to exit the OptiStruct panel.
2. Select the de le te panel on the Tool page.
or

Press F2 on the keyboard to jump to the delete panel.
3. Click de le te m o de l.
A message will pop-up asking you if you want to delete the current model.
4. Click Y e s .
Deleting the current model clears the current HyperMesh database. Information stored in
.hm files on your disk is not affected.
5. Click re turn to reach the main menu.
Step 14: Import the OptiStruct Input File sshield_newdesign.fem

1. From the File menu, select Im po rt .
2. Set the Import type: to FE M o de l by clicking on the icon .
3. Choose the File type: O ptis truct.
4. Select the Files button .
5. Select the sshield_newdesign.fem file, located in the HyperWorks installation directory

under <install_directory>/tutorials/hwsolvers/optistruct/.
6. Click Im po rt.
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.
7. Click C lo s e .

Step 15: Run RADIOSS Analysis
1. From the Analysis page, enter the R a dio s s panel.
name for the model, sshield_newdesign.fem, in the File name: field.
4. Click Sa v e .
Note that the name and location of the sshield_newdesign.fem file now displays in the
input file: field.
6. Click on the run options: switch and select a na ly s is .
8. Leave the options: field blank.
Post-processing the Final Results in HyperView
Step 16: View the Mode Shapes

1. While in the Radioss panel, click the green H y pe rVie w button.
This button 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 M o da l .
4. In the Results Browser, select M o de 1.
6. Make or verify the following settings in the Deformed panel.
Result Type: E ige n m o de (v )

Scale: M o de l Units
Type: Unifo rm
Value: 10
7. Click Apply .
8. Click the Pa us e / Pla y Anim a tio n button to start the animation .
An animation of the mode shape should be seen for the first frequency.
9. Click Pa us e / Pla y Anim a tio n button 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)?
We 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 exercise, you will perform a topology optimization using draw direction constraints on a
control arm. The finite element mesh containing designable (brown) and non-designable
regions (blue) is shown in Figure 1.
Figure 1. C ontrol arm schematic.
The following exercises are included in this tutorial:
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
A User Profiles GUI will appear.
2. Choose O ptiStruct in the User Profile dialog.

3. Click O K.
models in Bulk Data Format for RADIOSS (bulk) and OptiStruct.
Step 2: Retrieve the controlarm.hm file

An Open file browser window opens.
2. Select the controlarm.hm file, located in the HyperWorks installation directory under
3. Click O pe n.
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.
1. From the Analysis page, select the o ptim iz a tio n panel.
2. Select the to po lo gy 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 pro ps and select D e s ign.
6. Click s e le ct.
7. Set the type: toggle to PSO LID .
8. Click cre a te .
9. Click the draw radio button, and toggle the draw type: to s ingle .
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 a ncho r no de .
This selects node ID 3029.

12. Click firs t no de .
This selects node ID 4716.
14. Under obstacle, double-click pro ps , select No n- de s ign and click s e le ct.
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 upda te .
Setting Up the Optimization Problem in HyperMesh
Step 4: Create the Optimization Responses

2. Enter Volfrac in the response = field.
3. Select the switch below response type: and set it to v o lum e fra c.
4. Click cre a te .
5. Enter Compl in the response = field.
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 we ighte d co m p (use the arrows to access the second page,
if not shown).
7. Click lo a ds te ps , check the boxes next to both loadcases, and click re turn.
8. Click cre a te .
Step 5: Apply Design Constraints on Volume Fraction Response

1. Click dco ns tra ints 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 re s po ns e = and select Vo lfra c.
6. Click cre a te .
The volume fraction constraint is now created.
Step 6: Set Minimize Compliance as Objective

1. Click o bje ctiv e to define the objective function.
2. Click the min/max switch in the upper left corner and select m in.
3. Click re s po ns e and select C o m pl.
4. Click cre a te .
5. Click re turn twice.
This completes your optimization problem setup.
Step 7: Save the Database

1. From the File menu on the toolbar, select Sa v e a s .
2. Change the file name to controlarm_opt.hm and click Sa v e .
Step 8: Run OptiStruct

1. From the Analysis page, select the O ptiStruct panel.
You can also get to the OptiStruct panel from the Applications menu on the toolbar.
This launches the OptiStruct job. 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.
The default files that will be written to your directory are:
controlarm_opt.hgdata HyperGraph file containing data for the objective function,

percent constraint violations and constraint for each

iteration.
controlarm_opt.HM.comp. HyperMesh command file used to organize elements into

cmf components based on their density result values. This file
is only used with OptiStruct topology optimization runs.
controlarm_opt.HM.ent. HyperMesh command file used to organize elements into

cmf entity sets based on their density result values. This file
is only used with OptiStruct topology optimization runs.
controlarm_opt.hist 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.
controlarm_opt.oss OSSmooth file with a default density threshold of 0.3.

The user may edit the parameters in the file to obtain the
desired results.
controlarm_opt.out OptiStruct output file containing specific information on

the file setup, 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. 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 file used to post-process the .h3d with HyperView

html 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

2. Click clo s e to close the message GUI.
3. Select the last iteration in the Results Browser.
4. Click the Contour panel toolbar button .
5. Under Result type:, select E le m e nt de ns itie s (s ) from the first menu and D e ns ity for
the second menu.
6. Set the Averaging method: to Sim ple .
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 panel toolbar button .
2. Set the Result type: to E le m e nt de ns itie s (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 Abo v e .
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 .
3. Click the Contour panel toolbar button
4. Set the Result type: to D is pla ce m e nts (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 the Next Page button.

Displacement contour for the second loadstep at the last iteration.

OS-2040: Spot Weld Reduction using CWELD and 1-D
This tutorial demonstrates how to perform 1-D 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 <install_directory>/tutorials/hwsolvers/optistruct

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.
Defining 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.
2. Choose OptiStruct in the User Profile dialog and click O K.
User Profile can also be accessed from the Preferences menu on the toolbar.

4. Select the hut.hm file, located in the HyperWorks installation directory under
5. Click O pe n.
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 o ptim iz a tio n.
This brings up the optimization module.
4. Set the radio button to create.
5. Enter desvar = tpl.
6. Set the type to PW E LD .
7. Click pro ps .
8. Select the tick box PWELD_500.
9. Click re turn.
This defines the design space.
11. Click re turn.
Step 3: Define the Responses

2. From the drop-down menu below response type:, select v o lum e fra c from the list of
responses that are available for optimization in OptiStruct.
3. Click on the toggle next to total and select by e ntity .
This action makes the yellow selection box show up.
4. Switch the yellow box to the props box.
5. Click pro ps .
6. Select the tick box PWELD_500.
7. Click s e le ct.

8. Enter response = volfrac.
9. Click cre a te .
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 we ighte d co m p 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 tick boxes for the subcases.
15. Change the weighting factors for SUBCASE2 and SUBCASE3 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 re turn.
This defines the weighted compliance response.
18. Click re turn.
Step 4: Define the Constraint and Objective

1. Click dco ns tra ints .
2. Select response = v o lfra c.
3. Select the tick box upper bound = and enter 0.3.
4. Enter constraint = volfrac.
5. Click cre a te .
This defines the volume fraction constraint.
6. Click re turn.
8. Select response = wco m p.
9. Select min as the objective.
This defines the weighted compliance objective.

11. Click re turn.
This concludes the definition of the optimization problem. Some optimization parameters
should be modified to achieve a good result.
12. Click o pti co ntro l.
13. Select the tick box DISCRT1D = and enter 20.0.
This increases the penalty factor in the density method only for the 1-D elements to
achieve a discrete result.
14. Select the tick 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 O ptiStruct 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 Sa v e .
Note the name and location of the hut_opt.fem file now displays in the input file: field.
5. Select export options: a ll.
6. Select run options: o ptim iz a tio n.
7. Select memory options: m e m o ry de fa ult.
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 R un > C o m m a nd File .
This will open the command file execution panel.
2. Use browse to find the output hut_opt.HM.comp.cmf from your OptiStruct run.

3. Click O pe n.
4. Click e xe cute .
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.
5. 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 dis pla y e d in the Radioss panel.
Final configuration.

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 processes 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 needs to be retrieved from <install_directory>/tutorials/hwsolvers/

optistruct/ 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
2. Choose O ptiStruct as the user profile and click O K.
3. From the File menu on the toolbar, select Im po rt > M o de l.
5. For File type:, select O ptiStruct.
6. Click the Select file... button to find and open the no_repeat.fem file, located in the
optistruct/.
7. Click Im po rt.
The no_repeat.fem OptiStruct input file is loaded into the current HyperMesh session.
8. Click C lo s e .
Setting Up the Optimization Problem Without Pattern Repetition
Step 2: Create the Topology Design Variable

2. Click to po lo gy to enter the panel.
of the panel.

4. Click de s v a r = and enter dv1.
5. Click pro ps and select the property labeled firs t by checking the box beside it.
6. Click s e le ct.
7. Set the type: selector to PSH E LL.
8. Click cre a te .
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 m indim = and enter 2.0.
12. Click upda te .
13. Repeat steps 3 through 12 for the components called second and third with desvar
names dv2 and dv3, respectively.
This defines the design space.
14. Click re turn.
Step 3: Create the Volume Fraction and Compliance Response

1. Enter the re s po ns e s panel.
2. Click re s po ns e = and type volfrac.
3. Set the switch below response type: to v o lum e fra c.
4. Verify that the toggle in the center of the panel is set to to ta l.
5. Click cre a te .
This creates the volume fraction response.
6. Click re s po ns e = and enter comp.
7. Set the selector under response type: to co m plia nce .
8. Verify that the toggle in the center of the panel is set to to ta l.
9. Click cre a te .
This creates the compliance response.
10. Click re turn.
Step 4: Create a Constraint on Volume Fraction Response

2. Click co ns tra int = and enter volfrac.

4. Check the box next to upper bound =.
6. Click cre a te .
This creates a volume fraction constraint.
7. Click re turn.

3. Click re s po ns e = and select co m p.
4. Click lo a ds te p and select s ub.
5. Click cre a te .
This creates the compliance response as the objective.
6. Click re turn twice to return to the main menu.
This completes the definition of the topology optimization problem without pattern
repetition.

1. Click O ptiStruct to enter the panel to run OptiStruct.
name for the model, no_repeat_opt.fem, in the File name: field.
The .fem extension is suggested for OptiStruct input decks.
4. Click Sa v e .
Note the name and location of the no_repeat_opt.fem file now displays in the input file:
field.
8. Let the Options: field remain blank.

window.
Post-processing the Results Without Pattern Repetition
Step 7: Review an Iso Value Plot of Element Densities

1. Click the H y pe rVie w button 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 C lo s e in the Message Log window that appears.
3. Click the Iso Value toolbar button.
4. Under Result type:, select E le m e nt D e ns itie s (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 Abo v e .
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.

HyperView page, as seen in the image below.
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 num be rs panel.
2. Click the no de s button and select by id.
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 E NTE R.
5. Click the green o n button.
This displays the selected node numbers.
6. Click re turn to exit the Numbers panel.
7. From the View menu, select the M a s k 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.
10. Click to po lo gy to enter the panel.
11. Select the pa tte rn re pe titio n subpanel using the radio buttons on the left side of the
panel.
12. Double-click the de s v a r= and select dv 1.
13. Make sure the switch is pointing to master.
14. Toggle from system to co o rdina te s .
15. Click the green firs t button and choose node ID 6.
16. Notice that the blue border moves over second after the first has been selected; now
choose the second node ID 46.
17. Choose the third node ID 1329.
18. Click the a ncho r button and choose the node ID 66.
19. Click upda te on the right side to create a master DTPL card.
20. Click de s v a r= and select dv 2.
21. Click the switch and select s la v e .
22. Make sure master= is pointing to dv 1.
23. Set the following values: sx= 0.6, sy= 0.6, sz= 1.0.
24. Click the firs t button and choose the node ID 447.
25. For the s e co nd button, choose the node ID 487.

26. For the third button, choose the node ID 1329.
27. For the a ncho r button, choose the node ID 507.
28. Click the upda te button on the right side to create the slave DTPL card.
29. Click de s v a r= and select dv 3.
30. Click the switch and change to s la v e .
31. Make sure the master= button is pointing to dv 1.
32. Set the following values: sx= 0.3, sy= 0.3, sz= 1.0.
33. Click the firs t button and choose the node ID 892.
34. For the s e co nd button, choose the node ID 928.
35. For the third button, choose the node ID 1329.
36. For the a ncho r, choose the node ID 948.
37. Click the upda te button 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 DTPLs 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.
You can right-click on any of the design variables in the Results Browser and select
C a rd E dit to view the card image for the DTPL card. The card image for dv2 is shown
below.

1. From the Analysis page, click O ptiStruct to run the solver.
name for the model, repeat_opt.fem, in the File name: field.
4. Click Sa v e .
Note that the name and location of the repeat_opt.fem file now displays in the input

file: field.
8. Let the options: field be blank.
window.
Post-processing New Results with Pattern Repetition
Step 10: Review an Iso Value Plot of Element Densities

1. From the OptiStruct panel, click the green H y pe rVie w button.
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 Is o toolbar button .
5. Choose 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 Abo v e .
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, choose E xit to quit HyperView.

OS-2060: Symmetry and Draw Direction Applied
Simultaneously in Topology Optimization
The purpose of this tutorial is to demonstrate how to perform a topology optimization on an

automotive control arm with the simultaneous application of symmetry and draw direction
constraints.
This tutorial will use 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:

Design variables: Element density.
This tutorial covers the following processes:
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 O ptiStruct in the User Profile dialog and click O K.
3. Click the Import Solver Deck button and navigate to and open the the
carm_draw_symm.fem file, located in the HyperWorks installation directory under
4. Click Im po rt.
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 o ptim iz a tio n panel.
2. Click on to po lo gy to enter the panel.
3. Click on re v ie w and select the desvar s o lid.
4. Select the pa ra m e te rs subpanel and define a minimum member size = 16.0 mm.
This forces the diameter or thickness of any structural member to be higher then 16 mm;
if this is not user-set, OptiStruct will automatic select a minimum member size based on
the average mesh size (if a manufacturing constraint is selected).

5. Click on upda te to confirm the minimum member size set up.
6. Select the dra w subpanel to set up the draw direction.
7. Set the selector under draw type: to s ingle .
8. Select the Ancho r no de and the firs t no de 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 no nde s ign property.
10. Select the pa tte rn gro uping subpanel to define the symmetry constraint and toggle the
pattern type: to 1- pln s y m .
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 s y m option enforces symmetry across a defined plane. A symmetric mesh is not
required, as OptiStruct will create variables that are nearly identical across the plane(s) of
symmetry. The plane of symmetry is defined by specifying the a ncho r and the firs t
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 a ncho r no de , input the node id= 1, and press E NTE R.
This selects the node with the ID of 1.
12. Click firs t no de , input the node id= 2 and press E NTE R.
13. Click the upda te button 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.
14. Click re turn twice to go back to the Analysis page.

This tutorial problem takes nearly one hour to run.
2. Click s a v e a s , enter carm_draw_symm_complete.fem as the file name, and click Sa v e .
5. Make sure the memory options: toggle is set to 2000.
6. Let the options: field remain blank.
8. Close the DOS window or shell when the message ...Pro ce s s ing co m ple te 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 directory as the .fem file.
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. Once you see the message Process completed successfully in the command window,
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 E le m e nt D e ns itie s [s ]; this should be the only results type in
the file_name_des.h3d file. The second drop-down list shows D e ns ity .
5. In the Averaging method: field, select Sim ple .
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
This plot provides the information about the element density. Is o Va lue retains all of the
1. From Graphics menu, click on Is o , and choose E le m e nt D e ns itie s 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).

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.
5. From the File menu, select E xit 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 will be 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.
C antilever 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 RADIOSS, 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

A User Profiles dialog will appear by default.
3. Click O K.

Step 2: Retrieve the cantilever_full.hm File
2. Click the O pe n M o de l icon and load the cantilever_full.hm file into the current
HyperMesh session.
C omplete model.
Generate a Superelement
Step 3: Create ASETs (specifying boundary degrees of freedom of the

superelement assembly)
1. Right-click on the Model Browser and select C re a te > Lo a d C o lle cto r.
2. Name the new load collector Asets and set the card image to no ne .
3. From the Analysis page, select co ns tra ints .
5. Select the boundary nodes (as shown in the image before step 1) by clicking in the
graphics window.
6. Make sure dofs 1 through 6 are checked.
Dofs with a check will be assigned to the ASET.
7. Click on Lo a d Ty pe = and choose ASE T.
8. Click cre a te .

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.
2. Click the entity selection switch and select e le m s from the pop-up menu.
3. Click e le m s and select by windo w 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 de le te e ntity .
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 will be used for this tutorial.
1. On the Analysis page, select the co ntro l ca rds panel.
2. Click ne xt twice to be able to select PAR AM , check the box next to EXTOUT.
3. Select D M IG PC H .

4. Click re turn to exit PARAM.
5. Click re turn to get back to the main menu.
Step 6: Save the DMIG Database
1. Click on the Sa v e M o de l icon set the directory in which to save the file and, in File
name:, type cantilever_dmig.hm.
2. Click Sa v e .

3. Select the directory where you would like to write the file and enter the name
cantilever_dmig.fem in the File name: field.
4. Click Sa v e .
Note that the name and location of the cantilever_dmig.fem file shows in the input file:
field.
6. Set the run options: toggle to a na ly s is .
This launches the OptiStruct job.
If the analysis is successful, no error messages are reported to the shell. The analysis is
complete when the line 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 the input deck if any errors are present.
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. Review this file for warnings and errors.
cantilever_dmig_AX. Reduced matrices (DMIG) file.

pch

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 Ne w.
This will clear the existing HyperMesh database.
Include the Superelement in the Model
Step 9: Re-retrieve the cantilever_full.hm file

1. Select the File menu on the toolbar and move the mouse over Recent Files.
2. Move the mouse to the right until the list appears and select 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.
2. Click the entity selection switch and select e le m s from the pop-up menu.
3. Click e le m s and select by windo w 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 following figure.

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 co ntro l ca rds panel.
2. Click INC LUD E _B ULK.
3. Enter the file name cantilever_dmig_AX.pch.
The reduced matrices (DMIG) will be included in RADIOSS input deck. Here we 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 re turn to exit INCLUDE_BULK.
5. Select K2G G .
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 re turn to exit K2GG subpanel.
8. Select the P2G subpanel.
9. Enter PAX in the P2G= field.
10. Click re turn 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 o ptim iz a tio n panel.
2. Go to the to po lo gy panel.
4. Click de s v a r = and enter topo.
5. Click pro ps .
6. Check the box next to design.
7. Click s e le ct.
8. Set the type toggle to PSH E LL.
9. Click cre a te .
10. Click pa ra m e te rs .
11. Toggle minmemb off to m indim = and enter 1.2.
12. Click upda te .
13. Click re turn to go back to the optimization page.
Step 13: Create Volume Fraction and Compliance Responses

1. Select re s po ns e s .
2. Enter Volfrac in the response = field.
3. Set the switch below response type to v o lum e fra c.
4. Click cre a te .
5. Enter Compl in the response = field.
6. Turn the response type selector to co m plia nce .
Just eight characters can be used here, since the name is used, a label is needed for the
response.
7. Click cre a te .

Step 14: Create Constraints on Volume Fraction
1. Click dco ns tra ints 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 re s po ns e = and select Vo lfra c.
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 cre a te .
The volume fraction constraint is now created.
Step 15: Define Minimize Compliance as Objective

1. Click o bje ctiv e to define the objective function.
2. Set the switch in the upper left corner to m in.
3. Click re s po ns e and select C o m pl.
4. Click lo a ds te p.
5. Select the loadstep s te p.
6. Click cre a te .
This completes your optimization problem setup.

1. Select the Files panel toolbar button.
2. Select the hm file subpanel.
3. Click s a v e a s to set the directory in which to save the file and, in File name:, type
cantilever_opti.hm.
4. Click Sa v e .


cantilever_opti.fem in the File name: field.
4. Click Sa v e .
Note that the name and location of the cantilever_opti.fem file shows 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 cantilever_opti.out file is a good place to look
for error messages that will help to debug the input deck if any errors are present.
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.

The user 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 each
optimization iteration, and compute time information.
Review this file for warnings and errors.
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
necessary, run OSSmooth files for topology
optimization.
cantilever_opti.stat Summary of analysis process providing CPU information

for each step during analysis process.
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 section describes how to view those results in HyperView.
Step 18: Contour Plot of Element Densities

3. Under Result type:, select E le m e nt de ns itie s (s ) from the drop-down list and review
the D e ns ity component.
4. In the Averaging method: field, select Sim ple .
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.
1. Click the Iso toolbar button .
3. Make sure that Show is set to Abo v e .
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.
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.

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.
The structural model is loaded into HyperMesh. The constraints, loads, subcases and material
properties are already defined in the model. The topology design variables and the
optimization problem set up will be defined using HyperMesh, and OptiStruct will be used to
determine the optimal material layout. The results will then be reviewed in HyperView.
Objective Minimize volume.

function:
Constraints: von Mises stress < 1.6 e 04.
Design variables: The density of each element in the design space.
The processes covered in this tutorial include:
Setting up the optimization problem in HyperMesh
Exercise

Step 1: Launch HyperMesh and Set the User Profile
2. Choose O ptiStruct as the user profile by selecting the radio button beside it.
3. Click O K.
Step 2: Import the Finite Element Model File

The model file for this exercise, hook.fem, is located in
<install_directory>\tutorials\hwsolvers\optistruct.
1. Select the Import Solver Deck icon .
2. Make sure the File type: is set to O ptis truct.
3. Click the Select files icon.
4. Browse for your file and select it.
5. Click O pe n.
6. Click Im po rt.
Setting Up the Optimization Problem in HyperMesh
Step 3: Create the Design Variables for Topology Optimization

1. On the Analysis page, select the o ptim iz a tio n panel.
2. Click the to po lo gy panel.
3. Select the cre a te radio button.
4. Enter the name shells in the desvar= field.
5. Click pro ps and select the check boxes by the Design and Base properties.
6. Click s e le ct.
7. Set the component type: switch to PSH E LL.
8. Click cre a te .

