altair info-tag strukturmechanik 2015-3-24
DESCRIPTION
composite, finite element, ALTAIR HyperMesh, ALTAIR HyperWorks, laminate optimizationTRANSCRIPT
24/03/2015
1
Innovation Intelligence®
Info-Tag Strukturmechanik
Christian Alscher
Kristian Holm
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
9:00 Registrierung und Kaffee
9:30 Begrüßung
Überblick: Aufgabenstellungen in der Strukturmechanik
Kaffeepause
Thermisch-mechanische Analyse am Beispiel eines Motorblocks
Materialmodellierung für unterschiedliche Werkstoffe
Strukturberechnung mit MKS-Lastbestimmung
13:00 Mittagessen
Composites: Modellaufbau, Berechnung und Auswertung
Workflow für Schwingungs- und Akustikanalysen
Möglichkeiten zur Strukturoptimierung
Diskussion
Agenda
24/03/2015
2
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
• High stiffness to weight ratio!
• Tailored properties!
• Fibers can be aligned to provide directional stiffness
• Thermal expansion control• Vibrational damping
• Desirable Material Properties!
• Fatigue and corrosion resistance
• Design and manufacturing flexibility:
fewer parts!
Concrete Carbon
Design Challenge:• High Number of Variables• Orthotropic Material Properties• Orientation of the Ply Angles• Stacking Sequence
Why Composites?
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
• Each layer with at least one solid
• Large model, long CPU time
• High accuracy
• Mixed approach (middle layer thick)
• Shells for top and bottom layer
• Solid, thick shell or coehesive for middle layer
• Several solid layers to provide rotation
• Sandwich shell approach
• One shell element through the thickness
• Multiple layers, with different materials
solid
solid shell
shell
Modeling Techniques for Composites
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Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
• One property required for each ply drop/add (i.e. Zone)
• Properties are not linked across zones ���� Data duplication, No Direct Ply Shape
• No direction relationship to manufacturing process
• Example:
Plate requires three property tables
with repeating ply definitions
Delete P4 requires three updates
Zone 1 Zone 2 Zone 3 Zone 2 Zone 1
Zone 1 – Property Table
Ply Mat Thk Theta
P7 M1 0.01 45
P4 M1 0.01 0
P1 M1 0.01 45
Zone 2 – Property Table
Ply Mat Thk Theta
P7 M1 0.01 45
P5 M1 0.01 -45
P4 M1 0.01 0
P3 M1 0.01 -45
P1 M1 0.01 45
Zone 3 – Property Table
Ply Mat Thk Theta
P7 M1 0.01 45
P6 M1 0.01 90
P5 M1 0.01 -45
P4 M1 0.01 0
P3 M1 0.01 -45
P2 M1 0.01 90
P1 M1 0.01 45
P1 45P2 90
P3 -45
P4 0
P6 90P7 45
P5 -45
Composite Modeling Intro: Zone Based
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
• One stack (property) required per part
• A stack defines zones via ply shape definitions ���� No Data Duplication
• Direction relationship to manufacturing process
• Example:
Plate requires seven ply definitions,
no repeating plies, each ply shape defined
Stacking plies automatically defines zones
Delete P4 requires only one update
P1 45P2 90
P3 -45
P4 0
Zone 1 Zone 2 Zone 3 Zone 2 Zone 1
P6 90P7 45
P5 -45
Stack Table
Ply Mat Thk Theta
P7 M1 0.01 45
P6 M1 0.01 90
P5 M1 0.01 -45
P4 M1 0.01 0
P3 M1 0.01 -45
P2 M1 0.01 90
P1 M1 0.01 45
Ply Based Composite Modeling
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Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Integrated into HyperMesh via Model Browser Dialogs
Ply Based Composite Modeling
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
• Objective: Visually verify engineering data associated with math model
• “Live” 3D representation of 1D/2D elements w/ or w/o layers
• Color “by thickness”
• Element normal
• Material direction
• Ply orientations
• Ply expansion
Composite Visualization
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Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
• Individual Ply Results
• Strain Tensor Components
• Stress Tensor Components
• Principal Strain/Stress
• Failure Theories (Maximum
Strain, Hoffman, Tsai-Hill, Tsai-
Wu)
• Envelope Ply Results
• Min/Max/Extreme
• Sum/Average/Range (12.0)
• Identify Min/Max/Extreme Layer
Ply-Based Post-Processing
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
HyperWorks Solvers
Thermal and CFD
Highly Nonlinear
CrashSafety
Forming
Multi-bodyDynamics
OptiStruct RADIOSS MotionSolve AcuSolve
Optimization
Smart Multiphysics
FEKO
Electro-Magnetics
Statics
NVH
Thermal
Nonlinear
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Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Phase 1: Concept
Free-Size
Phase 2: Dimension
Size
Phase 3: Sequence
Shuffle
OptiStruct: Composite Optimization
• Objective: minimize mass (failure index, …)• Constraint: displacement (stress, …)• Manufacturing constraints:
• Min. and max. total laminate thickness• Min. and max. ply thickness• Min. and max. percentage of a fibre orientation• Linkage of thicknesses of plies• Constant thickness for a particular ply orientation
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Phase 1: ConceptQ: Which fibre angles do I need where?A: Free-Size-Optimization creates a thickness
distribution for each fibre angle.