9. Select the pa ra m e te rs subpanel.
10. Toggle m inm e m b o ff to m indim = .
11. For mindim=, enter 0.3.
12. Under stress constraint:, toggle from no ne to s tre s s = .
13. For stress=, enter 1.6e4.
This stress serves as a constraint to the optimization, but can handily be created in-line
with the design variable for the design regions.
14. Click upda te .
This value is the stress constraint for the model.
15. Click re turn to get back to the optimitization panel.
Step 4: Create the Responses

A detailed description is available in the Opt iSt ruc t Use r's Guide , under Responses.
1. Click re s po ns e s to go to the Responses panel.
2. Click re s po ns e = and enter volume.
3. Click the response type: switch and select v o lum e from the pop-up menu.
4. Ensure that the total/by entity toggle is set to to ta l (this is the default).
5. Click cre a te .
A response, volume, is defined for the total volume of the model.

In this example, the objective is to minimize the volume response defined in the previous step.
1. Select the o bje ctiv e panel.

2. Click the switch in the upper left corner of the panel and select m in from the pop-up
menu.
3. Click re s po ns e = and select v o lum e from the response list.
4. Click cre a te .
The objective function is now defined.
In this example we will not define any design constraints. The stress target specified in
the topology panel acts as a design constraint. Hence, the topology optimizer has to
minimize the volume while keeping the stress to less than 1.6e4 units.
Step 6: Save the HyperMesh Database
1. Click the Save Model File button .
A Save file... browser window opens.
2. Select the directory where you would like to save the database and enter the name for
the database, hook_opt.hm, in the File name: field.
3. Click s a v e .
Step 7: 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 Sa v e .
Note the name and location of the hook_opt.fem file now displays in the input file: field.
5. Make sure the memory options: toggle is set to m e m o ry de fa ult.
7. Make sure the export options: toggle is set to a ll.
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 hook_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.

Element density results are output from OptiStruct for all of the iterations. In addition,
displacement and stress results are output for each subcase for the first and last iterations
by default. This section describes 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 8: View an Isosurface Plot of the Density Results

1. While still in the OptiStruct panel, click the green H y pe rVie w button.
HyperView launches and loads the results generated by OptiStruct.
2. Click the iso Value toolbar button .
3. Select the Result type: E le m e nt de ns itie s (s ).
4. Ensure that the drop-down selector for the animation controls is set to Tra ns ie nt M o de
and click the Pla y button to start the animation.
5. The Current Value in the Iso panel can be adjusted to show more or less of the resulting
design.

The isosurface post-processing feature is an excellent tool to use for viewing the density results from
OptiStruct
Step 9: Query the Results of the Elements with Stresses Higher than
0.9e4
1. Use the Open Model icon to load the subcase result file hook_opt_s19.h3d.
2. In the Subcase Selection section of the Results Browser, change Iteration 0 which
shows your results at the beginning of the optimization to Iteration 36, as shown
below, which has analysis results for the final iteration for this optimization.

3. Click on the C o nto ur icon to enter the contour panel and click Apply to display
results for the optimized shape of subcase 19.
4. Click on the Q ue ry button to bring up the query panel.
5. Click on Adv a nce d to load the advanced query editor.
6. Set the Apply to:, Value:, and Display options: sections to search for elements with a
stress above 1.6e4, as shown below.
7. Click Apply to run the query, and then click C re a te Se t to create a new set within the
session with only those elements.
8. The new set is shown in the Results Browser. Right-click on the set and select Is o la te
O nly to display only those elements within the graphics area.

Notes: The advantages of using stress-based optimization over the classical
minimize (compliance) subject to volume fraction constraint is that it
eliminates the guessing of the right volume fraction. Additionally, it
eliminates the need for compliance weighting bias for multiple subcases.
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 variables: The density of each element in the design space
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 on the Im po rt So lv e r D e ck icon .
3. Browse to the rail_complete.fem file.
4. Click Im po rt.
Setting Up Extrusion Constraints in HyperMesh
Step 2: Create the Topology Design Variables

of the panel.
4. Click de s v a r= , type design_solid, and press E NTE R.
5. Click pro ps , choose ne w_s o lid from the list of props, and
click on s e le ct.
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.
8. Click re turn twice to go back to the main menu.
Step 3: Define Extrusion Problem and Extrusion Path

1. From the Tool page, enter the num be rs panel.

2. Click no de s and select by id.
3. Enter numbers 71559,70001 and press E NTE R, check the display box, then click o n.
The numbers 71559 and 70001 should be displayed on the screen.
4. Click re turn.
5. From the Analysis page, enter o ptim iz a tio n panel.
7. Make sure the extrusion subpanel is selected using the radio buttons on the left-hand
side of the panel.
8. Double-click de s v a r = and select de s ign_s o lid.
9. Switch the toggle to no twis t.
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 no de lis t and clicking by pa th.
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 upda te .
Extrusion path definition
A line of nodes starting from 71559 and ending with node 70001 should be highlighted,
indicating the extrusion path.

You do not have 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
2. Click re s po ns e = and enter volfrac.
3. Click on the switch below response type and select v o lum e fra c from the pop-up menu.
5. Click cre a te .
6. Click re s po ns e = and enter wcomp1.
7. Click on the switch below response type and select we ighte d co m p from the pop-up
menu.
8. Click lo a ds te ps and select s te p1, s te p2, s te p3, s te p4, s te p5, s te p6, and s te p7 from
the extended entity selection menu that pops up.
9. Click re turn.
A response, wcomp1, is defined for the weighted compliance.
Step 5: Create Constraints on Volume Fraction Response

C onstraint set up

5. Select re s po ns e = and set it to v o lfra c.
6. Click cre a te .

3. Click re s po ns e = and select wco m p1.
4. Click cre a te .
Step 7: Submit the Job to OptiStruct

name for the model, rail_complete_extrusion.fem, in the File name: field.
4. Click Sa v e .
Note the name and location of the rail_complete_extrusion.fem file now displays in
5. Make sure the memory options: toggle and set uppe r lim it in M b = to 2000 M b.
7. Make sure the export options: toggle is set to a ll.
in the directory where the OptiStruct 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 the H y pe rVie w button 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 button and set the Result type: to E le m e nt D e ns itie s .
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. Click Add to add a new section cut.
2. For Define plane:, select Y Axis .
3. Click B a s e to active it, and click on any corner at the center of the model.
4. Click Apply .
5. Move the slider bar below Y Axis to scroll though the model.
6. Under Display options:, use the slider bar next to Width to change the Cross section
width.
C ontour 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 processes are covered in this tutorial:
Setting up a modal frequency response analysis in HyperMesh
Post-processing FRF results
Setting up a topology optimization
Post-processing the topologic results
Exercise

Import a File
2. Choose O ptiStruct.
3. Click O K.
models in bulk data format for RADIOSS and OptiStruct. The Us e r Pro file s GUI can also
be accessed from the Preferences menu on the toolbar.
4. Click the Im po rt FE M o de l icon .
5. Choose the File type: O ptiStruct.
6. Select the File button and browse to open the frf_response_input.fem file,
located in the HyperWorks installation directory under <install_directory>/tutorials/
hwsolvers/optistruct/.
7. Click Im po rt.
The frf_response_input.fem OptiStruct input file is loaded into the current HyperMesh
session.
8. Click C lo s e 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. We
first need to create the two load collectors spcs and unit-load.
1. Click the M o de l B ro ws e r tab to active it.
2. Right-click inside the Model Browser window and move the mouse over Create to
activate the extended menu and click Lo a d C o lle cto r.
3. In the Name: field, type spcs.

4. Click co lo r and select a color from the palette.
5. Leave the Select type: field set to no ne under the Card Image.
A new load collector, spcs, is created.
activate the extended menu and click Lo a d C o lle cto r again.
8. Click na m e = and enter unit-load.
9. Click co lo r and select a different color from the color palette.
11. A new load collector, unit-load, is created.

1. From the Model Browser, expand LoadCollectors, right-click on s pcs , and click on
M a ke C urre nt.
2. From the Tool page, select the num be rs panel.
4. Enter the following numbers one by one: 1, 2, 3, and 4.
5. Click o n.
6. Click re turn.
7. From the Analysis page, click on the co ns tra ints panel.
of the panel.
10. Select the nodes with the following IDs: 1 & 2.
11. Constrain All D o fs .

This applies these constraints to the selected nodes.
13. Again select no de s and choose no de by id, node 4.
14. Uncheck all dofs except dof3 and click cre a te .
Step 4: Create a Unit Load at a Point on the Flat Plate

1. From the Model Browser, expand Lo a dC o lle cto rs , right-click on unit- lo a d, and click on
M a ke C urre nt.
2. From the Analysis page, click on the co ns tra ints 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 to type in a value of 20
.
7. Click on the load types field and select D AR E A.
8. Click cre a te .
9. Click re turn.

FE plate model with dofs
Step 5: Create a Frequency Range Table

2. Click na m e = and enter tabled1.
4. Below the Card Image:, toggle the Select type and choose TAB LE D 1 from the drop-
down list.
5. Ensure that C a rd e dit lo a dco lle cto r upo n cre a tio n is checked and click cre a te .
A new window appears in the work area screen.

6. Click TAB LE D 1_NUM = and input a value of 2.
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 re turn.
This gives us a frequency range of 0.0 to 1000.0 with a constant load over this range.

Step 6: Create a Frequency Dependent Dynamic Load
2. Click na m e = and enter rload2.
4. Below the Card Image:, toggle the Se le ct ty pe and choose R LO AD 2 from the drop-down
list.
5. Ensure that C a rd e dit lo a dco lle cto r upo n cre a tio n is selected and click cre a te .
6. Double-click E X C ITE ID in the yellow box.
A list of collectors appears in the left-hand bottom corner.
7. Select the collector unit- lo a d from the list of collectors.
A 2 appears below the yellow EXCITEID box.
8. Double-click TB in the yellow box.
A list of collectors appears in the left-hand bottom corner.
9. Select collector ta ble d1.
10. Click on [Ty pe ] and set LO AD .
This defines the input as a force.
11. Click re turn to exit the panel.
Step 7: Create a Set of Frequencies to be Used in the Response

Solution
1. Right-click inside the Model Browser window and move the mouse over C re a te to
2. Click na m e = and enter freq5.
4. Below Card Image:, toggle Se le ct ty pe , and choose FR E Q i from the drop-down list.
5. Ensure that C a rd e dit lo a dco lle cto r upo n cre a tio n is selected and click cre a te .

6. Check the FR E Q 5 checkbox and enter NUM B E R _O F_FR E Q 5= as 1 and

FR E Q 5_M AX _NUM B E R _O F_FR = as 3.
7. Click F1, then click in the field box below it and input a value of 1.0.
8. Click F2 and input a value of 1000.
9. Click FR (0,0) and input a value of 1.
10. Click FR (0,1) and input a value of 0.8.
11. Click FR (0,2) and input a value of 0.2.
12. Click re turn.
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

1. Right-click inside the Model Browser window and move the mouse over C re a te to
2. Click na m e = and enter eigrl.
4. Below Card Image:, toggle Se le ct ty pe and choose E IG R L from the drop-down list.

5. Ensure that C a rd e dit lo a dco lle cto r upo n cre a tio n is checked and click C re a te .
6. Click ND and enter a value of 17 in the field below it.
7. Click re turn.
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)

1. From the Analysis page, click lo a ds te ps .
2. Click na m e = and enter subcase1.
3. Click the ty pe : switch and choose fre q.re s p (m o da l) from the pop-up menu.
5. Click on the entry field and select s pcs from the list of load collectors.
6. Check the box preceding METHOD (STRUCT).
7. Click on the entry field and select e igrl from the list of load collectors.
8. Check the box preceding DLOAD.
9. Click on the entry field and select rlo a d2 from the list of load collectors.
10. Check the box preceding FREQ.
11. Click on the entry field and select fre q5 from the list of load collectors.
An OptiStruct subcase has been 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 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 e dit and check the box next to RESVEC.
14. Set TYPE to APPLO AD with OPTION set to Y E S.
15. Click re turn twice to go to the main menu.
Step 10: Create a Set of Nodes for Output of Results

1. From the Analysis page, click on the e ntity s e ts panel.
2. Click na m e = and type in SETA. Set the card image to SET_GRID.
3. Set the set type: switch to no n- o rde re d.
4. Click the entity: switch and choose no de s from the pop-up menu.
5. Make sure that the yellow selection type box is set to no de s and select the node 3.
This is the node where the load was applied.
6. Click cre a te .
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 the user can specify only the points of interest.
This will reduce CPU time and the amount of data to be saved.
7. Click re turn.
Step 11: Create a Set of Outputs and Include Damping for Frequency
Response Analysis
1. On the Analysis page, click on the co ntro l ca rds panel and enter the
G LO B AL_O UTPUT_R E Q UE STS panel.
2. Check D ISPLAC E M E NTS.
A new set of options appears in the work area screen.
3. Click the field box for FORM and select PH ASE from the pop-up menu.
4. Click the field box for OPTION and select SID from the pop-up menu.
A new field appears in yellow.
5. Double-click the yellow SID box and select SE TA 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.
6. Click re turn to exit the GLOBAL_OUTPUT_REQUEST menu.
7. Select the FO R M AT subpanel.
8. Click num be r_o f_fo rm a ts = and input a value of 2.
9. On the extended menu in the work area, click the FO R M AT_V1 field box and select O PTI

from the pop-up menu for the second time.
10. Click re turn to exit the FORMAT menu.
11. Click ne xt to move to another page.
12. Select the PAR AM subpanel, and check the box next to G.
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.
14. Click re turn to exit the PARAM menu.
15. Select the O UTPUT subpanel.
A new window appears in the work area.
16. Verify KEYWORD is set to H G FR E Q .
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 re turn to exit the OUTPUT subpanel.
20. Click re turn to exit the control cards menu.

1. From the Analysis page, click on the R a dio s s panel.
2. Click s a v e a s 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 Sa v e .
Note that the name and location of the frf_response_analysis.fem file now displays in
7. Let the options: field remain blank.
This launches the Radioss analysis job. If the job is successful, new results files can be
seen in the directory where the Radioss model file was written. The
frf_response_analysis.out file is a good place to look for error messages that will help
to debug the input deck if any errors are present.

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 on the H y pe rVie w button in the R a dio s s panel to load the results from the analysis
into the next page.
2. Click clo s e 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 O pe n ...> Se s s io n.
An Open Session File windows opens.
4. Find the directory where the job was run and open the file
frf_response_analysis_freq.mvw. If you launched from the Radioss panel, you will
have to click Y e s to discard the current session.
Two graphs are displayed.
Note that 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 on the Curve Attributes button and change the line attribute to continue
.
7. On the same panel, click on Symbol Attributes and select the square symbol.
8. Click on the Axes button and change to Ve rtica l to edit the vertical axis.
9. Click on the Sca le a nd Tics (M a gnitude ) tab and change it to Lo ga rithm ic.
10. Change the Min: to 5 and the Max: to 200000.
11. Click on the Sca le a nd Tics (Pha s e ) tab and change the Tics pe r a xis : to 7.
12. Click on the H o riz o nta l 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 m a xim um button to see the maximum Y-magnitude ~ 15055 in the table. The
peak displacement of the baseline model.

This concludes the HyperGraph results processing.
Step 14: Create the Design Variables for Topology Optimization
1. Return to HyperMesh by changing the client selector to H y pe rM e s h . Reload the

frf_response_input.hm file and save it as frf_response_optimization.hm.
2. From the Analysis page, click the o ptim iz a tio n panel.
3. Click on to po lo gy to enter the panel.
5. Click de s v a r = and enter plate.
6. Click pro ps .
7. Check the box next to Design and click s e le ct.
8. Set the type: toggle to PSH E LL.
9. Set the base thickness toggle to ba s e thickne s s = .
10. Click on ba s e thickne s s = and enter 0.15.
12. Click the parameters radio button.
13. Toggle m inm e m b o ff to m indim and then type 2.
14. Toggle m a xm e m b o ff to m a xdim and then type 6.
15. Click upda te .
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. Click the Card Editor toolbar button .
18. Change the yellow selector to pro ps , click the pro ps button and check the box next to
de s ign.

20. Click e dit.
The PSHELL card image for the design component collector pops up.
21. Replace 0.150 in the T field with 1.000.
22. Click re turn twice to get back to the optimization panel.
Step 15: Create Responses

A detailed description of the available responses can be found in the OptiStruct Use r's Guide
under Responses.
Two responses will be defined here:
Frequency Response Displacement (Constraint)
Total Volume Response (Objective)
2. Click re s po ns e = and enter frfdisp.
3. Click on the re s po ns e ty pe : switch and select frf dis pla ce m e nt.
4. Make sure the component switch is set to m a gnitude and the function switch is set to
a ll fre q.
5. Click the yellow no de s button and choose node ID 3.
6. Choose the do f3 radio button.
7. Click cre a te .
A response, frfdisp, is defined for the maximum magnitude on dof3.
9. Click the re s po ns e ty pe : switch and select v o lum e from the pop-up menu.
10. Make sure the toggle is set to to ta l.
A response, volume, is defined for the volume of the design space.
12. Click re turn to go to the o ptim iz a tio n panel.
Step 16: Create the Constraints

The maximum displacement criteria for the load case in this problem is 600mm.
1. Select the dco ns tra ints panel from the optimization panel
2. Click co ns tra int= and enter constr.

3. Click re s po ns e = and select frfdis p from the response list.
4. Check the box to the left of uppe r bo und = .
5. Click uppe r bo und = and enter the value 600.
6. Click lo a ds te p and select s ubca s e 1.
7. Click cre a te .
8. Click re turn to go to the optimization panel.

1. Select the o bje ctiv e panel from the optimization panel.
2. Click re s po ns e = and select v o lum e re s po ns e .
3. Click cre a te .
4. Click re turn twice to exit the panel.

1. From the Analysis page, click on O ptiStruct.
3. Select the directory where you would like to write the OptiStruct model file, enter the
name for the model, frf_response_optimization.fem, in the File name: field, and click
Sa v e .
Note that the name and location of the frf_response_optimization.fem file now
displays in the input file: field.
the directory where the OptiStruct model file was written. The
frf_response_optimization.out file is a good place to look for error messages that will
help to debug the input deck if any errors are present.
Important files written to the directory include:
frf_response_optimization. HyperGraph file containing data for the objective

hgdata function, percent constraint violations and
constraint for each iteration.

frf_response_optimization. OptiStruct history file containing iteration
his_data number, objective function values, and percent of
constraint violation for each iteration.
frf_response_optimization.HM. HyperMesh command file used to organize

comp.cmf elements into components based on their density
result values. This file is only used with
OptiStruct topology optimization runs.
frf_response_optimization.HM. HyperMesh command file used to organize

ent.cmf elements 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. The user 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 each optimization iteration, and
compute time information. Review this file for
warnings and errors.
frf_response_optimization.sh Shape file for the final iteration. It contains the

material density, void size parameters and void
necessary, to run OSSmooth files for topology
optimization.
frf_response_optimization_des. The .h3d file is a compressed binary file,

h3d containing both model and optimization history
data results. It can be used to post-process
results in Altair HyperView.
frf_response_optimization_s#. The .h3d file is a compressed binary file,

h3d 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

2. In the HyperView window, select File on the menu bar, and select O pe n > Se s s io n.
An Open Session File windows opens.
3. Find the directory where the job was run and open the file frf_response_optimization.
mvw.
6. Set the last Load Case Simulation by clicking the Subcase Selection Box above the
Results Browser.
7. Change the averaging method to Sim ple .
8. Click Apply in the contour panel.
element for the selected iteration. The last design iteration gives the optimized material
layout.

C ontour of the baseline model (final design iteration)
Step 20: Compare the Peak Displacement of the Optimization Run

1. From the File menu, select O pe n.
2. Open the analysis session FRF_response_analysis_freq.mvw.
3. Click on the B uild Plo ts button 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 Subca s e :, select the last iteration. Leave the X Ty pe : as Frequency. Select Y Ty pe :
Displacement (Grids), Y R e que s t: N3, and Y C o m po ne nt: X,Y, & 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
3. Click O K.
4. Click the O pe n M o de l icon .
5. Select the Excavator_MBD.hm file, located in the HyperWorks installation directory under
The Excavator_MBD.hm database is loaded into the current HyperMesh session.
Step 2: Submit the Transient MBD Simulation in RADIOSS

The model Excavator_MBD.hm already has the excavator MBD analysis set up with all the
bodies defined as rigid bodies. We will run the analysis and look at the animation.
1. From Analysis page, click on R a dio s s .
name for the model, excavator_MBD_analysis.fem, in the File name: field.
7. Change the options: field so that it is blank.
8. Click Sa v e .
Note the name and location of the file displays in the input file: field.

9. Click R AD IO SS.
This launches a RADIOSS run in a separate shell (DOS or UNIX) which appears.
If the analysis was successful, no error messages are reported to the shell and you will
see 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. Once you see the message ANALYSIS COMPLETED in the command window, close the
window.
2. Click H y pe rVie w from within the Radioss 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 C lo s e 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 D e le te Pa ge button and return back to
HyperMesh.
Step 4: Change the Rigid Body into a Flexible Body

In this step, we are going to define topology optimization on the body Low e r_Arm . It is
originally modeled as a rigid body and needs to be converted to a flexible body for the
optimization.
1. From the Analysis page, click on bo die s .
2. Select the upda te option.
3. Double-click B o dy = and select Lo we r_Arm .
4. Click re v ie w.
The lower arm component is highlighted. Body type PRBODY is shown for type=,
indicating that lower arm is modeled as a rigid body. We will update this body to a flexible
body type, and also define topology optimization on this body.
5. Click ty pe = and select PFB O D Y .
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 upda te .
A message appears in the lower left corner to indicate that the body has been update to
a new type.
8. Click re turn.
Step 5: Define Topology Design Variable

2. Select to po lo gy to enter the topology panel
of the panel.
4. Click D E SVAR = , type L_Arm_Topology, and press E NTE R.
5. Click pro ps and choose lo we ra rm from the list of props;

click s e le ct.
8. Activate the pa ra m e te rs option.
9. Click the toggle next to minmemb off to activate mindim= and set the value to 0.05.
10. Click upda te .
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 re s po ns e s panel.
2. Click re s po ns e = and enter Volfrac.

3. Select the switch below response type and select Vo lum e fra c from the pop-up menu.
4. Toggle Total to by e ntity .
5. Click pro ps in the cyan border and select lo we ra rm .
6. Click cre a te .
A volume fraction response, Volfrac, is defined for the topology design volume.
7. Click re s po ns e = and enter Comp.
8. Select the switch below response type and select co m plia nce from the pop-up menu.
9. Make sure the entity selection toggle is set to To ta l.
A compliance response 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.
2. Click on co ns tra int = and enter Vol_Constr.
4. Click uppe r bo und = and enter 0.5.
5. Click re s po ns e = and select Vo lfra c from the list of responses.
6. Click cre a te .
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 o bj re fe re nce .
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 re s po ns e and select C o m p.
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 cre a te .
Step 9: Define an Objective Function

The objective is to minimize the maximum compliance of the equivalent static loadsteps.
1. Choose the o bje ctiv e panel.
2. Click the left-most toggle and select m inm a x.
3. Click do bjre fs and select M AX _C o m p.
4. Click cre a te .

1. From the File menu, click on Sa v e As .
2. Select the directory in which to save the file and, in File name:, type
excavator_MBD_Topology.hm.
3. Click Sa v e .
Step 11: Submit the ESL Optimization Job in OptiStruct

name for the model, excavator_MBD_Topology.fem, in the File name: field.
7. Click Sa v e .
Note the name and location of the file displays in the input file: field.
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 line 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. Once you see the message OPTIMIZATION HAS CONVERGED in the command window,
close the DOS window.
2. Click H y pe rVie w from within the OptiStruct panel.
about the successful loading of the model and result 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 button .
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 Abo v e .
10. Using the Model Browser on the left, display only the Lo we r_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.

OS-3000: Topography Optimization of a Plate Under Torsion
OS-3020: Automatic Recognition of Bead Results from Topography Optimization of an L-

bracket

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 is used to determine 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 variables: Shape variables generated automatically on the designable space

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
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 in Bulk Data Format for RADIOSS and OptiStruct.
3. From the File menu, click O pe n and browse to open the torsion_plate.hm file, located
in the HyperWorks installation directory under <install_directory>/tutorials/
hwsolvers/optistruct/.
4. Click O pe n.
The torsion_plate.hm database is loaded into the current HyperMesh session, replacing
any existing data.
Step 2: Check the Thickness of the Component

1. From the Results Browser, expand the Pro pe rty entities.
2. Right-click on de s ign and select C a rd E dit.

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, please
see the reference manual section on the DTPG card.
1. From the Analysis page, click o ptim iz a tio n to enter the panel.
2. Select the to po gra phy panel.
of the panel.
4. Click de s v a r= and type topo.
5. Click the highlighted pro ps .

7. Click cre a te 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 on de s v a r = and select to po from the list of topographical
design spaces.
11. Click m inim um 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 dra w a ngle = 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 dra w he ight= 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 no rm a l to e le m e nts .
This parameter defines the direction in which the shape variables are created.
16. Make sure the boundary skip: switch is set to lo a d & s pc.
This tells OptiStruct to leave nodes at which loads or constraints are applied out of the
design space.
17. Click upda te .
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 page of the Re fe re nc e Guide .
18. Select the bo unds 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 on de s v a r = and
select to po from the list of topographical design spaces.
20. Click on uppe r bo und 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 on lo we r bo und and enter 0.0 (this is the default).
22. Click upda te .

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 online manual under Responses. Define one
response for the objective: displacement at the node where the force is applied.
2. Click re s po ns e = and enter displace.
3. Select the switch below response type and select s ta tic dis pla ce m e nt from the pop-up
menu.
4. Click no de s and select by ID from the extended entity selection menu that pops up.
5. Type 2500 and press the E NTE R key.
The node where the force is applied is now selected.
6. Select do f3.
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 cre a te .
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 o bje ctiv e panel from the optimization panel.
2. Click the switch in the upper-left corner of the panel, and select m in from the pop-up
menu.
3. Click re s po ns e = and select dis pla ce from the response list.
A loadstep button should appear in the panel.
4. Click on lo a ds te p and select to rs io n from the subcase (loadstep) list.
5. Click cre a te .

Step 6: Submit the Job

name for the model, torsion_plate.fem, in the File name: field.
4. Click Sa v e .
Note that the name and location of the torsion_plate.fem file now displays in the input
file: field.
5. Set the export options toggle to a ll.
6. Set the run options toggle to o ptim iz a tio n.
7. Set the memory toggle to m e m o ry de fa ult.
in the directory where the OptiStruct model file was written. The torsion_plate.out file
errors are present.
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

flagged from processing the torsion_plate.fem file.
torsion_plate_des. HyperView binary results file for information on shape changes.

h3d
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
restart a run and, if necessary, run OSSmooth files for topology
optimization.
torsion_plate.stat Summary of analysis process, providing CPU information for

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

This will launch HyperView within the HyperMesh Desktop and load 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 Sha pe C ha nge (v ) and type to M a g.

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.
C ontour 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 stop 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 Line a r Sta tic.
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 D is pla ce m e nt(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.
HyperView page, as seen in the image below.
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, we 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 re turn to exit the OptiStruct panel.
3. Click to po gra phy to enter the panel.
4. Select the pa tte rn gro uping subpanel using the radio buttons on the left-hand side of
the panel.
5. Click de s v a r = and choose to po from the list of topographical design spaces.
6. Click on the pattern type: switch and select line a r.

7. Make sure the sub-type: switch is set to ba s ic.
8. Click a ncho r no de 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 upda te .
Step 11: Submitting the Job

1. From the Analysis page, click O ptiStruct to enter the panel.
name for the model, torsion_pattern.fem, in the File name: field.
4. Click Sa v e .
Note the name and location of the torsion_pattern.fem file now displays in the input
file: field.
6. Click the run options switch and select o ptim iz a tio n.
7. Set the memory toggle to m e m o ry de fa ult.

in the directory where the OptiStruct model file was written. The torsion_pattern.out
file is a good place to look for error messages that will help to debug the input deck if any
errors are present.
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.
C ontour plot showing the reinforcement pattern with pattern grouping constraint at the last iteration

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
Retrieve the File
A User Profiles dialog will appear.
2. Choose O ptiStruct as the user profile.
3. Click O K.
4. From the File menu on the toolbar, select O pe n and browse to open the Lbkttopog.hm
file, located in the HyperWorks installation directory under <install_directory>/
tutorials/hwsolvers/optistruct/.
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, please
see the reference manual section on the DTPG card.
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.
1. From the Analysis page, click on the o ptim iz a tio n panel.
2. Click on the to po gra phy panel.
4. Click de s v a r= and type topo.
5. Click pro ps .
7. Click cre a te 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 include 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 on de s v a r = and select to po from the list of topographical
design spaces.
10. Click m inim um 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 dra w a ngle = 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 dra w he ight= 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 lo a d & s pc.
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 upda te .
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 page of the reference guide.
17. Select the pa tte rn gro uping 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 spaces.
19. Click the pattern type: switch and select 1- pln s y m from the pop-up menu.
20. Click a ncho r no de and enter 337.
21. Click firs t no de and enter 613.
22. Click upda te .
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 spaces.
25. Click uppe r bo und and enter 1.0 (default).
26. Click lo we r bo und and enter 0.0 (default).
27. Click upda te .
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 online OptiStruct manual under
Responses.
2. Click re s po ns e = and enter FREQ.
3. Select the switch below response type and select fre que ncy from the pop-up menu.
4. Click M o de Num be r: and enter 1.
5. Click cre a te .
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 o bje ctiv e panel from the optimization panel.
2. Click the switch in the upper left corner of the panel, and select m a x from the pop-up
menu.
3. Click re s po ns e = and select FR E Q from the response list.
4. Click lo a ds te p and select STE P from the subcase (loadstep) list.
5. Click cre a te .

1. Select the Files panel toolbar button.
2. Select the hm file subpanel.
3. Click s a v e a s to set the directory in which to save the file and, in File name:, type
Lbkttopog.hm.
4. Click Sa v e .

1. Select the O ptiStruct panel on the Analysis page.
name for the model, Lbkttopog.fem, in the File name: field.
4. Click Sa v e .
Note the name and location of the Lbkttopog.fem file now displays in the input file: field.
6. Click the run options: switch, and select o ptim iz a tio n.
in the directory where the OptiStruct model file was written. The lbkttopog.out file is a
are present.
lbkttopog.grid An OptiStruct file where the perturbed grid data is written.
lbkttopog. HyperGraph file containing data for the objective function, constraint
hgdata 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. The user 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. HyperView binary results file for information on shape changes.

h3d
Lbkttopog_s1_h3 HyperView binary results file for displacement and stress results for
d 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 during analysis process.
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 the green H y pe rVie w button.
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.
2. Click C lo s e to exit the window.
3. Set the animation mode menu to Transient, as shown below:

4. Click on the button to start the animation.
5. Click the button 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 ( Ite ra tio n 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 button to set the Current time: to the last step.
Topography results
3. From the File menu, select E xpo rt > So lv e r D e ck.
4. Set Select format: to R a dio s s (B ulk)/ Na s tra n.
5. For File name:, select your working directory for the field and name the file deformed.
fem before clicking O K.
6. Click Y e s 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, 0S-
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 Im po rt So lv e r D e ck .
4. Set the Import type: to FE M o de l.
5. Choose the File type: O ptiStruct.
6. For File:, click on the Se le ct file ... icon to open the OptiStruct file browser.
7. Select the Lbkttopog_bead.fem file, located in the HyperWorks installation directory

8. Click Im po rt.
The Lbkttopog_bead.fem OptiStruct input file is loaded into the current HyperMesh
session.
9. Click C lo s e to exit the Import tab.
Step 2: Run the OptiStruct Job

1. From the Analysis page, click on the O ptiStruct panel.
name for the model, Lbkttopog_bead.fem, in the File name: field.
4. Click Sa v e .
in the directory where the OptiStruct model file was written. The lbkttopog_bead.out
errors are present.
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 on H y pe rVie w.
2. When the Message Log dialog appears, click C lo s e .
3. Click on File > O pe n Se s s io n and select Lbktto po g_be a d.m v w to load the results
session into the HyperView client.
4. Ensure that the animation mode is set to Tra ns ie nt and click the Pla y button 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 on 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 re turn to exit the OptiStruct panel.
2. From the Post page, click on the a pply re s ults panel.
3. Click s im ula tio n = and select D E SIG N - ITE R 12 from the list of simulations.
4. Click da ta ty pe = and select Sha pe C ha nge .
5. Choose displacements using the radio buttons on the left-hand side of the panel.
6. Click the component selection switch and select to ta l dis p.
7. Click no de s and select a ll from the extended entity selection switch.
8. Click m ult = and enter 1.
9. Click a pply .
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 re je ct to get back the original shape and re turn to go back to main menu.
Step 6: Extract/Import Final (concept) Geometry Using OSSmooth and

autobead
1. From the Post page, select the O SSm o o th panel.
2. For file:, select the OptiStruct base input file from which to extract the final geometry.
3. For output:, select the IG E S 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 lo a d ge o m 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 O SSm o o th.
8. Click Y e s 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 Sa v e and E xit to continue.
11. Using the Mask tab, click on Is o la te for Geometry and on H ide 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

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
Submit the job to OptiStruct
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
1. Launch HyperMesh.

generating OptiStruct models.
The File type: is O ptiStruct.
4. Click the o pe n file button .
A Select OptiStruct file browser window opens.
5. Select the panel.fem file, located in the HyperWorks installation directory under
6. Click O pe n.
The location of panel.fem now displays in the file: field.
7. Click Im po rt.
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.
1. From the Analysis page, go to the o ptim iz a tio n panel.
2. Click to po gra phy 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 de s v a r = and type plate.
5. Click the highlighted pro ps .
6. Check the box next to PSHELL_5 and click s e le ct.
7. Click cre a te to create the topography design variable.
8. Click the bead params subpanel using the radio button.
9. Click de s v a r= and select pla te .

10. Enter the bead parameters as shown in the following image.
11. Click upda te .
12. Select the pattern grouping subpanel using the radio button.
13. Click de s v a r= and select pla te .
14. Under pattern type:, click on the switch and select 2- plns s y m .
15. For anchor node, first node, and second node, click the switch to change from node id
to co o rdina te s .
16. Enter the values as shown below to define a 2-plane symmetry constraint.
17. Click upda te .
18. Go to the bounds subpanel using the radio button.
19. Set Upper Bound = 1.0 and Lower Bound = -1.0.
20. Click upda te .
21. Click re turn 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 re s po ns e s .

2. For the response = field, enter psdaccl.
3. Select the switch below response type, select ps d a cce le ra tio n.
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 do f1 for the PSD acceleration in X direction.
7. Click ra ndps = and select R AND PS100, which specifies the Power Spectral Density for the
random response analysis.
8. Leave the frequency selection as a ll fre q.
9. Have the region set to no re gio nid.
10. Click cre a te and re turn 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 o bj re fe re nce in the Optimization Setup panel.
2. Type psdacclref in the dobjref= field.
3. Click re s po ns e = and select the response ps da ccl.
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 a ll to apply this DOBJREF entry to all subcases.
7. Click cre a te .
8. Click re turn and go back to Optimization Setup panel.
10. Toggle the option to m inm a x.
11. Click the highlighted do bjre fs and select ps da cclre f.
12. Click cre a te and re turn back to the Analysis page.
Submit the Job

Step 5: Launch OptiStruct
name for the model, panel_complete.fem, in the File name: field.
4. Click Sa v e .
Note the name and location of the panel_complete.fem file now displays in the input
file: field.
5. Toggle memory options: to m e m o ry de fa ult.
6. Toggle run options: to o ptim iz a tio n.
7. Toggle export options: to a ll.
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

1. Once you see the message Process completed successfully appear in the command
window, click H y pe rVie w.
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 Sha pe C ha nge (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 Fre que ncy (H z ).
5. Select G ro up 1 Acce le ra tio n 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 Axe s panel and convert the linear plot of PSD acceleration to logarithmic
plot for the y-axis.
8. Select the last group acceleration as Y Ty pe 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.

OS-3100: Combined Topology and Topography Optimization of a Slider Suspension

OS-3200: Optimization-driven Design of a Composite Aircraft Underbelly Fairing

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
A Us e r Pro file s dialog will appear.
2. Choose O ptiStruct and click O K.
3. From the File menu on the toolbar, select Im po rt > So lv e r D e ck.
An Im po rt tab is added to your tab menu.
4. Choose the proper File type: O ptiStruct.
5. Click on the Se le ct File s button and browse for the combined.fem file located in the
optistruct/.
6. Click O pe n.
7. Click Im po rt.
8. Click C lo s e to close the Import tab menu.
Step 2: Set up the Topology Design Space

3. Verify you are in the cre a te subpanel.
4. Click pro ps , select 1pin, and click s e le ct.
5. For desvar =, enter the name pin.
6. Change type: to PSH E LL.
7. Verify base thickness is 0.0.
8. Click cre a te .
9. Click pro ps , check only 3be nd and click s e le ct.

10. For de s v a r = , enter the name bend.
11. Verify base thickness is 0.0.
13. Click re turn.
Step 3: Set up the Topography Design Space

1. Click to po gra phy .
2. Verify you are in the cre a te subpanel.
3. Click pro ps , check 1pin and 3be nd, and click s e le ct.
4. For desvar=, enter the name tpg.
5. Click cre a te .
6. Select the be a d pa ra m s 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 no rm a l to e le m e nts .
9. Toggle boundary skip: to lo a d & s pc.
10. Activate buffe r z o ne .
11. Click upda te .
We will use 1-plane symmetric beads, as it is the simplest and can be symmetric at the
same time.
12. Go to the pa tte rn gro uping subpanel and set pattern type: to 1- pla ne s y m .
13. Click a ncho r no de , type 41, and press E NTE R.
14. Click firs t no de , type 53, and press E NTE R.
15. Click upda te .
16. Select the bo unds subpanel.
17. Verify the bounds are as follows:
upper bound = 1.0, lower bound = 0.0.
18. Click upda te .
19. Click re turn.
Step 4: Create Responses for Optimization

Since this problem is a combined linear static and normal mode analysis, we are trying to

minimize compliance and increase frequency for the two load cases, while constraining the
seventh frequency. Therefore, we define two responses: c om b and fre q.
2. For response =, enter the name freq.
3. Change the response type to fre que ncy .
4. For Mode Number, enter a value of 7.
5. Click cre a te .
6. For response =, enter the name comb.
7. Change the response type to co m plia nce inde x.
8. Click lo a ds te ps and activate fo rce .
9. Make sure that the option to define normalizing factor is toggled to a uto no rm .
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
12. Click re turn.
Step 5: Define Constraints

2. For co ns tra int = , enter the name frequency.
3. Check lo we rbo und and enter a value of 12.
4. Click re s po ns e = and select fre q.
5. Click lo a ds te ps and click the fre que ncy checkbox, then click s e le ct.
6. Click cre a te .

7. Click re turn.

2. Verify that o bje ctiv e is set to m in.
3. Click re s po ns e = and select co m b.
4. Click cre a te .
5. Click re turn.
Step 7: Define the Optimization Control Cards

1. Click o pti co ntro l.
2. Click the checkbox for M IND IM 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 M ATINIT 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 co ntro l ca rds and click ne xt twice.
2. Click PAR AM .
3. In the panel, check M O D E TR AK.
4. In the card panel, set MODET_V1 to Y e s .
5. Click re turn.
Note that the PAR AM button is now green, indicating that it is active.
6. Click re turn to go back to the Ana ly s is page.

Step 9: Submit the OptiStruct Job
3. Set the run options: toggle to o ptim iz a tio n.
5. Click s a v e a s ... following the input file: field.
name for the model, comb_complete.fem, in the File name: field.
7. Click Sa v e .
Note the name and location of the file now displays in the input file: field.
This launches an OptiStruct run ain a seperate shell (DOE or UNIX) which appears.
optimization is complete when the line Pro ce s s ing co m ple te appears in the shell.
Post-process Optimization Results in HyperView
Step 10: Post-process the Shape Change Result (Topography)

1. Once you see the message Jo b C o m ple te in the HyperWorks Solver View window, close
the command window to return to HyperMesh.
2. Back in HyperMesh, click H y pe rVie w (from the OptiStruct panel) to launch HyperView.
The HyperView GUI window opens and the results get loaded automatically in HyperView.
A M e s s a ge Lo g window appears to inform about the successful loading of the model and
result files into HyperView.
4. Click on the D e fo rm e d toolbar button .
5. By clicking on the drop-down menus next to each option, for Result type:, select Sha pe
C ha nge (v ); for Scale:, select Sca le fa cto r; and for Type:, select Unifo rm .
6. For Value:, enter 1.0.

7. Below the Undeformed shape: section, click on the drop-down menu next to Sho w: and
select No ne .
8. Click Apply to display the shape change because of topography optimization.
9. 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)
1. Click the C o nto ur toolbar button .
2. Select the first drop-down list below Result Type: and select E le m e nt Thickne s s e s (s ).
3. Select the second drop-down list below Result Type: and select Thickne s s .
4. Select Sim ple in the field below Averaging method:.
Step 12: Add Iso-surface of the Optimum Material Distribution

(Topologic)
1. Click the Is o Va lue toolbar button .
2. For the first drop-down list below Result Type:, choose E le m e nt D e ns itie s (s ) and
D e ns ity in the second list.
3. Make sure that Abo v e 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 the E NTE R key.

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 is used to identify the optimal ply shapes and locations of
patches per ply orientation.
Phase 2 Design fine tuning

Size optimization is used to identify the optimal thicknesses of each ply bundle.
Phase 3 Ply stacking sequence optimization

Shuffling optimization is used to obtain 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.
Constraints: Volume fraction < 0.3
Design Element thickness 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

2. Select O ptiStruct in the User Profile dialog and click O K.
models OptiStruct.
4. The File type: is O ptiStruct.
5. Click the o pe n file button in the File: field.
A Select OptiStruct file browser window pops up.
6. Select the fairing.fem file, located in the HyperWorks installation directory under
7. Click O pe n.
The location of fairing.fem now displays in the file: field.
8. Click Im po rt.
The fairing.fem database is loaded into the current HyperMesh session.
Step 2: Create the design variables for free-size optimization

2. Click fre e s iz e to enter the free-size optimization panel.
3. On the create subpanel, type fairing in the field of desvar=.
4. Click the switch under type and select PC O M P(G ).
5. Click the highlighted pro ps , select fa iring_ply , and click s e le ct.
6. Click cre a te .
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 fa iring is selected as the design variable.
8. Click the green e dit button and enter the D SIZ E panel to define the manufacturing
constraints on ply percentage and ply balance.
9. Check the box in front of PLYTHK.
10. Make sure the Ply Thickness Options are set to ALL.
11. Check the box in front of PLYPCT.
12. Set Ply Percentage Options to Spe cify Num be r.

13. In the field of DSIZE_NUMBER_OF_PLYPCT =, enter the value of 1.
Two PLYPCT lines pop up.
14. Check the box in front of BALANCE.
15. In the field of DSIZE_NUMBER_OF_BALANCE=, enter the value of 1.
One BALANCE line pops up.
16. Define the PLYTHK, PLYPCT, and BALANCE constraints, as shown in the following plot.
17. Click return to go back to the composite subpanel.
18. Click upda te .
19. Click re turn and go back to the optimization panel.
Step 3: Create the responses

2. Enter wcomp in the response= field.
3. Set the response type: to we ighte d co m p.
4. Click the highlighted lo a ds te ps .
5. Select gra v ity and pre s s ure loadcases, and make sure the factors are 1.0 for both
loadcases.
6. Click re turn to go back to the response panel.
7. Click cre a te .
8. Enter volfrac in the response= field.
9. Set the response type: to v o lum e fra c.
10. Make sure the total volume fraction is selected and the toggle is set to no re gio nid.
Step 4: Define constraints for optimization


2. Type con_vol in the constraint= field.
4. Activate upper bound= and input a value 0.3.
5. Click cre a te .
6. Click re turn.
Step 5: Define the objective function

2. Select m in as the optimization type.
3. Click re s po ns e = and select wco m p.
4. Click cre a te .
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.
1. From the Analysis page, select co ntro l ca rds .
2. Click G LO B AL_O UTPUT_R E Q UE ST.
3. Input the following request to output all composite strain results of all elements to H3D
file.
4. Input the following request to output all composite stress results of all elements to H3D
file.
5. Click re turn.
6. Click ne xt and click on the O UTPUT card.
7. In the OUTPUT panel, enter 1 as the number_of_outputs.
8. Set FSTO SZ as the KEYWORD and Y E S for FREQ.
OptiStruct will automatically generate 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 Sa v e .
Note the name and location of the fairing_freesize.fem file now displays in the input
file: field.
5. Toggle memory options: to m e m o ry de fa ult.
6. Toggle run options: to o ptim iz a tio n.
7. Toggle export options: to a ll.
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. Review this
file for warnings and errors.
fairing_freesize_sizing.*. A ply-based sizing optimization input file generated during

fem 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.*. An ASCII include file contains the same ply-based

inc 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 the H y pe rVie w button (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 (you can click C lo s e 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 C o nto ur panel and select the plot options, as shown below:
3. Select the last iteration in the Load Case and Simulation Selection drop-down in the
Results browser.
4. Click Apply .
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.