Phase 2: DimensionQ: How many plies of each shape do I need?A: Discrete Size-Optimization calculates optimal
number of each ply shape of each fibre angle.
Phase 3: SequenceQ: I which order do I have to stack the plies?A: Shuffle-Optimization finds optimal stacking order
under consideration of ply book rules.
Phase 1: Concept
Free-Size
Phase 2: Dimension
Size
Phase 3: Sequence
Shuffle
OptiStruct: Composite Optimization
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Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Initial Design
Final Design
Composite Free-Size OptimizationWhat are the most efficient ply shapes?
Composite Size OptimizationHow many plies of each ply shape to meet engineering targets?
Composite ShufflingWhat is the exact stacking sequence to meet
manufacturing requirements?
Ply SlicingDetermines ply shapes
OptiStruct: Composite Optimization
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Finite element model representation
Optimal shapes/patches: free size optimization
Optimal number and thickness of plies: sizing
optimization
Ply stacking sequence optimization
�Peak failure index reduction: 20%�Displacement constraint satisfied�Minimum reserve factor met
Optimization of a Composite Sports Car Wing
24/03/2015
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Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
HyperWorks Solvers
Thermal and CFD
Highly Nonlinear
CrashSafety
Forming
Multi-bodyDynamics
OptiStruct RADIOSS MotionSolve AcuSolve
Optimization
Smart Multiphysics
FEKO
Electro-Magnetics
Statics
NVH
Thermal
Nonlinear
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
RADIOSS - DALLARA Race cars design
24/03/2015
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Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
RADIOSS - DALLARA Race cars design
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
• Model: Helicopter floor structure
• Objective: Improve survivability of cabin crew under crash landing
• Loading: Crash landing Vi= 3-10 m/s
Helicopter Survivability
24/03/2015
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Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Helicopter Survivability
• Model: Helicopter floor structure
• Objective: Improve survivability of cabin crew under crash landing
• Loading: Crash landing Vi= 3-10 m/s
Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Partner Caterham Composites
Lotus T127 Formel 1 Simulation dynamischer Seitencrash
24/03/2015
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Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Gegenstand der Untersuchung
Seitencrash-Absorber aus Kohlenstofffaser-Kunststoff-Verbund
Laminatmaterial
• 2x2 Twill Gewebe
Paul Schischkin
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Gegenstand der Untersuchung
Realversuch Seitencrash: Vorher-Nachher-Vergleich
Paul Schischkin
24/03/2015
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Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Modellaufbau
Solver: RADIOSS V12.0.210
Vernetzung der Geometrie:
• Grundlage: CAD-Model
• 5x5mm 4-Knoten-Schalenelemente (quads)
• eine Schale pro Laminatdicke
• Anzahl: insgesamt ca. 7500 Elemente
Paul Schischkin
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Modellaufbau
Elementeigenschaften (properties):
• Definition des Laminataufbaus durch den
Sandwich Schalen Ansatz
• Jede property erhält Informationen zu Anzahl
der Lagen, sowie ihre jeweilige Position, Dicke,
Orientierung und Material
Paul Schischkin
24/03/2015
13
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Modellaufbau
Materialmodell:
Elasto-plastisch-orthotrop (exemplarisch)
Zugrichtung
Druckrichtung
Paul Schischkin
Zugrichtung
Druckrichtung
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
#---1----|----2----|----3----|----4----|----5----|----6----|----7----|----8----|----9----|---10----|
/MAT/COMPSH/10
Altair composite material
# Init. dens. Ref. dens.
1.5000E-6 0
# E11 E22 NU12 IFLAG E33
42 40 .05 1 0.50
# G12 G23 G31 EPSF1 EPSF2
3.4 3 3 0 0
# ESPT1 EPSM1 EPST2 EPSM2 Dmax
0 0 0 0 .9999
# Wpmax Wpref Ioff
0 0 5
# C EPS ALPHA Icc
0 0 0 0
# sig_trac_1 B_1T N_1T SIGMA_1MAXT C_1T
0.1 25 .10 0 0
# EPS_1T1 EPS_2T1 SIGMA_RST1 Wpmax_trac_1
0 0 0 0
# sig_trac_2 B_2T N_2T SIGMA_2MAXT C_2T
0.1 20 .10 0 0
# EPS_1T2 EPS_2T2 SIGMA_RST2 Wpmax_trac_2
0 0 0 0
# sig_comp_1 B_1C N_1C SIGMA_1MAXC C_1C
.0050 2000 .5 0 0
# EPS_1C1 EPS_2C1 SIGMA_RSC1 Wpmax_comp_1
0 0 0 0
# sig_comp_2 B_2C N_2C SIGMA_2MAXC C_2C
.0050 2000 .5 0 0
# EPS_1C2 EPS_2C2 SIGMA_RSC2 Wpmax_comp_2
0 0 0 0
# sig_12 B_12T N_12T SIGMA_12MAXT C_12T
.0040 83.0 .31 0 0
# EPS_1T12 EPS_2T12 SIGMA_RST12 Wpmax_trac_12
0.075 0.085 0.05 0
# GAMMA_INI GAMMA_MAX Dmax
1E31 1E31 .9999
# Fsmooth Fcut
0 0
#---1----|----2----|----3----|----4----|----5----|----6----|----7----|----8----|----9----|---10----|
Radioss Composite Material Model
Linear
Nonlinear
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Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
#---1----|----2----|----3----|----4----|----5----|----6----|----7----|----8----|----9----|---10----|