Element thickness contour plot after free-size optimization
Step 9: View the ply thickness results

1. On Contour panel, select Ply Thickne s s e s (s ) as the Result type. The other plot
options should be selected, as shown below:
2. Select the last iteration in Load Case and Simulation Selection drop-down.
3. Click Apply .
The thickness distribution of 0 degree super ply is generated and shown in Figure 3. It
represents the ply shapes and patch locations of the 0 degree ply bundles.
Ply thickness contour of 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).
5. The following images 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.
Ply thickness contour of +/-45 degree super ply
Ply thickness contour of 90 degree super ply
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 both +45; 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.
5. Select the fairing_freesize_sizing.*.inc file, located in the same directory where

the file fairing_freesize.fem is saved.
6. Click Im po rt to import the model into session.
7. Turn the display off for all the load collectors: go to the Model Browser, right-click on
Lo a dC o lle cto r and choose H ide .
8. On the Analysis page, click e ntity s e ts .
9. Click the re v ie w button on the right side of the window and select s e t 13 which
represents the ply bundle 1 of 45, as shown below:
The ply bundles can also be reviewed under Ply in the Model Browser, right-click on any
PLY S and click E dit.
Element set represents ply bundle 1 of 45 degree super-ply
10. Repeat step 2 to review the element set 14 though 16.

Element set (highlighted) representing ply bundle 2 of 45 degree super-ply
The shapes of the plies as indicated through the element set can be used as-is in design

Pha se 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 Pha se 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 load case of normal modes analysis 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 Pha se
variables: 1
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 Pha se 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 ( Pha se 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 of optimization.
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 co m po s ite s iz e .

2. Go to the pa ra m e te rs subpanel, click dco m p= , and select D C O M P9.
Click e dit and review the DCOMP card image, as shown below. PLYPCT and BALANCE
constraints are transferred to DCOMP card. The manufacturable ply thickness constraint
0.1 in PLYTHK is transferred to the PLY card.
3. Return back to parameters subpanel, and click upda te .
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 o ptire s po ns e s .
3. Click the highlighted o ptire s po ns e s and select wco m p and v o lfra c.
4. Click s e le ct.
The responses defined in free-sizing phase are deleted. The constraint and objective
function defined based on them are automatically removed.
6. Click re turn.
Step 5: Set up the normal modes analysis

Add a normal modes analysis to calculate the natural frequencies.
1. Go to the Load Collectors panel by clicking on the toolbar.
2. On the cre a te subpanel, type eigrl in the loadcol name = field.
3. Click ca rd im a ge = and select E IG R L.
4. Click cre a te / e dit and enter the EIGRL card image panel.
5. Click ND and type 8 to request the first 8 modes.
6. Click re turn three times to go back to the Analysis page.

8. Select no rm a l m o de s as the analysis type.
9. Type norm_modes in the name= field.
10. Activate SPC and select the load collector s pc.
11. Activate M E TH O D (STR UC T) and select e igrl.
Step 6: Create the responses for size optimization

The responses of volume, natural frequency, and composite strain are created for size
optimization.
1. Click o ptim iz a tio n and then click re s po ns e s .
2. For the response = field, enter volume.
3. Set the response type to v o lum e .
4. Make sure the total volume is defined and the toggle is set to no re gio nid.
5. Click cre a te .
6. For the response = field, enter freq1.
7. Set fre que ncy 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 re gio id.
9. Click cre a te .
10. Repeat step 6 through 8 to create frequency responses for mode 2, 3, 4, and 5.
11. For the response = field, type cstrain.
12. Select co m po s ite s tra in as the response type.
13. Toggle the selection option to plie s .
14. Click the highlighted plie s and select all plies.
15. Select m a j. Principa l as the strain type.
The cstrain response should be set, as shown below.

17. Click re turn 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 dco ns tra int.
2. For the constraint = field, type freq1.
3. Click re s po ns e = and select fre q1.
4. Activate the lo we r bo und and enter 0.02.
5. Click the highlighted lo a ds te ps and select the loadcase no rm _m o de s .
6. Click cre a te .
7. Repeat step 2 through 6 to create constraints freq2, freq3, freq4, and freq5
respectively with the same lower bound of 0.02.
8. In the constraint= field, type cstrain.
9. Click re s po ns e = and select cs tra in.
10. Activate the uppe r bo und= and type 0.001.
11. Click lo a ds te ps and select loadcases gra v ity and pre s s ure .
Step 8: Create objective function for the optimization

2. Select m in as the optimization type.
3. Click re s po ns e = and select v o lum e .
4. Click cre a te .
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) is used to write a ply
stacking optimization input deck.
1. On the Analysis page, select co ntro l ca rds .
2. Go to the O UTPUT panel.

3. Enter 1 as the number_of_outputs.
4. Set SZ TO SH as the KEYWORD and Y E S for FREQ.
OptiStruct will automatically generate a size model after the free-size optimization.
Step 10: Submit the size optimization job

1. From the Analysis page, click O ptiStruct.
2. Follow the instructions in Step 7 from the free-size phase ( Pha se 1) to save the input file
as fairing_size.fem and set up the run/memory options.
3. Click O ptiStruct to launch OptiStruct to run 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 file for warnings and errors.
fairing_size_shuffling.*. A ply stacking optimization input deck. The DESVAR and

fem 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.*. An ASCII include file containing ply stacking optimization

inc data.
Step 11: View the thickness results in HyperView

1. Invoke HyperView.
2. Follow the instructions in Step 8 from Pha se 1 to create the element thickness contour, as
shown in the following image.

Element thickness contour plot after size optimization
3. Set the Result type to O rie nta tio n Thickne s s e s (s ) to create the thickness contour for
each ply orientation.
4. Set the Result type to Ply Thickne s s e s (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 Pha se 1, and subsequently optimized ply bundle
thicknesses in Pha se 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
we 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 o ptim iz a tio n panel.
3. Click re s po ns e = and select cs tra in.
4. Click the highlighted plie s and select all of the plies.
5. Click s e le ct and go back to the responses panel.
6. Click upda te .
7. Click re turn.
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. On the optimization panel, click co m po s ite s huffle .
2. Go to the cre a te subpanel.
3. Click ds huffle = and select D SH UFFLE 1.
Review the type and stack ID.
4. Go to pa ra m e te rs .
5. Click ds huffle = and select D SH UFFLE 1.
6. Check the small box in front of pairing constraint.
7. Select re v e rs e as the pair type and make sure that ply angles1 and ply angles2 are
45.0 and -45.0, respectively.
8. Click upda te .
9. Click e dit.
10. Define the MAXSUCC constraint, as shown in the following image.

11. Click re turn.
12. Click upda te .
Step 4: Submit the shuffling job

1. On the Analysis page, click O ptiStruct.
2. Follow the instructions in Step 7 in free-size phase ( Pha se 1) to save the input file as
fairing_shuffling.fem and set up the run/memory options.
3. Click O ptiStruct to launch OptiStruct to run the optimization.
If the job was completed successfully, new results files can be seen in the same directory
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. An html file contains the history of the shuffling optimization

html 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 a Microsoft Internet Explorer window, as shown below.
The plies are color coded based on their fiber orientations.

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.

Size Optimization
OS-4070: Free-sizing Nonlinear Gap Optimization on an Airplane Wing Rib
OS-4080: Minimization of the Maximum Stress of a Rotating Bar: A Size Optimization
OS-4090: Manufacturing Constraints in a Free-size Optimization of a Composite Structure
OS-4095: Size Optimization using External Responses (DRESP3) through HyperMath

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 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 is used to determine 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 variables: Gauges of the two parts.
Set up 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 O ptiStruct user profile dialog and click O K.
models in Bulk Data Format for RADIOSS and OptiStruct. The User Profiles GUI can also
be accessed from the Preferences menu on the toolbar.
3. Select the Open Model file toolbar button .
4. Select the joint_size.hm file, located in the HyperWorks installation directory under
5. Click O pe n.
Step 2: Create the Size Design Variables for Optimization

2. Click on the s iz e panel.
3. Make sure the de s v a r subpanel is selected using the radio buttons on the left-hand side
of the panel.
4. Click de s v a r = and enter tube.
5. Click initia l v a lue = and enter 1.0.
6. Click lo we r bo und = and enter 0.1.
8. Make sure the move limit toggle is set to m o v e lim it de fa ult.
9. Make sure the discrete design variable (ddval) toggle is set to no ddv a l.
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
lower bound of 0.1, and an upper bound of 5.0.
12. Select the generic relationship subpanel using the radio buttons on the left-hand side of
the panel.

13. Click Na m e = and enter tube_th.
14. Click pro p and select tube 2 from the list of property collectors.
15. Make sure the toggle is set to Thickne s s T.
16. Click de s ignv a rs .
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 re turn.
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 Use r's Guide under Responses.
5. Click cre a te .
6. Click re s po ns e = and enter X_Disp.
7. Click the response type: switch and select s ta tic dis pla ce m e nt from the pop-up menu.
8. Click no de s and select by id from the pop-up menu.
9. Enter 3143 (node at center of rigid spider at loading point) and press E NTE R.
10. Select do f1 and click cre a te .
A response, X_Disp, is defined for the x-displacement of the node 3143.
11. Click re s po ns e = and enter Z_Disp.
12. Click no de s and select by id from the pop-up menu.

13. Enter 3143 (node at center of rigid spider at loading point) and press E NTE R.
14. Select do f3 and Click cre a te .
A response, Z_Disp, is defined for the z-displacement of the node 3143.
Step 4: Create Constraints on Displacement Response

constrain the response volume.
Upper bound constraints are to be defined for the responses X_Disp and Z_Disp.
2. Click co ns tra int = and enter Disp_X.
3. Check the box for uppe r bo und = .
5. Click re s po ns e = and select X _D is p from the list of responses.
A loadsteps button should appear in the panel.
7. Check the box next to FORCE_X and click s e le ct.
8. Click cre a te .
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 co ns tra int = and enter Disp_Z.
12. Click re s po ns e = and select Z _D is p from the list of responses.
14. Check the box next to FORCE_Z and click s e le ct.
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 o bje ctiv e to enter the panel.
2. The switch in the left should be set to m in.
4. Click cre a te .

1. From the File menu, select Sa v e a s > M o de l.
A save file dialog box 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 s a v e .

2. Click s a v e a s .
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 name is used for OptiStruct input decks.
4. Click Sa v e .
Note the name and location of the joint_sizeOPT.fem file now displays in the input file:
field.
in the directory where the OptiStruct model file was written. The joint_sizeOPT.out file
errors are present.
Important files for size optimization include:

joint_sizeOPT. HyperGraph file containing data for the objective function,
hgdata 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 an 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 each optimization iteration, and compute time information.
This file contains compliance, volume calculations, and gauge
information for each optimization iteration. It is highly
recommended to review this file for warnings and errors.
joint_sizeOPT.res HyperMesh binary result file.
joint_sizeOPT_des. HyperView binary result file containing the design iteration

h3d results.
joint_sizeOPT_s1. HyperView binary result file containing the analysis results of

h3d subcase with ID 1.
joint_sizeOPT_s2. HyperView binary result file containing the analysis results of

h3d subcase with ID 2.
joint_sizeOPT.stat Summary of analysis process, providing CPU information for each

step during analysis process.
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 each

iteration.
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)

click the H y pe rVie w button.
HyperView will launch and the results will be loaded. A message window appears to inform
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. Note that 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 E le m e nt Thickne s s e s (s ).
5. Make sure the second drop-down list is set to Thickness.
6. Make sure the field below Averaging method is No ne .
7. Set the last load case simulation in the HyperView Results Browser, as shown below.
Scroll down to choose the last iteration ( Ite ra tio n 4, in this case), and click O K.

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 button .
The third page, which has results loaded from the file joint_sizeOPT_s1.h3d, is
displayed. Note that 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.
3. Click the C o nto ur toolbar button .
4. Select the first drop-down list below Result type: and select D is pla ce m e nt [v ].
5. Select the second drop-down list and select X .
6. Click on Apply .
The resulting contours represent the x component displacement field resulting from the
applied loads and boundary conditions.
7. Click the Measure toolbar button .
8. Click Add to add a new measure group.
The Measure panel helps measure different results. Here, we will measure the
displacement at node 3143 for which we have constrained the displacement.
9. Click the drop-down menu and select No da l C o nto ur as shown below.
10. Click on No de s , which opens a new window to select no de s B y ID .
11. Click B y ID to open a new window.
12. Enter 3143 in the field next to Node ID and click O k.
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. Note that 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 Ite ra tio n # .
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 button again to move to the fourth page.
The fourth page shows results loaded from the joint_sizeOPT_s2.h3d file. Note that
the name of the page is displayed as Subcase 2 Force_Z to indicate that the results
16. Select the first drop-down menu below Result type: and select D is pla ce m e nt [v ].
17. Select the second drop-down menu and select Z.
18. Click on 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?

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 is used to determine 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

Submitting the job
Viewing the results
Exercise
Retrieve the Database File
This loads the OptiStruct user 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 button .
4. Browse to the bracket_size.hm file, located in the HyperWorks installation directory

under <install_directory>/tutorials/hwsolvers/optistruct/ and click O pe n.
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 s iz e panel.
3. Select the de s v a r subpanel using the radio buttons on the left-hand side of the panel.
4. Click de s v a r = and enter part1.
8. Set the move limit toggle to m o v e lim it de fa ult.
9. Click cre a te .
A design variable, part1, has been created. The design variable has an initial value of
2.5, a lower bound of 1.0, and an upper bound of 2.5.
10. Repeat steps 4 through 9 to create the design variable part2 using the same initial value,
lower, and upper bounds.

the panel.
12. Click na m e = and enter part1_th.
13. Click the e ntity s e le ctio n switch and choose pro p.
14. Click pro p and select pa rt1 from the list of component collectors.
A property selection switch now appears below the comp button.
15. Click the property selection switch and select Thickne s s T from the pop-up menu.
16. Click on de s ignv a rs .
17. Check the box next to part1.
Note that the linear factor (value is box beside part1) automatically gets set to 1.000.
18. Click re turn.
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 pa rt2.
Step 3: Link the Design Variables

1. Select the de s v a r link panel.
2. Click on dlink = and type link1.
3. Click on de s ignv a r= , under dependent:, and select pa rt2.
4. Click on de s ignv a rs , under independent:, and activate pa rt1.
Note the linear factor (value is box beside part1) automatically is set to 1.000.
5. Click re turn.
6. Set C 0 = 0.000 and C M ULT = 1.000.
7. Click cre a te .
The design variable part2 is now linearly dependent on the design variable 'part1'.

Make sure the type is set to to ta l.
4. Click cre a te .
5. Click re s po ns e = and enter stress1.
6. Click the response type: switch and select s ta tic s tre s s from the pop-up menu.
7. Click on pro ps and select the component pa rt1.
8. Click s e le ct.
A stress type selector switch appears.
9. Click the response selector switch and select v o n m is e s from the pop-up menu.
10. Click the switch under von mises and select bo th s urfa ce s from the pop-up menu.
A response, stress1, is defined for the von Mises stress of the elements in the
component part1.
13. Click pro ps .
14. Click one of the pink shell elements in the graphics window to select the component pa rt2
.
A response, stress2, is defined for the von Mises stress of the elements in the
component part2.

section.
2. Click the switch in the upper left corner of the panel, and select m in from the pop-up
menu.

4. Click cre a te .
5. Click re turn to return to the Optimization Setup panel.
Step 6: Define Constraints

Upper bound constraints are to be defined for the responses stress1 and stress2.
2. Click co ns tra int = and enter stress1.
3. Click re s po ns e = and select s tre s s 1 from the list of responses.
5. Check the box nest to STEP and click s e le ct.
7. Click uppe r bo und = and enter 100.
8. Click cre a te .
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.
12. Check the box next to STEP and click s e le ct.

1. From the File menu, click on Sa v e As .
A Save file browser window pops up.
2. Select the directory where you would like to save the database, enter the name
bracket_size.hm for the database, and click Sa v e .

A Save file browser window pops up.
name for the model, bracket_size.fem, in the File name: field.
The suggested file extension for OptiStruct input decks is .fem.
4. Click Sa v e .
Note the name and location of the bracket_size.fem file now displays in the input file:
field.
in the directory where the OptiStruct model file was written. The bracket_size.out file
errors are present.
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

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 each optimization iteration, and
compute time information. This file contains compliance,
volume calculations, and gauge information for each
optimization iteration. 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
restart a run and, if necessary, run OSSmooth files for
topology optimization.
bracket_size.stat Summary of analysis process, providing CPU information for

Viewing the Results
Size optimization results from OptiStruct are given in two places. The bracket_size.out file
contains gauge and volume information for each iteration. 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.
This launches HyperView and opens the results. A message window appears to inform
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 button .

The third page has the results loaded from the bracket_size_s1.h3d file. Note that the
name of the page is displayed as Subcase 1 STEP to indicate that the results
5. Select the first drop-down menu below Result type: and select E le m e nt Stre s s e s [2D &
3D ] (t).
6. From the second drop-down menu, select v o nM is e s .
7. Select No ne in the field below Averaging method:.
8. 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. 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 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 button to move to the First page.
2. Make sure Result type: is set to E le m e nt Thickne s s e s (s ).
3. Also make sure that you select Ite ra tio n 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?

In this tutorial you will learn the steps required to perform a ply orientation optimization for a
composite structure. The figure below illustrates the model that will be used for this exercise.
Bicycle frame model
Constraints: A given maximum nodal displacement.
Design variables: Layer thickness.
Set up 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
2. Choose O ptiStruct as the User Profile.
3. Click O K.
5. Browse to the bicycle_frame.hm file, located in the HyperWorks installation directory

6. Click O pe n.
The bicycle_frame.hm database is loaded into the current HyperMesh session, replacing
any existing data.
You will find that the structural model has already been set up with the necessary
elements, parts, property, and material data. We will now try to load the frame to
simulate a sprint scenario.
Step 2: Create Load Collectors for the Loads and Boundary Conditions
1. Select the Load Collectors toolbar button .
3. Click lo a dco l na m e = and enter crank.
4. Click C o lo r and select a color from the palette.
5. Click the creation method switch and select no ca rd im a ge from the pop-up menu.
6. Click cre a te .
This creates a new load collector, crank.
7. Click lo a dco l na m e = and enter spcs.
8. Click C o lo r and select another color from the palette.
9. Click cre a te .
This creates a new load collector, spcs.

Step 3: Create Loads
1. Click Se t C urre nt Lo a d C o lle cto r at the right bottom corner of the HyperMesh window to
enter a new panel in which the load collectors are listed.
2. Select cra nk from the list of load collectors.
3. From the Analysis page, select fo rce s to enter the panel.
4. Select the cre a te subpanel using the radio buttons on the left-hand side of the panel.
5. Click the entity selection switch, immediately to the right of the create radio button and
select no de s 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 glo ba l s y s te m .
8. Click m a gnitude = and enter -100.0.
9. Click the direction definition switch below magnitude = and select the z - a xis from the
pop-up menu.
This creates a point force at the pedal location.
11. Click re turn to return to the main menu.
12. From the Analysis page, select the m o m e nts 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 glo ba l s y s te m .
17. Click m a gnitude = and enter 100.0.
18. Click the direction definition switch below magnitude = and select the x- a xis from the
pop-up menu.
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 re turn.

1. Click Se t C urre nt Lo a d C o lle cto r 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 s pcs 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 co ns tra ints 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.

SPC s applied to rear wheel location of frame
SPC s 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.
This applies these constraints to the selected nodes.
9. Click re turn to go back to the main menu.
Step 5: Create an OptiStruct Loadstep

1. From the Analysis page, select lo a ds te ps to enter the panel.
2. Click na m e = and enter crank.
3. Click the type: switch and select line a r s ta tic if it is not already selected by default.
5. Click on the entry field and select s pcs from the list of load collectors.
6. Check the box preceding LOAD.
7. Click on the entry field and select cra nk from the list of load collectors.
8. Click cre a te .
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 H y pe rLa m ina te 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 should appear.
3. Right-click D E SVAR.
A floating menu should appear with the option New.
4. Click Ne w.
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 Ne wD v 1, choosing R e na m e , and
overwriting the default design variable name.
6. Enter 1.0 in the Initial value: field.
7. Enter 0.0 in the Lower bound: field.
8. Enter 2.0 in the Upper bound: field.
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 choose D uplica te 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 choosing
R e na m e .
11. Examine the PCOMP branch to see all of the PCOMPs in the model.
12. Select the s e a t_tube PCOMP.
Details of the laminate appear in the GUI.
13. Click on 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 Upda te La m ina te .
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 E xit from the File menu.

You will exit the HyperLaminate GUI and return 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 o ptim iz a tio n to enter the panel.
2. Select re s po ns e s to enter this panel.
3. Click re s po ns e = and enter disp.
5. Click the to ta l dis p radio button.
6. Click no de s and select the node at the bottom bracket where the loads were applied by
clicking on it in the graphical display window.
7. Click cre a te .
10. Leave to ta l set.
Step 8: Create Constraints on the Displacement Response

2. Click co ns tra int= and enter Disp.
5. Click re s po ns e = and select dis p from the list of responses.
7. Check the box next to cra nk and click s e le ct.
8. Click cre a te .
A constraint is defined on the response dis p. It states that any solution (min. volume)
needs to have a displacement lower than 1.8 mm to be feasible.

2. Select o bje ctiv e to enter the panel.
3. Click the left-hand switch and select m in.
4. Click re s po ns e = and choose v o lum e from the pop-up menu.
5. Click lo a ds te p and select cra nk.
6. Click cre a te .

1. From the Analysis page, select O ptiStruct to enter the panel.
2. Following the input file: field click s a v e a s .
name for the model, bicycle_frameOPT.fem, in the File name: field.
4. Click Sa v e .
Note the name and location of the bicycle_frameOPT.fem file now displays in the input
file: field.
the directory where the OptiStruct model file was written. The bicycle_frameOPT.out
errors are present.
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 button, as shown in the figure below.
2. From the File menu, select O pe n .
An Open Session File browser window appears.
3. Select the bicycle_frameOPT_hist.mvw file that was created from your OptiStruct run
and click O pe n.
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.

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 is used to determine
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.

Set up a size optimization with discrete design variables in HyperMesh
Post-process the optimization results in HyperView
Exercise
Retrieve the Database File
4. Browse for and select the bracket_size.hm file.
5. Click O pe n.
The bracket_size.hm database is loaded into the current HyperMesh session, replacing
any existing data.
Setting Up a Size Optimization with Discrete Design Variables in

HyperMesh
Step 2: Create the Design Variables

2. Select dis cre te dv s 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 cre a te .
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 s iz e panel.
9. Select the desvar subpanel using the radio buttons on the left-hand side of the panel.
10. Click de s v a r = and enter part1.
14. Toggle no ddv a l to ddv a l = .
15. Click ddv a l= and select D D V1 from the list.
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.
the panel.
19. Click na m e = and enter part1_th.
20. Click the entity selection switch and choose pro p.
21. Click pro p and select pa rt1 from the list of component collectors.
A property selection switch now appears below the pro p button.
22. Click the property selection switch and select Thickne s s T from the pop-up menu.
23. Click on de s ignv a rs .
24. Check the box next to part1.
25. Note that the linear factor (value in box beside part1) automatically gets set to 1.000.
26. Click re turn.
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.
part2_th, relating the design variable part2 to the thickness entry on the PSHELL card
for the component part2.

Step 3: Create the Responses
3. Click the re s po ns e ty pe : switch and select v o lum e from the pop-up menu.
4. Click cre a te .
6. Click the re s po ns e ty pe : switch and select static stress from the pop-up menu.
7. Click pro ps .
8. Click one of the green shell elements in the graphics window to select the component
pa rt1.
9. Click s e le ct.
A stress type selector switch appears.
10. Click the stress type selector switch and select v o n m is e s from the pop-up menu.
11. Click the selector switch below the stress selector and choose the bo th s urfa ce s option.
A response, stress1, is defined for the von Mises stress of the elements in the component
part1.
14. Click pro ps .
15. Click one of the pink shell elements in the graphics window to select the component pa rt2
.
A response, stress2, is defined for the von Mises stress of the elements in the component
part2.


Upper bound constraints are to be defined for the responses stress1 and stress2.
8. Click cre a te .

section.
menu.
4. Click cre a te .

5. Click re turn to return to the Optimization Setup panel.

1. From the Analysis page, select O ptiStruct to enter the panel.
name for the model, discrete_bracket_size.fem, in the file: field.
4. Click Sa v e .
Note the name and location of the discrete_bracket_size.fem file now displays in the
input file: field.
in the directory where the OptiStruct model file was written. The bracket_size.out file
errors are present.
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).
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 button to move to the third page.
The third page has the results loaded from the discrete_bracket_size_s1.h3d file.
Note that 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 v o nM is e s .
7. Select No ne in the field below Averaging method:.
8. Click Apply .
von Mises contour for the initial design.
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. 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 button 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 Ite ra tio n #
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.

A size optimization is performed in this tutorial using OptiStruct. Size optimizations involve
the changing of the properties of either 1-D or 2-D elements. These properties include area,
moments of inertia of the 1-D elements, and the thickness of 2-D 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.
In this chapter, we will also use OptiStruct macros under an OptiStruct user profile to set up
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 1-D element property
Post-process the optimization results
Exercise
Import an FE Model File
2. Choose O ptiStruct as the User Profile.
3. Click O K.
6. Choose the proper File type: O ptiStruct.
7. Click on the Select Files button and browse for the shredder.fem file located in the
optistruct/.
8. Click O pe n.
9. Click Im po rt.
10. Click C lo s e to close the Import tab menu.
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.
1. From the Analysis page, select the R a dio s s panel.
shredder_analysis.fem in the File name: field.
4. Click Sa v e .
Note that the name and location of the shredder_complete.fem file shows in the input
file: field.
This launches the RADIOSS job.
RADIOSS model file was written. The shredder_analysis.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 3: View the Eigen Modes of the Shredder

1. From the Radioss panel, click on H y pe rVie w.
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 C lo s e to exit the Message Log menu that appears.
3. Set the animation type to Modal .
4. Select the Deformed toolbar button .
5. Leave Result type set to E ige n M o de (v ).
6. Set Scale: to M o de l Units .
7. Set Type: to Unifo rm : and type in a scale factor of 1000 for Value.
This means that the maximum displacement will be 1000 modal units and all other
displacements will be proportional.
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, we are accentuating displacements in all

directions.
8. Under Undeformed shape:, set Show: to E dge s .
9. Set Color: to M e s h.
10. Click Apply .
11. In the Results Browser, use the Simulation drop-down to select M o de 1 and click O K.
12. Click the contour button and click Apply to plot the Eigen Mode contour.
13. Click on the Note button and remove the first two lines, leaving the rest as below,
and click Apply .
14. Click on the Page Window Layout button to choose the four window layout .
15. Click in the first window and, from the Edit menu, click on C o py W indo w.
16. Click in the second window and, from the Edit menu, click on Pa s te W indo w.

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 on the play button 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 on Sa v e a s > R e po rt Te m pla te .
21. Change Save as type: to R e po rt de finitio n (*tpl).
22. For File name:, enter report.tpl.

23. Use the page navigation buttons 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. We will define the first design variable using the size panel.
2. Click on the s iz e panel.
3. Make sure the desvar subpanel is selected using the radio button on the left hand side of
the panel.
4. Click de s v a r = , and enter the name covethck.
5. Enter the following values: initial value = 3.0, lower bound = 1.0, upper bound = 6.0
.

6. Click cre a te .
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
Beamthck1 10 5 15
Beamthck2 20 15 30
Step 5: Assign Cover Thickness to a Design Variable

1. Still from the size panel, select the ge ne ric re la tio ns hip subpanel using the radio button
on the left.
2. For name =, enter the name covethck.
3. For C0, enter a value of 0.0.
4. Click pro p and select co v e r.
5. Verify that the property switch is set to Thickne s s T.
6. Click de s ignv a rs and check the box next to covethck.
7. Click re turn.
8. Click cre a te .
9. Click re turn.
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 pro p box, and select fra m e 2.
5. Verify that the property is D im e ns io n1.
6. Click de s ignv a rs and check the box next to Beamwide.
7. Click re turn and cre a te .
8. For dvprel =, enter the name DIM2.
11. Toggle the property to D im e ns io n2.
12. Click de s ignv a rs and check the box next to Beamhigh.
17. Toggle the property to D im e ns io n3.
18. Click de s ignv a rs and check the box next to Beamthck1.

22. Click the yellow pro p box,and select fra m e 2.
23. Toggle the pro pe rty to D im e ns io n4.
24. Click de s ignv a rs and check the box next to Beamthck2.
26. Click re turn.

1. Click the re s po ns e s panel.
2. For response =, enter the name mass.
3. Select the response type as m a s s .
4. Click cre a te .
5. For response =, enter the name f3.
6. Change the response type: to fre que ncy .
7. Enter a value of 3 for Mode Number.
8. Click cre a te .
9. Repeat items 5 through 8 to create response= f4 and Mode Number 4.

2. For constraint =, enter the name c_f3.
3. Check lo we r bo und = and enter a value of 6.0.
4. Click re s po ns e = and select f3.
5. Click the lo a ds te p button and check the box beside ld1, then click s e le ct.
6. Click cre a te .
7. Repeat items 2 through 6 with the following values: constraint= c_f4, lower bound =
6.0, response = f4, and loadstep ld1.

2. Set objective option to m in.
3. Click re s po ns e = and select m a s s .
4. Click cre a te .

2. In the Save file... window, browse for the working directory and save the database as:
shredder_optimization.hm.
3. Click Sa v e .
Step 11: Run the Size Optimization

OptiStruct model file was written. The shredder_optimization.out file is a good place
to look for error messages that will help to debug the input deck if any errors are present.
Post-process the Optimization Results
Step 12: View Thickness Results from the Optimization Run

close the solver GUI window.
2. Click H y pe rVie w from within OptiStruct panel.

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 Ite ra tio n # and click O K, as shown in the
image below.
7. Select the first drop-down menu below Result type: and select E le m e nt Thickne s s e s
(s ) and Thickne s s .
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 Wide 70.10

(DIM1):
Beam High 125

(DIM2):
Beam Thck 5
(DIM3):
Beam wide 15
(DIM4):
This .prop file can be read into HyperMesh with over write mode on and the PBARL card
will be updated.

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 0.25psi on the bottom skin,
a second where the tail experiences a tip load of 400lbs, 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 3ksi (3000 psi) Rho 0.1 lb/in3

psi)
G1,Z 800ksi (800000 4ksi (4000 psi) Yield 50ksi (50000 psi)
psi)
G2,Z 800ksi (800000 4ksi (4000 psi)

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. Click O K.
4. From the File on the main menu, select O pe n > M o de l.
5. Select the tail_baseline.hm file, located in the HyperWorks installation directory under
6. Click O pe n.
7. Click Apply .
Step 2: Create Isotropic Materials and Properties and Assign to Metallic

Ribs
1. Click the M o de l tab on the tab menu to open the Model Browser.
2. Right-click in the Model Browser window, and select C re a te > M a te ria l.
3. In the Name: field, type al2024-t3.
4. Select M AT1 as Card image:.
5. Ensure that C a rd e dit m a te ria l upo n cre a tio n is checked and click C re a te .
The MAT1 card image pops up.
6. 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. Click re turn to return to panel view.
8. Right-click in the Model Browser window, and select C re a te > Pro pe rty .
9. In the Name: field, type Ribs.
10. Select PSH E LL for Card image:.
11. In the second tab, select a l2024- t3 as the Material:.
12. Ensure that C a rd e dit pro pe rty upo n cre a tio n is checked and click C re a te .
13. Click on C re a te / E dit.
The PSHELL card image pops up.
14. Enter the thickness for the shell component by clicking [T], clicking in the text box, and
typing 1.0.
16. Using the Model Browser, create a new Component named Ribs.
17. Set the property to R ibs .
This automatically sets the material to al024-t3.
A property collector called 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.
19. R e turn to the main menu.
Create Material and Geometric Properties with HyperLaminate
Step 3: Create Orthotropic Material Properties using HyperLaminate

This launches the HyperLaminate GUI.
2. On the left-hand tree structure, left click on M AT8 to highlight it, and then right-click on
the highlighted M AT8.
A floating menu appears with one option: New.
3. Click on Ne w.
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 G la s s _fa bric is now complete.
8. Repeat steps 4 through 8 to create other material called Core with the material properties
provided in the table. You could 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 PC O M P to highlight it.
2. Right-click on the pre-highlighted PC O M P.
A floating menu appears with one option: New.

3. Click Ne w.
A new laminate definition is created and appears in the left-hand tree structure on a
branch underneath PCOMP.
4. Under the Laminate definition, the default Name: NewLaminate1 appears.
5. Replace NewLaminate1 with Inboard_section_top.
6. To the right of this field, click co lo r and choose a color for this laminate.
7. Under Stacking sequence convention, toggle Convection: to select Sy m m e tric-

M idla y e r.
8. Under Add/Update plies, make the following selections/assignments:
- For Material , select G la s s _fa bric.
- For Thickness T1, enter 0.25.
- For Orientation (Degrees), enter 0.
- For No. of Repetitions, enter 1.
9. Click Add ne w ply three times.
10. Under Ply lay-up order, in the 2nd row, modify the information:
- For Material, select C o re .
- For Thickness T1, enter 0.5.
11. Under Ply lay-up order, in the 1st row, modify the information:
The Ply lay-up order should look as shown in the following figure:
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
13. Right-click on Inbo a rd_s e ctio n_to p and select D uplica te .
14. Rename the PCOMP to Inboard_section_btm by right-clicking on the PC O M P or editing

the Name: field and changing the color.
15. 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
17. From the File menu, choose E xit.
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, we have meshed the model and defined our material and geometric properties.
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 As s ign.
2. Select the property Inboard_section_top from the list in the dialog box and click O K 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. Using the Model Browser, right-click on Lo a dC o lle cto r, and select H ide .
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 re turn.
6. From Tool page, select the o rga niz e panel.
7. Select one of the elements on the top inboard section, shown in brown in the picture
below.
8. Click e le m s and select by fa ce .
Notice a number of elements are selected on the top surface, stopping where the angle
between elements is greater than 37deg. The ribs elements in between the top and
bottom surface create a 90deg, thus the selection set stops here.
9. Click de s t = and select Inbo a rd_s e ctio n_to p from the list of component collectors.
10. Click M o v e .
11. Repeat the steps 7 through 9 to generate a similar picture below.
Skin elements organized into correct component collectors.
12. Right-click on Ta il and select Is o la te O nly .
Only the elements forming the ribs which are in the tail collector should now be displayed.
13. From Tool page, select the o rga niz e panel.
14. Click e le m s and select dis pla y e d.

15. Click D e s tina tio n = and select R ibs from the list of component collectors.
16. Click M o v e .
17. Using the Model Browser, right-click on C o m po ne nt and select Sho w.
19. Press F2 on the keyboard.
20. Set the entity selection to co m ps .
21. Click pre v ie w e m pty and de le te e ntity to clear any empty components (the tail
component in this case).
22. Click R e turn.
Step 7: Orient Elements Which Reference Composite Properties

1. From Tool page, select the no rm a ls panel.
2. Make sure the elements radio button is selected at the left of the panel.
3. Set the entity selection type to e le m s .
4. Click on e le m s and select by co lle cto r.
5. Check the box next to Ribs.
6. Click on the co m ps entity selection and select re v e rs e from the extended selection list.
7. Click s e le ct.
8. Click dis pla y no rm a ls .
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 on e le m under orientation: and choose an element whose normal is pointing inward.
10. Click a djus t no rm a ls .
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 co m po s ite s panel.
13. Make sure the radio button is set to m a te ria l o rie nta tio n.
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 v e cto r from the
drop-down menu.
16. Click on the switch under by vector and select z - a xis from the drop-down menu.
17. Click pro je ct.

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, we
have fully established the local orientation for each element referencing a composite
laminate.
18. Click re turn.
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.
Currently we have a load collector containing the pressure loads and another containing the
tip load, but we do not have a load collector containing both together. We need to create a
load collector which is a combination of the load collectors pressure and tip_load.
Step 8: Create a Combination Load Collector

Lo a dC o lle cto r.
2. In the Name: field, type Combined.
3. Select a suitable color.
4. Set the Card image: to LO AD .
5. Ensure that C a rd e dit lo a dco lle cto r upo n cre a tio n is checked and click C re a te .
An OptiStruct LOAD card is created and the card image appears in the lower part of the
display area. For information on the LOAD card, please read the OptiStruct on-line help.
6. Click LO AD _Num _Se t = and enter 2.
This indicates how many load-collectors we wish to combine.
7. Enter 1.0 in the field under S, if it is not already there.
8. Enter 1.0 in the field under S1(1).
9. Double-click L1(1) and select pre s s ure from the list of load collectors.
10. Enter 1.0 in the field under S1(2).
11. Double-click L1(2) and select tip_lo a d from the list of load collectors.

12. Click re turn to create the load collector.
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. Under View > B ro ws e rs > H y pe rM e s h > Utility , make sure the Utility Menu tab is
selected.
2. Click on the Utility tab and select FE A.
3. Under Loadsteps:, click B uckling.
The Create Buckling Subcases window appears.
With this window, you will create a static subcase and an associated buckling subcase in
one step.
4. In the field 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 called
buck_name.
5. Select E IG R L 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. We will choose 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 pre s s ure from the drop-down list to the right of LOAD:.
10. Select co ns tra ints from the drop-down list to the right of SPC:.
You have now created a linear static subcase called 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 called 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 called 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 called 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. Right-click on the O utbo a rd_s e ctio n_to p property in the Model Browser and select
C a rd E dit.
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, please 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 you click H ILL, a list of other failure theories
pop-up - 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 on the button beneath SOUT(1) and select Y E S 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 Y E S also.
6. Click re turn 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 you click H ILL).
9. From Analysis page, select the co ntro l ca rds 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 re turn until you return to the main menu.
Step 11: Perform the Baseline Finite Element Analysis

1. From the Analysis page, enter the R a dio s s panel.
2. Click s a v e a s , enter tail_baseline_complete.fem as the file name, and click Sa v e .
3. Set export options: to a ll.
4. Set run options: to a na ly s is .
5. Set memory options: to m e m o ry de fa ult.
7. Click R a dio s s to run the analysis job.
The message Processing complete appears in the window at the completion of the
job. RADIOSS 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 re turn.
Step 12: Review the .out Analysis Summary File

In the directory where you ran the RADIOSS analysis, you should find a
tail_baseline_complete.out file. This file contains a summary of the analysis run.
Using a text editor of choice, open the tail_baseline_complete.out file.
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

about the successful loading of the model and result files into the HyperView client in a

new page.
3. Set the animation type to Linear .
5. Make sure that the Result type: is D is pla ce m e nt [v ].
The second drop-down menu shows Mag.
6. Click Apply to display the displacement contour.
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 button .
2. Make sure that the box for Auto apply mode: is checked.
3. Click the O ff button 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 button or select C o nto ur from the Graphics menu.
6. Toggle the Result type: to E le m e nt Stre s s e s (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 E ntity Attribute s toolbar button.
10. Click Flip.
The Ribs component is now hidden and the composite laminate components are
displayed.
11. Click the Contour toolbar button or select C o nto ur from the Graphics menu.
12. Set Result type: to C o m po s ite Stre s s e s (s ) from the first row and Ply Fa ilure from the
second row.
13. On the third list, select E ntity with La y e rs : 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 M a x 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
We return to HyperMesh now 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 on the
D e le te Pa ge button. To keep the page open but return to the HyperMesh client page,
click the Pre v io us Pa ge or Ne xt Pa ge buttons until the HyperMesh client returns.

Step 15: Create and Reference a Thickness Design Variable for the
Metallic Ribs
1. From Analysis page, select the o ptim iz a tio n panel.
2. From optimization panel, select the ga uge panel.
3. Make sure the radio button is set to cre a te .
4. Click pro ps and select the R ibs collector.
5. Make sure that the top toggle is set to v a lue fro m pro pe rty .
This sets the initial value of the design variable to be the thickness value defined on the
property card.
6. Toggle the lower bound % button to lo we r bo und = and enter 0.01.
This sets the lower bound for the design variable.
7. Toggle the upper bound % button uppe r bo und = and enter 2.0.
This sets the upper bound for the design variable.
8. Make sure type: is set to PSH E LL - T.
The following figure shows the how the settings should look.
Gauge panel settings for rib thickness design variable
9. Click cre a te .
10. Click re turn twice to go to the main page.
Step 16: Create Design Variables for Composite Laminates with

HyperLaminate
This launches the HyperLaminate GUI.
2. In the tree-structure on the left, click on D E SVAR to highlight it.
3. Right-click on the pre-highlighted D E SVAR.
A menu appears with options.
4. Select Ne w.

This creates a new design variable, which is named NewDv1 by default.
5. Rename the design variable istgf_th (inboard_section_top, glass_fabric, 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 called
isbgf_th following the procedure outlined in steps 4 through 9.
Alternately, you can right-click on is tgf_th and choose D uplica te 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 choosing
R e na m e .
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 Inbo a rd_s e ctio n_to p 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. Choose is tgf_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. Choose is tc_th from the drop-down menu.
Now the design variable istc_th is associated to the thickness of the Core material used in
ply2 & ply4 of the Inboard_section_top component collector.
7. Click in the field under Designvar, under Thickness in row 3.
8. Choose is tgf_th from the drop-down menu.
9. Click Upda te La m ina te 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.
11. From the File menu, choose E xit.
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 re s po ns e s .
3. Click re s po ns e = and enter mass.
4. Click the response type: switch and select m a s s from the pop-up menu.
5. Click cre a te .

The optimization response mass, which is the total mass of the structure, is created.
6. Click re s po ns e = and enter vm_strs.
8. Click pro ps and select the R ibs collector.
9. Click Se le ct.
A new selector switch appears next to comps.
10. Make sure that the switch is set to v o n M is e s .
11. Click the switch below von Mises and set it to bo th s urfa ce s .
The optimization response vm_strs, which is the von Mises stress for the metallic ribs, is
created.
13. Click re s po ns e = and enter hl_ist.
14. Click the response type: switch and select co m po s ite fa ilure from the pop-up menu.
15. Click pro ps and select the Inbo a rd_s e ctio n_to p collector.
16. Click the switch next to props and select hill.
17. Click on switch below hill and select a ll plie s .
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 17 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 re s po ns e = and enter buckle.
21. Click the response type: switch and select buckling from the pop-up menu.
22. Click M o de Num be r: and enter 1.
The optimization response buckle, which is the lowest calculated buckling mode for the
structure, is created.
Step 19: Create Constraints and an Objective

Finally, the constraints and objectives must be defined. We 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 co ns tra ints = and enter cnst1.
3. Click re s po ns e = and select v m _s trs .
4. Check the box preceding upper bound =.
5. Click uppe r bo und = and enter 50,000.
6. Click lo a ds te ps and select the loadsteps pre s s ure _o nly , tip_lo a d_o nly , and co m bo .
7. Click s e le ct.
8. Click cre a te .
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 re s po ns e = and select hl_is t.
11. Check the box preceding upper bound =.
13. Click lo a ds te ps and select the loadsteps pre s s ure _o nly , tip_lo a d_o nly , and co m bo .
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 re s po ns e = and select buckle .
19. Uncheck the box preceding upper bound = .
20. Check the box preceding lower bound = .
22. Click lo a ds te ps and select the loadsteps buck_pre s s ure _o nly , buck_tip_lo a d_o nly ,
and buck_co m bo .
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 m in.
28. Click re s po ns e = and choose m a s s from the pop-up menu.
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 o pti co ntro l panel.
2. Check the box preceding MAXBUCK=.
The box preceding GBUCK= gets checked automatically.
Together, these two options ensure that up to 10 modes are considered in the buckling
constraint. Please refer to the OptiStruct online help for a more detailed description.
3. Click re turn.

2. Click s a v e a s , enter tail_opt.fem as the file name, and click Sa v e .
job. OptiStruct also reports error messages if any exist. The file tail_opt.fem.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.
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 choice, open the tail_opt.out file.
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
each iteration 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, we can graphically review
the iteration history of the optimization using HyperView.
1. Create a new page with the HyperView client by using the Add Pa ge button .
2. From the File menu, select O pe n > Se s s io n.
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 on File > Ne w > Se s s io n to start a new session.
2. Change the current client to H y pe rVie w using the client selector drop-down .
3. Click the down arrow to the right of the Select application toolbar button and select
HyperView .
4. Click Y e s to continue.
5. Create a two pane view by clicking on the Page Window Layout icon and selecting the
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 button .
The Load Model File panel pops-up.
8. Select the Tail_baseline_complete.h3d file from the directory where you ran your
RADIOSS baseline analysis.
9. Click O pe n.
Note that 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.
14. Click on the Contour toolbar button .
15. Select D is pla ce m e nt (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
s ubca s e 1 (pre s s ure o nly ) in the Load Case area and select the last ITE R # in the
Simulation area.
19. Click O K.
20. Click on the Contour toolbar button .
21. Select D is pla ce m e nt (v ) from the drop-down menu under Result type:.
22. Click Apply .
You can now see 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 we were optimizing for mass without displacement
constraints.
23. With the animation mode set to Linear static , click the Pla y 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 Ne w > Se s s io n.
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 Im po rt > So lv e r D e ck.
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 Im po rt.
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. Under the Import tab, click on the arrow before the import options to expand.
8. Check the box beside FE overwrite.
9. Click Im po rt.
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 will be used to
demonstrate how to do free-sizing optimization using OptiStruct. HyperView will be 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:
Set up a free-sizing optimization with nonlinear gap elements
Post-process the thickness convergence in the design domain
Set up 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 O pe n M o de l.
An Open Model browser window pops up.
4. Select the rib_complete.hm file, located in the HyperWorks installation directory under
5. Click O pe n.
Step 2: Create Design Variable for Free-sizing Optimization

2. Select the fre e s iz e panel.
3. Choose the cre a te subpanel using the radio button on the left.
4. Click de s v a r= and enter shells.
5. Verify that type: is set to PSH E LL.

6. Click pro ps , choose the W e b component and click s e le ct.
7. Click cre a te .
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 pa ra m e te rs subpanel.
2. Click de s v a rs and select the s he lls design variable created previously.
3. Toggle m inm e m b o ff and, for m indim = , enter 2.0.
4. Click upda te .
5. Click re turn.
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 on we ighte d co m p.
4. Click lo a ds te ps and select both the C o up_Ve r and Pre s s ure loadcases.
The weighting factor should be 1.0 for both.
5. Click re turn.
6. Click cre a te .
7. For response =, input the name volfrac to create the volume fraction response.
8. For response type, click on v o lum e fra c.
9. Leave the type as to ta l.
11. Click re turn.
12. Click on the dco ns tra ints panel to define the volume fraction constraint.
13. For constraint =, input the name vol.
14. Click re s po ns e = , and select the v o lfra c response.
15. For upper bound =, input a value of 0.3.
17. Click re turn.

18. Click on the o bje ctiv e panel to define the objective.
19. Toggle to m in if not already done.
20. For response =, select the wco m p response.
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 Sa v e .
Note the name and location of the rib_freesize.fem file shows in the input file: field.
OptiStruct model file was written. The rib_freesize.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_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. This is a HyperMesh command file. When executed in

cmf 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. This is a HyperMesh command file. When executed in

cmf 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. The file contains two frames. The top frame opens one of
html 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

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 are 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 clo s e to close the message window.
3. Click the Entity Attributes icon on the toolbar and undisplay all of the components,
except Web. You can do this 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 M e s h:, shaded mesh option .
5. Click on the W e b component to get a shaded mesh.
6. Go to the Contour panel and set the Result type: to E le m e nt Thickne s s e s .
7. In the loadcase selection area above the Results Browser, select the last iteration listed
in the Simulation list and click O K.

8. Click To p Vie w 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 D e le te Pa ge until the HyperMesh client
is onscreen 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 Sa v e a s >
M o de l.
2. Select the directory where you are running the optimization and enter rib_freesize.hm
for the file name.
3. Click s a v e .
4. Right-click on the Design Variable section of the Model Browser and select D e le te .

6. Choose the to po lo gy panel.
7. Select the cre a te subpanel.
8. For desvar = input the name shells.
9. Click pro ps , choose the W e b component, and click s e le ct.
10. Under type, choose PSH E LL and leave the base thickness as 0.0.
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 Sa v e a s
> M o de l.
2. Select the directory where you are running the optimization and enter the name
rib_topology.hm for the file.
3. Click s a v e .
4. Select the parameters subpanel using the radio buttons on the left of the Topology
Optimization panel.
5. For desvars =, select s he lls .
6. Toggle m inm e m b o ff and for mindim =, enter the value 2.0 for minimum member size
control.
7. Click upda te .
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.

OptiStruct model file was written. The rib_topology.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_topology.hgdata HyperGraph file containing data for the objective function,

iteration.
rib_topology.HM.comp. HyperMesh command file used to organize elements into

cmf 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. The

user may edit the parameters in the file to obtain the
desired results.
rib_topology.out OptiStruct output file containing specific information on the

information for each optimization iteration, 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
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 clo s e to close the message window.
3. Click the Entity Attributes icon on the toolbar and undisplay all of the components,
except the Web component. You can do that by activating the Auto apply mode: (to
D is pla y O ff) and clicking on the components that you want turned off in the GUI.
4. Click the M e s h: panel shaded mesh option.
5. Click on the Web component to get a shaded mesh.
6. Go to the C o nto ur panel and set the Result type: to E le m e nt D e ns itie s .
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 O K.
9. Click To p 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.

C ontour 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

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:
Set up 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
models in Bulk Data Format for RADIOSS and OptiStruct. The Us e r Pro file s dialog can

3. From the File menu on the toolbar, select O pe n > M o de l.
4. Select the rotating_bar_design.hm file, located in the HyperWorks installation directory

5. Click O pe n.
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.
1. Right-click inside the Model Browser, activate the menu over Create, and select Lo a d
C o lle cto r.
2. In the Name: field, enter BCforOpt.
3. Click cre a te .
4. From the Preferences menu, select G ra phics .
5. Make sure the toggle is set to gra phics and check the box for coincident picking.
6. Click re turn to go to main menu.
7. On the Model Browser tab, select the display Pro pe rtie s v ie w .
8. From the Analysis page, click on co ns tra ints .
Only 6 DOF per flexible body should be fixed to remove 6 rigid body motion of each flexible
body.
9. From the graphics area, click the left end of the model. You should see two node numbers
at one location. Choose node number 1.
10. Make sure all dofs (dof1 to dof6) are checked and that their values are 0.00.

12. Click re turn.
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 co ntro l ca rds panel.
2. Click B ULK_UNSUPPO R TE D _C AR D S.
3. Make sure the following two cards are listed. If they are not listed, you need to enter the
cards.
4. Click O K.
5. Click re turn.
Step 4: Include Boundary Condition and MOTION in the Predefined MBD

Subcase for Structural Analysis and Optimization
1. From Analysis page, click on lo a ds te ps panel.
2. Click na m e = twice and select SUB C ASE 1.
3. Make sure that type: is switched to m ulti- bo dy dy na m ics .
4. Check SPC and click the = button to select B C fo rO pt.
5. Check the box next to MBSIM and click the = button to select M B SIM 1.
6. Check the box next to MOTION and click the = button to select M B SIM 1 again.
7. Click upda te .

Step 5: Define the Size Design Variables for Optimization
2. Click the s iz e panel.
3. Make sure that the desvar subpanel is selected using the radio buttons on the left-hand
side of the panel.
4. Click de s v a r = and enter rad1.
5. Click initia l v a lue = and enter 10.
8. Set the move limit toggle to m o v e lim it de fa ult.
9. Set the discrete design variable (ddval) toggle to no ddv a l.
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.
the panel.
13. Click na m e = and enter bar1_rad1.
14. Set the entity selection switch to pro p.
15. Click pro p and select PB AR L_1 from the list.
A property selection switch now appears below the prop button.
16. Make sure the property selection switch is set to Dimension 1.
17. Click de s ignv a rs .
18. Check the box next to rad1.

Note the linear factor (value is box beside tube) automatically gets set to 1.000.
19. Click re turn.
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.
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 Use r's Guide topic,
Responses.
2. Click re s po ns e = and enter Mass.
5. Click cre a te .
A response, mass, is defined for the total mass of the model.
6. Click re s po ns e = and enter Stress.
8. Click the entity selection switch and choose pro ps .
9. Click pro ps and select all properties in the list.
11. Make sure that stress is normal stress and stress recovery point is set to a ll.
A response, Stresses for all the bar elements are defined.


Upper bound constraint is to be defined for the response Mass.
2. Click co ns tra int = and enter Mass.
3. Click re s po ns e = and select M a s s from the list of responses.
6. Click cre a te .
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 o bj re fe re nce panel.
2. Click do bjre f = and enter MaxStress.
3. Click re s po ns e = and select Stre s s .
4. Check the boxes next to neg reference = and pos references =.
5. Make sure the toggle switch is set to lo a ds te ps .
6. Click lo a ds te ps and select SUB C ASE 1.
7. Click s e le ct.
8. Click cre a te .
11. Click the switch in the upper left corner of the panel and select m inm a x from the pop-up
menu.

12. Click do bjre fs = and select M a xStre s s .
Step 9: Save HyperMesh Database

2. Enter rotating_bar_design_user.hm in the file name field.
3. Click Sa v e .

1. From the Analysis page, click on the O ptiStruct panel.
Notice the input file: field is populated with the same path you just saved the .hm file to
with a new .fem extension.
optimization is complete when the line Processing completed successfully appears in
the shell.
input file was saved. In addition to ordinary output files, you can see a text file with the
name rotating_bar_design_user.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_user.eslout).

OS-4090: Manufacturing Constraints in a Free-size
Optimization of a Composite Structure
C omposite 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. Please refer to the Free-Size Optimization and Composite Topology and Free-
size Optimization pages of the Opt iSt ruc t Use r'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, we will set up free-size optimization with the following manufacturing

constraints:
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
This loads the selected user profile. It includes the appropriate template, macro menu,
generating models in Bulk Data Format for RADIOSS and OptiStruct.
The User Profiles GUI can also be accessed from the Preferences menu on the
toolbar.
4. Select the Composite_Wing.hm, located in the HyperWorks installation directory under

5. Click O pe n 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, we will review the layup information for the TopSkin and
BottomSkin components using the HyperLaminate panel.

Wing geometry
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 To pSkin 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 lay up information is also defined for the BottomSkin component. In this
tutorial, we will define free-size optimization on the TopSkin and BottomSkin
components.
4. From the File menu, select E xit.
You will exit the HyperLaminate GUI and return 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 o ptim iz a tio n to enter the panel.
2. Select fre e s iz e to enter this panel.

3. Select the create subpanel using the radio button on the left.
4. Click de s v a r= and enter Skins.
5. Click the selection switch below type: and select PC O M P(G ).
6. Click pro ps , choose the To pSkin and B o tto m Skin properties, and click s e le ct.
7. Clicks cre a te .
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 pa ra m e te rs subpanel.
2. Click de s v a rs and select the Skins design variable created previously.
3. Toggle m inm e m bo ff for m indim = , 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 upda te .
Step 5: Add Minimum Thickness Manufacturing Constraints for Free-

sizing Optimization
In this section, we will define the percentage following manufacturing constraints.
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 co m po s ite s subpanel.
2. Click de s v a r= and select the Skins design variable created previously.
3. Under the laminate thickness: section, toggle m inim um thickne s s o ff to minimum

thickne s s = .
4. Enter 0.2 in the field that appears next to minimum thickness =.
5. Click on upda te to update the above defined minimum laminate thickness constraint to
the free-size design variable.
6. Click on the green button e dit to open the panel.

7. Select PLY PC T by clicking in the box.
8. Click on the switch below PLYPCT and select Spe cify Num be r.
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.
PANGLE Ply orientation to which the PLYPCT constraints are

applied.
PPMIN Minimum ply percentage thickness for the PLYPCT
constraint.
PPMAX Maximum ply percentage thickness for the PLYPCT
constraint.
PTMAN Manufacturable ply thickness.
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.
BALANCE BALANCE flag indicating that a balancing constraint is

applied.
BANGLE1 First ply orientation to which the BALANCE constraint
is applied.

BANGLE2 Second ply orientation to which the BALANCE
constraint is applied.
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 re turn to return from the panel.
15. Click upda te to update the above defined manufacturing constraints to the free-size
design variable.
16. Click re turn 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 dis pla ce m e nt, select the nodes for which the response
is defined, and select the type of displacement (dof).
2. Click re s po ns e = and type disp.
3. Change the response type: to s ta tic dis pla ce m e nt.
4. Click on no de s to open the extended entity selection window and select by s e ts .
5. Click the box next to Nodes to select the set and click on s e le ct.
Notice that 6 nodes at the end side of the wing are selected.
6. Choose do f3.
7. Click cre a te to create the displacement response for the selected nodes.
8. Similarly, create another response with the name mass and a response type: of m a s s ,
with to ta l for the option.
9. Click cre a te to create the mass response.
10. Click re turn.

In this step, we set the upper and lower bound constraint criteria for the analysis.
2. Click co ns tra int= and enter disp_constr.

5. Select re s po ns e = and set it to dis p.
7. Check the boxes next to SubCase1 and SubCase2.
8. Click s e le ct.
9. Click cre a te .

4. Click cre a te .
5. Click re turn twice to exit the optimization panel.

2. Click s a v e a s , enter Wing_FreeSize_with_PLYPCT.fem as the file name, and click

Sa v e .
job. 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 on C o nto ur. Choose
E le m e nt thickne s s e s as the Result type; then choose the drop-down menu below and
select Thickne s s .
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 on Is o and click on Apply to display the isometric view of the model.
2. In the Model Browser, click on the Component view icon .
3. Click on the Isolate Shown button and then click on B o tto m Skin and To pSkin in the

component tree.
This will leave only these two components displayed.
4. Click on the Exploded View icon, .
5. Click on Add to add a new explosion view.
6. Click on 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 on C o nto ur. Choose Ply
Thickne s s as the Result type and leave Thickne s s 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
Set up 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 o pe n and open the file <install directory>/
dresp3_simple_h.hml.
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 profile dialog and click O K.
generating models in Bulk Data Format for RADIOSS and OptiStruct. The User Profiles
GUI can also be accessed from the Preferences menu on the toolbar.

6. Make sure the File type: is O ptiStruct.
7. Load the File: <install directory>/tutorials/hwsolvers/optistruct/

dresp3_simple.fem.
8. Click Im po rt.
9. Click C lo s e .
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.
1. From the Analysis page, select co ntro l ca rds .
2. Click ne xt.
3. Click LO AD LIB and enter the following inputs:
Type: DRESP3
GROUP: HLIB
PATH: <location of the hml 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, please exit the panel and edit
the rest in by hand in Step 5 of this exercise.
4. Click re turn.
5. Click pre v .
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 B ULK_UNSUPPO R TE D _C AR D S 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 O K.
3. Click re turn.
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 E xpo rt > So lv e r D e ck.
2. Select the export directory for the solver file.
3. Click , specify the file name dresp3_simple.fem, and click Sa v e .
4. Click E xpo rt.
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. Sa v e 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: s ta rt > All Pro gra m s > Alta ir H y pe rW o rks 12.0 >
O ptiStruct.

9. Browse to the dresp3_simple.fem file saved above.
10. Click R un to run the optimization.
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-5020: Shape Optimization of a 3-D Bracket Model using the Free-shape Method
OS-5060: Shape Optimization of a 3-D Model using the Free-shape Method with
Manufacturing Constraints

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. C antilever 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 is used to determine 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.
Set up the shape optimization problem in HyperMesh
Post-process the results in HyperView
Exercise

Step 1: Load the OptiStruct User Profile and Retrieve the Geometry
2. Choose O ptiStruct as the User Profile and click O K.
3. From the File menu, select O pe n > M o de l.
4. Select the beamshape.hm file, located in the HyperWorks installation directory under
5. Click O pe n.
The beamshape.hm is loaded into the current HyperMesh session, replacing any existing
data. The database only contains geometric data.
Note the location of beamshape.hm now displays in the file: field.
Setting Up the Shape Optimization Problem in HyperMesh
Step 2: Create Shapes using HyperMorph

This section makes use of HyperMorph. For a more detailed description of the functionality of
HyperMorph, please refer to the HyperMorph section of the HyperMesh documentation.
2. Select the H y pe rM o rph panel.
3. Select the do m a ins panel.
4. Select the cre a te subpanel using the radio buttons on the left side of the panel.
5. Change the s witch subpanel to a uto functio ns and keep the default settings.
6. Click ge ne ra te .
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;
local handles, which are represented by smaller yellow balls. Only local handles will be
covered in this tutorial.

7. Click re turn to return to the HyperMorph panel.
8. Select the m o rph panel.
9. Select the m o v e ha ndle s subpanel.
10. Click the right-hand switch and select m o v e to no de 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 s a v e s ha pe subpanel.
16. Click s ha pe = 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 a s no de pe rturba tio ns .
19. Click s a v e .
20. Click Y e s .
This shape has been saved, and can be associated with a design variable later.
21. Click undo a ll.
The model returns to its original shape.

23. Select the ha ndle s panel.
25. Click on na m e = and enter aux1.
26. Click on do m a in 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 no de s .
29. Click on no de s and select the node at the center of the top edge of the beam by clicking
on it in the graphics window.
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 m o v e ha ndle s subpanel.
34. Click the switch beside move to node and select inte ra ctiv e from the pop-up menu.
35. The handle button should be highlighted. If not, click on it.
36. Select the handle you just created by clicking on it in the graphics window.
37. Click m o rph.
38. Click the ne w ha ndle in the graphics window and keep the mouse button held down.
39. Move the mouse downwards in a straight line.
40. Note how the mesh morphs interactively as you move the handle.
41. When the handle is roughly at what was the center of the beam, release the mouse
button.

42. Select the s e t bia s ing subpanel using the radio buttons on the left-hand side of the
panel.
43. Click on ha ndle s .
44. Check the box next to aux1 and click s e le ct.
45. Verify that the box next to make retroactive is checked.
46. Switch the bia s to s cre e n e dit.
47. Click s cre e n e dit.
The number 1.000 appears next to the handle 'aux1'.
48. Click the number and keep the mouse button held down.
If you move the mouse upwards the number increases, if you move the mouse downwards
the number decreases.
49. Move the mouse upwards until the value reads 1.500, then release the button and click
upda te .
50. Note how the curvature of the top edge has altered. See Figure 6.
51. Select the s a v e s ha pe subpanel using the radio buttons on the left-hand side of the
panel.
52. Click s ha pe = and enter shape2.
53. Select a color or leave the default.
54. Set the toggle under s ha pe = to a s no de pe rturba tio ns .
55. Click s a v e .
56. Click Y e s in the dialog box that asks if you want to Save perturbations for nodes at

global and morph volume handles.
We have now saved this shape, later we can associate it to a design variable.
58. Click re turn twice to return to the OptiStruct panel.
Step 3: Define the Shape Design Variables

1. Select the s ha pe panel.
2. Select the de s v a r subpanel.
3. Switch the design variable option from single desvar to m ultiple de s v a rs .
4. Click s ha pe s .
5. Check the boxes next to shape1 and shape2 and click s e le ct.
6. Click cre a te .
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 Use r's Guide under Responses.
2. Click re s po ns e = and enter vol.
3. Click the response type switch and select Vo lum e from the pop-up menu.
4. Click cre a te .
5. Click re s po ns e = and enter disp.
6. Click the response type switch and select s ta tic dis pla ce m e nt from the pop-up menu.
8. Enter 1115 and press E NTE R.
9. Select do f1.
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.

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 co ns tra int = and enter constr.
3. Click re s po ns e = and select dis p from the list of responses.
4. Click lo a ds te p.
5. Check the box next to Load and click s e le ct.
6. Check the box next to uppe r bo und = .
8. Click cre a te .
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'.

section.
menu.
3. Click re s po ns e = and select v o l from the response list.
4. Click cre a te .
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 SH APE .
3. Use the green ne xt button to see more cards.
4. Set both TYPE and OPTION to ALL.

name for the model, beamshape.fem, in the File name: field.
4. Click Sa v e .
Note that the name and location of the beamshape.fem file now displays in the input file:
field.
in the directory where the OptiStruct model file was written. The beamshape.out file is a
are present. Make sure the process is complete before checking the results files.
This section describes how to view results in HyperView, which will be launched from within
the OptiStruct panel of HyperMesh.
HyperView is a comprehensive post-processing and visualization environment for finite element

Step 9: View the Shape Results

1. While in the OptiStruct panel of the Analysis page, click the green H y pe rVie w button.
Note that a message window pops up to indicate that beamshape_des.h3d and

beamshape_s1.h3d are loaded.
beamshape_des.h3d will be opened on page 2 and beamshape_s1.h3d will be opened on

page 3 of HyperView.
3. Use the navigations buttons seen in the figure below to navigate to Design History (page
2).
4. Select last iteration from Simulation using the drop-down selection, as seen in the figure
below.
5. Go to the C o nto ur panel .
6. Set the Result type: to Sha pe cha nge (v ).
7. Select M a g.
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 3 using the page navigation arrow button.
2. Select the last iteration from Sim ula tio n using the drop-down selection, as seen in the
image below.
3. Go to the Deformed panel and set Sha pe C ha nge (v ) as the Result type:.
4. Click Apply .
The optimized shape of the beam is shown on the screen now.
5. Go to the Contour panel and set D is pla ce m e nt (v ) as the Result type:.

6. Select M a g using the toggle.
7. Click Apply .
8. Click the Measure panel toolbar button .
9. Check the box in front of Static MinMax Result.
10. Notice that node 1115 has a displacement which is within the constraint value.

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.
C antilever 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
Retrieve the File
A User Profiles dialog will appear.
2. Choose O ptiStruct as the user profile and click O K.

4. Select the Lbeamshape.hm file, located in the HyperWorks installation directory under
5. Click O pe n.
Step 2: Create Shapes using HyperMorph

This section makes use of HyperMorph. For a more detailed description of the functionality of
HyperMorph, please refer to the Hy pe rM orph section of the HyperMesh documentation.
2. Select the H y pe rM o rph panel.
3. Select the do m a ins panel.
5. Click the switch next to global domain and select the a uto functio ns from the pop-up
menu.
6. Click ge ne ra te 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. We will only be dealing
with the local handles in this tutorial.
10. Select the m o v e ha ndle s subpanel using the radio buttons on the left side of the panel.
11. Click the right-hand switch and select tra ns la te 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 v a l = and enter -10.0.
15. Click m o rph.
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 s a v e s ha pe subpanel using the radio buttons on the left side of the panel.
17. Click na m e = and enter shape1.
18. Click co lo r and choose a color from the palette.
19. Set the toggle beneath shape = to a s no de pe rturba tio ns .
20. Click s a v e .
21. Say Y e s to the message regarding the perturbations as shown above.
We have now saved this shape as shape1, later we 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 re turn 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 s ha pe .
2. Select the de s v a r subpanel using the radio buttons on the left side of the panel.
3. Toggle the switch to m ultiple de s v a rs from single desvar.
4. Click s ha pe s , (the yellow button that appears).
5. Check the boxes next to shape1, shape2, shape3, and shape4 and click s e le ct.
6. Click cre a te .
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 re s po ns e s panel (accessed through the optimization panel on the Analysis
page).
4. Click cre a te .
5. Click re s po ns e = 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 do f 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 cre a te .
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 o bje ctiv e panel (accessed from the optimization panel on the Analysis
page).
menu.
3. Click re s po ns e = and select m a s s from the response list.
4. Click cre a te .

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 dco ns tra ints panel (accessed from the optimization panel on the Analysis
page).
2. Click on co ns tra int = and enter Constr.
3. Click re s po ns e = and select D is p from the list of responses.
5. Check the box next to load and click s e le ct.
6. Check the box next to lower bound =.
7. Click lo we r bo und = and enter -2.0.
Note this is a lower bound as the response is negative.
8. Click cre a te .
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

2. In the Save As dialog box, type lbeamshape_opt.hm as the file name.
3. Click Sa v e .

name for the model, lbeamshape_opt.fem, in the File name: field.
4. Click Sa v e .
Note the name and location of the lbeamshape_opt.fem file now displays in the input

file: field.
5. Set the memory options: toggle, located in the center of the panel, to m e m o ry de fa ult
.
6. Click the run options: switch, located at the left of the panel, and select o ptim iz a tio n.
in the directory where the OptiStruct model file was written. The lbeamshape_opt.out
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

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 the green H y pe rVie w button.
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 buttons, 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 Sha pe cha nge (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 button 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 button 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 C o nto ur panel toolbar button.
3. Under Result type:, select D is pla ce m e nt (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. Note that the
maximum displacements for the last Iteration # is still below 2.0.

OS-5020: Shape Optimization of a 3-D Bracket Model
using the Free-shape Method
In this exercise, 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:
Set up a free-shape optimization
Post-process the free-shape optimization results
Set up 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
2. Choose O ptiStruct as the User Profile and click O K.
3. Select the Open Model toolbar button .
4. Select the free_shape3D.hm file, located in the HyperWorks installation directory under
5. Click O pe n.
The free_shape3D.hm database is loaded into the current HyperMesh session, replacing
any existing data. Note the location of free_shape3D.hm file now displays in the file:
field.
Step 2: Create Free-shape Design Variables (DSHAPE Cards)

1. From the Analysis page, click on o ptim iz a tio n.
2. Select the fre e s ha pe panel.
3. Click na m e = 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 cre a te .
Step 3: Define the Optimization Problem

1. Select re s po ns e s panel.
2. Enter Stress in the response= field.
3. Set the response type to s ta tic s tre s s .
4. Click the pro p button and select the s tre s s _fa ce s component which contains skin shells.
5. Click on the button below von mises and select bo th s urfa ce s .
6. Click cre a te .
Step 4: Define the Objective Reference

2. Enter MAX_STR in the dobjref= field.
3. Check po s re fe re nce ; this gives the value 1.0.

4. Click re s po ns e and select s tre s s .
5. Click cre a te .

2. Click the left-most toggle and select m inm a x.
3. Click do bjre fs and select M AX _STR.
4. Click cre a te .
5. Click re turn twice to go back to main menu.

look 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 SH APE .
3. Use the green ne xt button to see more cards.
4. Set both TYPE and OPTION to ALL.

name for the model, Free_Shape3D.fem, in the File name: field.
4. Click Sa v e .
Note that the name and location of the Free_Shape3D.fem file now displays in the input
file: field.
5. Set the memory options toggle to m e m o ry de fa ult.

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 line Job completed appears in the window.
Post-processing the Free-shape Optimization Results
This section describes how to view the results in HyperView which will be launched from
within the OptiStruct panel of HyperMesh.

Step 8: View Shape Results

Note that the message window pops up 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 button, 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 Sha pe cha nge .
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 navigations buttons 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 E le m e nt Stre s s e s [2D & 3D ] as the Result
type:.
4. Select v o n M is e s as the stress type.
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 re turn and go to the 1D page.
3. Click s y s te m s .
4. Choose the cre a te by a xis dire ctio n subpanel.
5. Click no de s and select node ID 20999 (See the following figure).
6. Click o rigin and select the same node (ID 20999) as no de s .
7. Click x- a xis and select node ID 15989.
8. Click xy - pla ne and select node ID 19462.

Local coordinate system
9. Click cre a te .
10. Click re turn.
11. From the Analysis page, click on o ptim iz a tio n.
12. Select the fre e s ha pe panel.
13. Select the gridco n subpanel.
The constraints on the flat part will be created first without any coordinate system.
14. Click de s v a r= and select s ha pe .
15. Select co ns tra int ty pe as pla na r.
16. Select nodes shown in the following figure.

C onstraints on Free Shape design space
17. Click the vector definition switch and select v e cto rs .
18. Select N1, N2, N3 as those three nodes on plane geometry (as shown in the figure).
Three nodes to defined the plane
19. Click a dd.
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 co ns tra int ty pe as v e cto r.
21. Click no de s .
22. Select nodes shown in the following figure (select only the nodes that are on the curved
part).
C onstraints on free-shape design space on curved part
23. Click dire ctio n s e le cto r and select lo ca l s y s te m .
24. Click the local coordinate system created in the previous step.
25. Click the vector definition switch and select v e cto r.
26. Click the direction definition switch below v e cto r, and select z - a xis from the pop-up
menu.
27. Click a dd.
28. Click re turn twice to get back to the main menu.


name for the model, Free_Shape3D_const.fem, in the File name: field.
4. Click Sa v e .
Note that the name and location of the Free_Shape3D_const.fem file now 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.

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, we can increase the buckling factor and thereby increase
critical buckling force.
We want to perform buckling optimization to minimize the maximum von Mises stress among
several elements. We do this using the minimize 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.
Set up a buckling optimization simulation
Post-process the results with HyperView
Exercise

Retrieve the File
4. Select the os_buckle_original.hm file, located in the HyperWorks installation directory

5. Click O pe n.
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. We will review
the design variables and animation of the previously defined shape changes.
1. Click on the Utility tab on the Model Browser.
If the Utility tab is not visible on the left side of the GUI in HyperMesh, go to the View
menu, and select B ro ws e rs > H y pe rM e s h > Utility .
2. On the Utility tab, choose O pti (near the bottom).
3. Under Optimization Info:, click D e s ign Va ria ble s .
The Size and Shape Design Variables dialog appears.
v1 and v2 are pre-defined with Lower Bound = -2.0, Initial Value = 0.0, and Upper
Bound = 2.0 (see figure below).

4. Click C lo s e to close the Size and Shape Design Variables window.
6. Click s ha pe .
7. Set the radio button to de s v a r, and then click a nim a te .
8. Set simulation = to SH APE - v 1 (1).
9. Set data type = to Pe rturba tio n Ve cto r.
10. Click line a r and notice the animation of the first shape.
11. To review the second shape repeat steps 7 9, setting change simulation = to SH APE -
v 2 (2).
12. Click re turn three times to go back to the optimization panel.
Step 3: Define the Size Optimization Design Variable

The shape optimization setup is pre-defined 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 ga uge panel.
2. Verify that the create subpanel is selected with the radio buttons on the left.
3. Set the type: switch to PSH E LL- T and the toggle beneath to s a m e de s v a r fo r a ll pro ps
.
4. Click de s v a r= and enter shells.
5. Click pro ps .
6. Click both do m and s he ll_e le m e nts .

7. Click s e le ct.
8. Enter a value of 6.0 in initial value =.
9. Click the first toggle and change from lower bound % = to lo we r bo und = and enter a
value of 3.0.
10. Click the second toggle and change from upper bound % = to uppe r bo und = and enter
a value of 9.0.
Step 4: Create Eigenvalue Analysis (buckling) Load Collectors

We will create a load collector to perform real eigenvalue analysis (buckling analysis).
1. Select the Load Collectors toolbar button .
2. Select the cre a te subpanel using the radio buttons on the left side of the panel.
3. Click lo a dco l na m e = and enter Buckling.
4. Click ca rd im a ge = and choose the E IG R L card image for this load collector.
5. Click cre a te / e dit.
6. Set V1 = 0.01, V2 = 100.0, and ND = 20.
To enter a value for a field in the card image, click the number field and type in the
number.
OptiStruct will search for the three lowest eigenvalues below 100.
Step 5: Set up a Buckling Optimization Load Step

1. From the Analysis page, click lo a ds te ps .
2. Click na m e = and enter Buckling.
3. Click the type: switch and choose line a r buckling from the pop-up menu.
4. Click the box preceding STATSUB and select LINE AR (already existing static loadcase).
5. Click the box preceding METHOD(STRUCT) and select buckling.
6. Click cre a te and re turn to get back to the main menu.
Step 6: Define the Responses for Optimization


3. Create three responses with the following settings: Region ID is not required.
Response = Response type: Characteristics
Buckle buckling M o de Num be r: 1
Von s ta tic s tre s s pro ps : do m

Stre s s ty pe : v o n m is e s / bo th s urfa ce s
Vol v o lum e by e ntity

pro ps : do m
4. Click re turn.
Step 7: Define the Constraints for Optimization

1. From the optimization panel, click dco ns tra ints .
2. For co ns tra int = , enter the name BUCKLE.
3. Click the check box to the left of lower bound and assign a value of 30.
4. Click re s po ns e = and click B uckle .
5. Click lo a ds te ps , then click the box besides the Buckling and click s e le ct.
6. Click cre a te .
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 cre a te .
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 re s po ns e = and select Vo n.
5. Toggle all to lo a ds te ps .

7. Click the check box to the left of LINEAR, and click s e le ct.
8. Click cre a te .
This creates the minimize maximum optimization response.
9. Click re turn.
Step 9: Define the Objective for Optimization

2. Click the switch and set to m inm a x.
3. Click do bjre fs .
4. Check the box to the left of MAX_STRESS.
5. Click s e le ct.
6. Click cre a te .
Step 10: Solve the Buckling Optimization Problem

file name, os_buckle_optimization.fem, in the File name: field.
4. Click Sa v e .
Note the name and location of the os_buckle_optimization.fem file now displays in the
input file: field.
This exports the OptiStruct input file and launches the OptiStruct job. If the job is
successful, new results files can be seen in the directory where the OptiStruct model file
was written. The os_buckle_optimization.out file is a good place to look for error
messages that will help to debug the input deck if any errors are present.
9. At the end of the optimization run, close the solver GUI window.

Post-processing the Results with HyperView
Step 11: View Animations in HyperView
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 Sha pe C ha nge (v ) from the first drop-down list, and M a g
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 button 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, please refer to the on-
line 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 C o nto ur panel toolbar button.
3. Under Result type:, select E le m e nt Stre s s e s (2D & 3D )(t) from the first drop-down list,
and v o nM is e s 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 button 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 button and go to M o da l.
4. Click the Animation Controls toolbar button.
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.

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

Set up a shape optimization problem in HyperMesh
Exercise
Step 1: Launch HyperMesh Desktop, Set the User Profile and Retrieve
the File
The User Profiles GUI can also be accessed from the Preferences menu on the
toolbar.
4. Select the rail_joint_original.hm file, located in the HyperWorks installation directory

Performing an Analysis of the Initial Design
Step 2: Run the Baseline Analysis

1. From the Analysis page, click on R a dio s s .
2. Click s a v e a s , enter rail_joint_original.fem as the file name, and click Sa v e .
4. Set the run options: toggle to a na ly s is .
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 H y pe rVie w 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 v o n M is e s .
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 re turn to exit the panel.
Step 4: Display Node Numbers

1. From Tool page, select num be rs panel.
2. Click no de s and select by s e ts .
3. Select no de s e t by clicking the check box to the left of node.
4. Click s e le ct.
16 nodes are highlighted on screen.
5. Click o n to display node IDs.
6. Click re turn.
Step 5: Build 2-D Domains on the Rail

1. In the Model Browser window, expand the Component list.
2. Right-click on the component PSH E LL and click on Is o la te .
All other components are turned off for ease of visualization.
4. Go to the H y pe rM o rph panel, and select do m a ins .
5. Toggle the radio button on the left to pa rtitio ning.

6. Verify that domain angle = 50.
7. Verify that curve tolerance = 8.0000.
8. Toggle back the radio button to cre a te .
9. Click the switch (small triangle) and select 2D do m a ins .
10. Toggle all elements to e le m s .
11. Click e le m s and select by s e ts from the pop-up window.
12. Check the boxes for rail_set1 and rail_set2.

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. Toggle the radio button to e dit e dge s subpanel.
2. Verify the top selector is s plit.
3. Click do m a in and select the circular edge-domain passing through nodes 1300, 1305,
1311, 1316.
4. Click no de and select node 1311 from the display. Refer to the previous figure.
5. Click s plit.
The circular domain is split at Node 1311 and a new handle is created at node1311.
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 steps 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 do m a in and select the circular domain passing through nodes 931, 926, 937 and
942.
10. Click no de and select node 931 on screen.
11. Click s plit.
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 11-14), 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 m e rge edges.
2. Click the left do m a in, below merge and select the outer red curve from node 926 to pre-
existing handle (refer to previous figure).

3. Click the right do m a in and select the outer red curve from pre-existing handle to node
942.
4. Verify that retain handles is unchecked.
5. Click m e rge .
Notice the pre-existing handle is removed.
6. Repeat steps 1 through 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 2-D Domains on the Tube

1. In the Model Browser window expand the Component.
2. Right-click on the component PSH E LL.1 and click Sho w.
3. Toggle back the radio button to cre a te .
4. Make sure the switch (small triangle) is selected to 2D do m a ins .
5. Click e le m s and select by s e ts from the pop-up window.
6. Check the boxes for elem_set1.
7. Click s e le ct.

8. Click cre a te .
9. Repeat steps 5 through 8 to create three more 2-D domains for elements in sets
elem_set2, elem_set3, and elem_set4 respectively.
10. Click re turn and go back to the HyperMorph module.
Domains on Rail and Tube Joint
Step 9: Create Shapes

In this step, we create three shapes using the created domains and handles.
1. Click m o rph.
We use the alter dimensions feature in HyperMorph to modify the curvatures of selected
edge domains.
2. Toggle to a lte r dim e ns io ns .
3. Toggle the right switch and select curv a ture .
4. Toggle ce nte r ca lcula tio n and change the setting to by e dge s .
5. Toggle the switch below and select ho ld e nds .
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 do m a ins 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 curv e ra tio = and enter 20.
10. Click m o rph.
A new curvature is applied to the selected eight edge domains. See the following figure
below.
11. Toggle the radio button to s a v e s ha pe .
12. Click on s ha pe = , enter the name sh1.
13. Toggle as handle perturbation to a s no de pe rturba tio n.
14. Click on the color button and change the color of the shape vectors or leave the default
color.
15. Click s a v e .
Shape vectors (arrows) are created of the selected color.
16. Click undo a ll to prepare for the generation of the next shape.
17. In the Model Browser tab, right-click on Sha pe and select H ide .

First shape variable, sh1.
18. Toggle the radio button to a lte r dim e ns io ns .
19. Under edges only, click re s e t .
This will clean up previous selection from buffer.
20. Click do m a ins and select the red edge curves as shown the following figure.
Morph edge domains for the second shape.

21. Click m o rph.
A new curvature is applied to the selected eight edge domains. See the following figure
below.
22. Toggle the radio button to s a v e s ha pe .
23. Click on s ha pe = , enter the name sh2.
24. Toggle as handle perturbation to a s no de pe rturba tio n.
25. Click on the co lo r button and change the color of the shape vectors or leave the default
color.
26. Click s a v e .
Shape vectors (arrows) are created of the selected color.
27. Click undo a ll to prepare for the generation of the next shape.
Refer to the following figure for the new shape changes.
Second shape variable, sh2.
29. Toggle the radio button to a pply s ha pe s .
In HyperMorph, a new shape can be created as a linear combination of existing shapes.
30. Click s ha pe s and select both s h1 and s h2.
31. Click Se le ct.
32. Verify that the multiplier is 1.0.
33. Click a pply .
34. Toggle the radio button to s a v e s ha pe s .

35. Click s ha pe = and enter sh3.
36. Make sure that the toggle is set to no de pe rturba tio ns .
The new shape sh3 includes influences from both sh1 and sh2 shapes as shown in the
next figure.
37. Click s a v e .
Do NOT click undo all at this moment because we will create one more shape based on
this third shape change.
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 PSH E LL and click on H ide .
These components are turned off for ease of visualization.
40. Toggle the radio button to a lte r dim e ns io ns .
41. Under edges only, click reset .
This will clean up previous selection from buffer.
42. Switch the top selector from curve ratio to dis ta nce = .
This feature allows you to shorten the distance between selected domains.
43. Switch the end a: selector from two handles to no de s a nd ha ndle s .

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 ha ndle s 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 ha ndle s 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 ho ld m iddle .
49. In the Model Browser, right-click on the component PSH E LL and click on Sho w.
These components are turned on for ease of visualization
50. Click dis ta nce = and enter 20.
51. Click m o rph.
A rectangular shape appears to the joint as shown in the next figure.
52. Toggle the button to s a v e s ha pe .
53. Click s ha pe = and enter sh4.
54. Make sure that the toggle is set to no de pe rturba tio ns .

55. Click s a v e .
56. Click undo a ll to restore the mesh to the baseline configuration.
57. In the Model Browser, right-click on Sha pe and select H ide .
58. Click re turn three times to go the main menu.
Fourth shape variable, sh4
Step 10: Define the Shape Design Variables and Review by Animation
2. Click on the s ha pe panel.
3. Make sure the radio button is set to de s v a r and cre a te .
4. Toggle the switch to select m ultiple de s v a rs .
5. Click s ha pe = and select s h1, s h2, s h3 and s h4.
6. Click s e le ct.
8. Click lo we r bo und = and enter -1.0.

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 a nim a te .
12. Click on s im ula tio n = SH APE s h1 (1).
13. Make sure that data type = is set to Pe rturba tio n v e cto r.
14. Click m o da l to animate the first shape variable.
15. Click ne xt and then a nim a te to see the next shape variable, and so forth.
16. Click re turn three times to go back to the optimization panel.
Step 11: Create the Mass and Static Stress Response

3. Click on the response type switch and select m a s s from the pop-up menu.
5. Click cre a te .
7. Click on the response type switch and select s ta tic s tre s s from the pop-up menu.
8. Click the pro ps button and select the PSH E LL.1 component which contains skin shells.
9. Do NOT select any element under excluding:.
10. Make sure that the toggle is selected to v o n M is e s .
11. Toggle the bottom switch to select bo th s urfa ce s .
A response, Stress, is defined for the model.

3. Click re s po ns e = and select M a s s .
4. Click cre a te .
Step 13: Create Constraints on Stress Response

2. Click co ns tra int= and enter con.
4. Click uppe r bo und= and enter 200.
5. Select re s po ns e = and set it to Stre s s .
6. Click lo a ds te ps and check STE P.
7. Click s e le ct.
8. Click cre a te .
9. Click re turn 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 co ntro l ca rds panel.
2. Click the Ne xt button twice and choose the PAR AM card.
3. Check the box next to CHECKEL.
4. Click the Y E S button under CHECKEL_V1 and change to NO .
5. Click R e turn twice.


2. Click s a v e a s , enter rail_joint_opt.fem as the file name, and click Sa v e .
3. Set the export options: toggle to All.
job. OptiStruct also reports error messages if any exist. The file carm_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.
7. Close the DOS window or shell.
Step 16: Review the Shape Optimization Results

The HyperView client is launched and the results are loaded into a new page. 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.
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 button.
Note the Result type: is Sha pe C ha nge [v ]; this should be the only results type in the
file_name_des.h3d file.
The second drop-down menu select m a g.
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 on the name D e s ign < > Ite ra tio n 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)
Optimized Model
1. Click the Next arrow to move to page 2.
2. Click the C o nto ur toolbar button.
Note the Result type: is E le m e nt Stre s s e s [2D & 3D ] [t].

The second drop-down menu shows von Mises.
3. At the bottom of the GUI, click on the name Subca s e 1 (STE P) < > M o de l Ste p 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?

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
Set up an MBD transient analysis
Post-process MBD results in HyperView
Set up an ESL MBD optimization problem in HyperMesh
Post-process optimization results using HyperView
Exercise

the File
3. Click O K.
5. Select the 4bar _des i gn. hm file, located in the HyperWorks installation directory under
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.
1. From the Analysis page, click on co ntro l ca rds .
2. Click B ULK_UNSUPPO R TE D _C AR D S.
3. Make sure the following card is there; if not, it needs to be entered.
C onstant velocity (50 Rad/s) applied to the joint 66299.

4. Click O K.
5. Click re turn.
Step 3: Update Boundary Condition and MOTION in the Predefined MBD

Subcase
1. From the Analysis page, click on lo a ds te ps .
4. Check M B SIM if not checked, and click the = button to select M B SIM .
5. Click upda te .
6. Click e dit.
7. Scroll down to the bottom of the card image, and select SUB C ASE _UNSUPPO R TE D .
8. Enter MOTION = 1 in Comments.

9. Click re turn.
10. Click upda te .
Step 4: Submit the Transient MBD simulation in RADIOSS

1. From Analysis page, click on R a dio s s .
name for the model, 4bar_design_analysis.fem, in the File name: field.
7. Change the options: field so that it is blank.
8. Click Sa v e .
9. Click R AD IO SS.
This launches an RADIOSS run in a separate shell (DOS or UNIX) which appears.
If the analysis was successful, no error messages are reported to the shell. The analysis
is complete when the line Process complete successfully appears in the shell.

Post-processing the MBD Results in HyperView
Step 5: Post-process the transient MBD Analysis

2. Click H y pe rVie w from within the Radioss panel.
files.
5. Select the first drop-down menu below Result type: and select E le m e nt Stre s s e s (2D &
3D ) (t).
6. Click Apply .
7. Click E dit Le ge nd and change the Type: to D y na m ic s ca le .
Other properties can be changed here to created the desired legend.
8. Click on Page Layout button and change the page for 2 Vertical windows .
9. Click on empty window on the right side to make it current.
10. Click on the Client Selector drop-down switch and select H y pe rG ra ph 2D .

11. Click on windo w 1 to make it current.
12. Click on Measure .
13. In the Measure Groups list, check the box beside Dynamic MInMax Result.
14. Click on M a x at the list below Resolved in and, below Create curve:, modify Place
curve on: to E xis ting Plo t.
This will expose a list of plot windows on this report.
15. Check the Live link box, select W indo w 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)
16. From the File menu, select the option Sa v e Se s s io n File As : and change the Save as
type: to R e po rt de finitio n (*.tpl).
17. Enter Stress_report.tpl click Sa v e .
18. Use the page navigation buttons 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.
1. Click the Load Collectors button.
2. Select the cre a te subpanel.
3. Click na m e = and enter BCforOpt in the field.
4. Click the switch next to the card image and choose no ca rd im a ge from the pop up
menu.
5. Click cre a te .
7. From the Preferences menu, select G ra phics .

8. Make sure co incide nt picking is checked on.
10. From the Analysis page, click on co ns tra ints .
11. 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.
12. 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.
13. From the graphics area, click the center of the left spider of the component Middle and
choose node number 143.
14. From the graphics area, click the center of the lower spider of the component Right and
choose node number 441.
15. Make sure the Load Type= is set to SPC .

Step 7: Update Boundary Condition and MOTION in the Predefined MBD

Subcase
1. From Analysis page, click on lo a ds te ps .
4. Check SPC and click the = button to select B C fo rO pt.
5. Check M B SIM if not checked, and click the = button to select M B SIM .
6. Click upda te .
Step 8: Define Shape Variables

The shape perturbation vectors already have been created in this database. For more details
about creating shape perturbation vectors, please refer to other tutorials related to
HyperMorph. In this section, we will define shape design variables with the predefined shape
perturbation vectors.
2. Click s ha pe .
3. Select the de s v a r subpanel using the radio buttons on the left side of the panel.
4. Click the switch next to single desvar and change it to m ultiple de s v a rs .
5. Click s ha pe s in the cyan border in the right upper corner, select a ll from the pop-up
menu, and click s e le ct.
6. Click re turn.
7. Enter -1.0 for the lower bound and 1.2 for the upper bound.
8. Click cre a te .
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 re s po ns e s panel.
3. Click the response type switch and select m a s s from the pop-up menu.
4. Click cre a te .
6. Click the response type switch and select s ta tic s tre s s from the pop-up menu.
7. Click pro ps in the cyan border and select M iddle , Le ft, and R ight.
8. Click s e le ct.
9. Make sure that stress type is v o n m is e s and fo r bo th s urfa ce s .
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 o bje ctiv e panel (accessed from the optimization panel on the Analysis
page).
menu.
3. Click re s po ns e = and select M a s s from the response list.
4. Click cre a te .
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 dco ns tra ints panel (accessed from the optimization panel on the Analysis

page).
2. Click on co ns tra int = and enter Constr.
5. Click re s po ns e = and select Stre s s from the list of responses.
7. Check the box next to SUBCASE1 and click s e le ct.
8. Click cre a te .
A constraint is defined on the response "Stress." The constraint will force the maximum
stress on SUBCASE1 to be less than 30000.0 N/cm2.

1. From the File menu, click on Sa v e As > M o de l.
2. Select the directory in which to save the file and, in File name:, type 4bar_design_opt.
hm.
3. Click Sa v e .
Step 13: Submit the ESL Optimization Job in OptiStruct

name for the model, 4bar_design_opt.fem, in the File name: field.
7. Click Sa v e .

optimization is complete when the line Pro ce s s ing co m ple te appears in the shell.
input file 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

2. Click H y pe rVie w from within the OptiStruct panel or open HyperView from the Start
menu.
3. From the File menu, select O pe n > R e po rt Te m pla te .
4. Browse for the report Stress_report.tpl and click O pe n.
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 will appear explaining that the Element Stresses (2D & 3D) results do not
exist -- this is because the stress results on MBD simulations are just called 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 Stre s s (t).
10. Click on the traffic light button to start the animation.

2
von Mises stress contour (Max < 30000 N/cm )
Step 15: Contour the Shape Change
1. Click on to add a new page to the session.
2. Click on the Load Results toolbar button 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 Sha pe C ha nge (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 3-D Model using the
Free-shape Method with Manufacturing Constraints
In this exercise, 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.
Set up 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 O pe n > M o de l.
4. Select the freeshape3d_mfg.hm file, located in the HyperWorks installation directory

5. Click O pe n.
The freeshape3D_mfg.hm database is loaded into the current HyperMesh session,

replacing any existing data. Note the location of freeshape3D_mfg.hm now displays in
the file: field.

2. Click fre e s ha pe .
3. In the Create subpanel, click on de s v a r= , and enter shape.
4. Click on no de s and select the by s e ts check the box next to shape_nodes.
5. Click on s e le ct.
Free-shape design space
6. Click cre a te .
7. Click on the pa ra m e te rs subpanel and select the direction as gro w.

8. Set mvfactor= to 0.5.
9. Set nsmooth to 10 and click upda te .
Step 3: Convert Existing Shell Elements to Create the Barrier Mesh Face
(BMFACE)
1. Go to the 2D page.
2. Enter the e le m ty pe s panel.
3. Click on e le m s to get the extended entity list.
4. Select by co lle cto r.
5. Check the box next to barrier.
6. On the 2D & 3D subpanel, click on C TR IA3 in the field next to tria3.
7. Select B M FAC E from the list of options.
8. Click on C Q UAD 4 in the field next to quad4.
9. Select B M FAC E from the list of options.
10. Click upda te .
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 fre e s ha pe ; make sure that the desvar selected is shape.
3. Click on pa tte rn gro uping in the free shape panel.
4. Select the pattern type: 1- pln s y m .
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 a ncho r no de , input the node id= 1, and press E NTE R.
6. Click firs t no de and input the node id= 2.
7. Click the upda te button 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 ba rrie r.
1. Click on s ide co n in the free shape panel.
2. Click on de s v a r = and select s ha pe .
3. Click on B a rrie r m e s h: co m po ne nt= and select ba rrie r from the list.
4. Click upda te .
5. Click re turn to go back to the main menu.
Mesh barrier component
Step 6: Define Responses for Optimization

1. Click on the re s po ns e s panel.
2. Enter Stress in the response= field.
3. Set the response type to s ta tic s tre s s .
4. Switch from props to e le m s .
5. Click the e le m s button and click by s e ts .
6. Check the box next to stress and click s e le ct.
7. Choose v o n m is e s and click cre a te .

8. Click re s po ns e = and assign m a s s .
9. Set the response type: to m a s s .
Step 7: Define Constraints for Optimization

2. Click co ns tra int= and type the name stress.
3. Click re s po ns e = select s tre s s .
4. Activate uppe r bo und = and assign a value 62.
5. Click on lo a ds te ps , activate ls 2, and click s e le ct.
6. Click cre a te .
7. Click re turn.

2. Click the left-most toggle and select m in.
4. Click cre a te .

look at stress results on top of a shape change that was applied to the model in HyperView, a
2. Click the green ne xt button three times and select SH APE .
3. Set format to h3d and both TYPE and OPTION to ALL.

1. From the Analysis page, click O ptiStruct.

name for the model, freeshape3d_mfgopt.fem, in the File name: field.
4. Click Sa v e .
Note that the name and location of the freeshape3d_mfgopt.fem file now displayed in
This launches an OptiStruct run in a separate (DOS or UNIX) shell.
optimization is complete when the line Processing complete appears in the shell.
Post-processing Free-shape Optimization Results in HyperView
within the O ptiStruct panel of HyperMesh.

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 C lo s e 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 Se le ct Lo a d C a s e .
This will bring up the Load Case and Simulation Selection dialog which is also accessible
from the lower right portion of the status bar.
5. Select Ite ra tio n14 from beneath Simulation (load final iteration results).
6. Click O K.

7. Go to the Deformed panel .
8. Set the Result type: to Sha pe cha nge (v ).
9. Click Apply .
Shape optimization results are applied to the model.
Optimized Model
1. Go to the Contour panel and select E le m e nt Stre s s e s (2D & 3D ) (t) as the Result
type:.
2. Select v o n M is e s as the stress type.
3. Click on E le m e nts , click B y s e t, and select the set s tre s s .
4. Click on Add and close.
5. Click Apply .
von Mises stress contour on the final shape.

In this exercise, 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 C urve of Steel
Set up S-N Fatigue Problem using Fatigue Process Manager (FPM)
Set up free-shape optimization problem in HyperMesh
Post-process free-shape fatigue optimization results in HyperView
The following files are needed to perform this tutorial:
tarm_fatigue.fem, tarm_loadY.csv and tarm_loadX.csv
These files can be found in <install_directory>/tutorials/hwsolvers/optistruct/ and

copied to your working directory.

Exercise
Setting Up the S-N Fatigue Problem using Fatigue Process Manager

(FPM)
Step 1: Launch HyperMesh Desktop and Process Manager

A User Profiles dialog will appear. User Profiles can also be accessed from the
Preferences menu on the toolbar.
2. Choose O ptis truct in the User Profile dialog.
3. Click O K.
4. From the Tools menu, select Fa tigue Pro ce s s , and choose C re a te Ne w.
5. Type in a New Session Name, choose a Working Folder, and click C re a te .
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. From Model file type:, select R AD IO SS (B ulk D a ta ).
2. Click the Open Model file icon .
An Open file browser window pops up.
3. Browse for tarm_fatigue.fem file.
4. Click Im po rt.
This loads the control arm model. It includes a whole definition of two static subcases,
elements sets, and material static properties, etc.
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.
4. From Select existing fatigue subcase:, select the newly created fatigue subcase,
fa ts ub.
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.
Step 4: Fatigue Analysis Parameters Definition

1. Make sure the task Analysis Parameters is selected in the fatigue process tree.
2. Select the following options:
Analysis type: S-N
Stress Abs. Max.

combination Principal
method:

Mean stress GOODMAN
correction:
FEA stress MPA
unit:
Rainflow type: LOAD
3. Enter the following values:
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, please consult the HyperWorks online help.
Step 5: Fatigue Elements and Materials Definition

1. Make sure the task Elements and Materials is selected in the fatigue process tree.
2. Click Add.
A Material Data window opens.

3. For Element entity type:, select Pro pe rty - PSH E LL.
4. For Element entity name:, select s he lls .
5. Make sure the Ultimate tensile strength (UTS) is selected to define the material data.
6. Enter the value 1800 for UTS.
7. For Input method under Define SN Curve, select E s tim a te Fro m 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 C lo s e .
10. For Material type:, select Ste e l and click E s tim a te .
All the data for SN curve definition are automatically estimated.
11. Click the Plo t SN C urv e button 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 TO P a nd B O TTO M .
14. For Surface finish, select No Finis h.
15. For Surface treatment, select No Tre a tm e nt.
16. Leave the field after Fatigue strength reduction factor blank.
17. Click Sa v e 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.
Step 6: Load-Time History Definition

1. Make sure the task Load-Time History is selected in the fatigue process tree.
2. Click Add by File .
A Load Time History window opens.

3. For Load-time history name, enter hist_y.
4. For Load-time history type, select C SV.
5. Click the O pe n lo a d- tim e file icon .
An Open file browser window opens.
6. Browse for tarm_loadY.csv.
7. Click O pe n.
8. Click Im po rt.
9. Click Plo t L- T to show the load-time history.
10. Click Sa v e to write the new load-time history into HyperMesh database.
11. Close the Load Time History window.
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.
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 that the task Loading Sequence is selected in the fatigue process tree.
2. Click Add.
A Loading Definition window pops up.

3. For Select static loadcase, select lo a dx.
4. For Select load-time history, select his t_x.
5. Enter the value 1.0 for Scale.
6. Make sure Create new is selected using the radio buttons.
7. Enter Event1 for the new created fatigue event name.
8. Click Sa v e .
9. Click Add.
A Loading Definition window opens.
10. For Select static loadcase, select lo a dy .
11. For Select load-time history, select his t_y .
12. Enter the value 1.0 for Sca le .
13. Make sure Existing is selected using the radio buttons.
14. From Existing, select E v e nt1.
15. Click Sa v e .
16. Click Apply .

This completes the fatigue problem set-up. Next, we shall 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 fre e s ha pe .
3. In the create subpanel, click on de s v a r= and enter upper.
4. Click on no de s and select the by s e ts and check the box next to node set upper.
5. Click on s e le ct.
6. Click cre a te .
7. Click on the pa ra m e te rs subpanel.
8. Activate the o ptio ns checkbox.
9. Set nsmooth = 10, and mvfactor = 0.25.
10. Click upda te .
11. Repeat steps 4-10 and create a new design variable named lower with the node set
lower.
Step 9: Define Responses for Optimization

1. Click on the re s po ns e s panel.
2. Enter volume in the response= field.

3. Set the response type to v o lum e .
4. Click cre a te .
5. Click re s po ns e = and enter life.
6. Set the response type to fa tigue .
7. Click on pro ps and select the s he lls property.
8. Click cre a te .
Step 10: Define Constraints for Optimization

2. Click co ns tra int= and type the name con_life.
3. Click re s po ns e = and select life .
4. Activate lo we r bo und= and assign a value 2.0E4.
5. Click on lo a ds te ps , activate fa ts ub, and click s e le ct.
6. Click cre a te .

7. Click re turn.

2. Make sure the left-most toggle is selected to m in.
3. Click re s po ns e = and select v o lum e .
4. Click cre a te .

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 the green ne xt button two times and select SH APE .
3. Set format to H 3D 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 on it to
activate).
2. Click the Save .fem file as icon.
3. Set the directory in which to save the file, and in File name, enter tarm_fatigue_opti.
fem.
4. Click Sa v e to close the window.
5. Click Sa v e to save the OptiStruct model file.
6. From Run Options:, select o ptim iz a tio n.
7. Click Subm it.

This launches the OptiStruct to run the fatigue optimization.
OptiStruct model file was written.
The default files written to your directory are:
tarm_fatigue_opti.0.4. An ASCII format file which contains fatigue results of each

fat fatigue subcase in iteration step.
tarm_fatigue_opti_s4. Hyper 3D binary results file, with both static analysis results
h3d 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.
Step 14: Post-processing

1. Make sure the task Po s t- Pro ce s s ing is selected in the fatigue process tree.
When the fatigue optimization is finished successfully, it will automatically go into this
task.
2. Click Lo a d H 3D R e s ults (H V).
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 on the Sta rt/ Pa us e Anim a tio n icon to stop the animation.
5. Change the animation mode from Line a r Sta tic to Tra ns ie nt .
This shows the Life Contour on top of shape results.
7. Click on E dit Le ge nd and edit the legend (if you wish) to be the same as shown in the
following two images.
8. Click E xit 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.

In this exercise, 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.
Figure 1. Model review
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:
Step1: Load the OptiStruct user profile and import the model
2. Select O ptiStruct in the User Profile dialog.
3. Click OK.
models OptiStruct.

4. From the File menu, select Im po rt > So lv e r D e ck.
7. Select the rib_opt.fem file, located in the HyperWorks installation directory under
8. Click O pe n.
The location of rib_opt.fem now displays in the file: field.
9. Click Apply .
rib_opt.fem database is loaded 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. Please 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, please click s ha pe on the optimization panel.

3. Click a nim a te and enter the Deformed Shape panel.
One of the shapes should be displayed in simulation=.
4. Click line a r, you will see the animation of that shape.
5. The other shapes can be reviewed by clicking the next or prev button.
6. Return to the optimization panel.
Step 3: Submit the job as is

1. From the Analysis page, go to the OptiStruct panel.
The name and location of the rib_opt.fem file now 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 co ntro l ca rds .
2. Click C ASE _UNSUPPO R TE D _C AR D S, and input DGLOBAL=1.
3. Click B ULK_UNSUPPO R TE D _C AR D S, and input DGLOBAL,1.
4. Click re turn.
Both subcase and bulk data entries for global search are created with default parameters.

1. On the Analysis page, select the O ptiStruct panel.
2. Click s a v e a s , following the input file: field.
name for the model, rib_opt_global.fem, in the File name: field.
The .fem filename extension is the suggested extension for OptiStruct input decks.
4. Click Sa v e .
Note the name and location of the rib_opt_global.fem file now displays in the input
file: field.

in the directory where the OptiStruct model file was written. The rib_opt_global.out
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 on the H y pe rVie w button 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 Sha pe C ha nge (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

In this exercise, 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/m.
The temperature of the surrounding air is 10C 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:
2. Select O ptiStruct in the User Profile dialog.
3. Click O K.

models OptiStruct.
4. From the File menu, select Im po rt > So lv e r D e ck.
5. The File type: is OptiStruct.
7. Select the fins.fem file, located in the HyperWorks installation directory under
8. Click O pe n.
The location of fins.fem now displays in the file: field.
9. Click Apply .
The fins.fem database is loaded into the current HyperMesh session.
Step 2: Create shapes in HyperMorph

The Freehand module in HyperMorph is used to create the shapes. For a more detailed
description of the functionality of HyperMorph, please refer to the HyperMorph section of the
HyperMesh documentation.
1. From the Analysis page, go to the o ptim iz a tio n panel.
2. Click H y pe rM o rph.
3. Click Fre e ha nd.
4. Select the m o v e no de s subpanel using the radio buttons on the left side of the panel.
5. Set the movement option as tra ns la te .
6. Input the translation distance in the basic coordinate system, x=0.03, y=0.0, z=0.0.
We only want to extend the fins in x-direction.
7. Select m o v ing no de s .
8. Click the highlighted nodes and click by s e ts on the pop-up window.
9. Check the small box in front of node set sh1_move and click s e le ct.
The selected moving nodes are highlighted on the screen.
10. Select fixe d no de s .
11. Click the highlighted nodes and click by s e ts on the pop-up window.
12. Check the small box in front of node set sh1_fix and click s e le ct.

The selected fixed nodes are highlighted on the screen.
13. Select a ffe cte d e le m e nts .
14. Click the highlighted e le m s and click by s e ts on the pop-up window.
15. Check the small box in front of element set sh1_elem and click s e le ct.
The selected elements are highlighted on the screen.
16. Click the m o rph button.
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 s a v e .
The shape, shp1, for shape design variable is created.
21. Repeat steps 5 through step 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 re turn 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 s ingle de s v a r to m ultiple de s v a rs .
4. Click the highlighted shapes.
5. Check the boxes next to sh1, sh2, and sh3 and click s e le ct.
6. Input initial value = 0.0, lower bound = -1.0, upper bound = 2.0.
7. Click cre a te .
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 v o lum e from the pop-up menu. Make sure
the total volume is selected.
4. Click cre a te .
The total volume of the fins is created as the response.
5. Input re s po ns e = temperature.
6. Select te m pe ra ture as the response type.
7. Click no de s and click by id, type the node ID 2450 in the field and press E NTE R.
8. Click cre a te .
The temperature response at node 2450 is created.
9. Click re turn 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 re s po ns e = and select volume.
4. Activate the upper bound and enter 1.0e-5.
5. Click cre a te .
A volume constraint with the upper bound of 1.0e-5 is created.
Step 6: Define the objective function

1. Go to objective panel.
2. Toggle the option to m in.
3. Click re s po ns e = and select te m pe ra ture .
4. Click lo a ds te ps and select he a t tra ns fe r s ubca s e .
5. Click cre a te .
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

2. Click the green ne xt button to find SH APE 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 Sa v e .
Note that the name and location of the fins_opt.fem file now displays in the input file:
field.
5. Set the memory toggle toggle to m e m o ry de fa ult.
7. Set the export options toggle to cus to m .
in the directory where the OptiStruct model file was written. The fins_opt.out file is a
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 the H y pe rVie w button 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 G rid Te m pe ra ture s (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 Sha pe C ha nge (v ) as the Results type and click Apply .
The optimized shape at final iteration is loaded.
9. Select G rid Te m pe ra ture s (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.

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Location Telephone e-mail

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ii OptiStruct 12.0 Tutorials Altair Engineering

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Altair Engineering OptiStruct 12.0 Tutorials 1

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OS-2000: Design Concept for a Structural C-clip

OS-2010: Design Concept for an Automotive Control Arm

OS-2020: Increasing Natural Frequencies of an Automotive Splash Shield with Ribs

OS-2030: Control Arm Topology Optimization with Draw Direction Constraints

OS-2050: Pattern Repetition using Topology Optimization

OS-2060: Symmetry and Draw Direction Applied Simultaneously in Topology Optimization

OS-2070: Topology Optimization of a Reduced Model using DMIG

OS-2080: Topology Optimization of a Hook with Stress Constraints

OS-2090: Topology Optimization with Extrusion Constraints

OS-2095: Frequency Response Optimization of a Rectangular Plate

OS-2098: Topology Optimization of an Excavator Arm Model

2 OptiStruct 12.0 Tutorials Altair Engineering

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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 variables: The density of each element in the design space.

In this tutorial, you will:

Set up the model in HyperMesh

Analyze the baseline model

Set up the optimization

Post-process the optimization results

Set Up the Model in HyperMesh

Step 1: Launch HyperMesh Desktop and Set the User Profile

The User Profiles dialog will appear by default.

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Step 3: Create Materials and Properties; Assign to Components

1. Select the Model tab.

3. In the Name: field, type Steel.

4. Select M AT1 as Card image:.

The MAT1 card image opens.

6. For E, enter the value 2.1E5.

7. For Nu, enter the value 0.3.

8. For RHO, enter the value 7.9E-9.

11. In the Name: field, type prop_shell.

12. Select PSH E LL as the Card image:.

14. From the Name menu, select Ste e l as the material.