/MAT/COMPSH/10
Altair composite material
# Init. dens. Ref. dens.
1.5000E-6 0
# E11 E22 NU12 IFLAG E33
42 40 .05 1 0.50
# G12 G23 G31 EPSF1 EPSF2
3.4 3 3 0 0
# ESPT1 EPSM1 EPST2 EPSM2 Dmax
0 0 0 0 .9999
# Wpmax Wpref Ioff
0 0 5
# C EPS ALPHA Icc
0 0 0 0
# sig_trac_1 B_1T N_1T SIGMA_1MAXT C_1T
1e+30 0 0 0 0
# EPS_1T1 EPS_2T1 SIGMA_RST1 Wpmax_trac_1
0 0 0 0
# sig_trac_2 B_2T N_2T SIGMA_2MAXT C_2T
1e+30 0 0 0 0
# EPS_1T2 EPS_2T2 SIGMA_RST2 Wpmax_trac_2
0 0 0 0
# sig_comp_1 B_1C N_1C SIGMA_1MAXC C_1C
1e+30 0 0 0 0
# EPS_1C1 EPS_2C1 SIGMA_RSC1 Wpmax_comp_1
0 0 0 0
# sig_comp_2 B_2C N_2C SIGMA_2MAXC C_2C
1e+30 0 0 0 0
# EPS_1C2 EPS_2C2 SIGMA_RSC2 Wpmax_comp_2
0 0 0 0
# sig_12 B_12T N_12T SIGMA_12MAXT C_12T
.0040 67.0 .29 0 0
# EPS_1T12 EPS_2T12 SIGMA_RST12 Wpmax_trac_12
0.00 0.00 0.00 0
# GAMMA_INI GAMMA_MAX Dmax
1E31 1E31 .9999
# Fsmooth Fcut
0 0
#---1----|----2----|----3----|----4----|----5----|----6----|----7----|----8----|----9----|---10----|
Composite Material Model: Yield Stress
Yield Stress
(((( )))) 1====σσσσF
1σσσσ
2σσσσ
t
1σσσσc
1σσσσ
c
2σσσσ
t
2σσσσ
t
12σσσσ
c
12σσσσ
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
#---1----|----2----|----3----|----4----|----5----|----6----|----7----|----8----|----9----|---10----|
/MAT/COMPSH/10
Altair composite material
# Init. dens. Ref. dens.
1.5000E-6 0
# E11 E22 NU12 IFLAG E33
42 40 .05 1 0.50
# G12 G23 G31 EPSF1 EPSF2
3.4 3 3 0 0
# ESPT1 EPSM1 EPST2 EPSM2 Dmax
0 0 0 0 .9999
# Wpmax Wpref Ioff
0 0 5
# C EPS ALPHA Icc
0 0 0 0
# sig_trac_1 B_1T N_1T SIGMA_1MAXT C_1T
1e+30 0 0 0 0
# EPS_1T1 EPS_2T1 SIGMA_RST1 Wpmax_trac_1
0 0 0 0
# sig_trac_2 B_2T N_2T SIGMA_2MAXT C_2T
1e+30 0 0 0 0
# EPS_1T2 EPS_2T2 SIGMA_RST2 Wpmax_trac_2
0 0 0 0
# sig_comp_1 B_1C N_1C SIGMA_1MAXC C_1C
1e+30 0 0 0 0
# EPS_1C1 EPS_2C1 SIGMA_RSC1 Wpmax_comp_1
0 0 0 0
# sig_comp_2 B_2C N_2C SIGMA_2MAXC C_2C
1e+30 0 0 0 0
# EPS_1C2 EPS_2C2 SIGMA_RSC2 Wpmax_comp_2
0 0 0 0
# sig_12 B_12T N_12T SIGMA_12MAXT C_12T
.0040 67.0 .29 0 0
# EPS_1T12 EPS_2T12 SIGMA_RST12 Wpmax_trac_12
0.00 0.00 0.00 0
# GAMMA_INI GAMMA_MAX Dmax
1E31 1E31 .9999
# Fsmooth Fcut
0 0
#---1----|----2----|----3----|----4----|----5----|----6----|----7----|----8----|----9----|---10----|
Composite Material Model: Plasticity
Plasticity, Strain Rates
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Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
#---1----|----2----|----3----|----4----|----5----|----6----|----7----|----8----|----9----|---10----|
/MAT/COMPSH/10
Altair composite material
# Init. dens. Ref. dens.
1.5000E-6 0
# E11 E22 NU12 IFLAG E33
42 40 .05 1 0.50
# G12 G23 G31 EPSF1 EPSF2
3.4 3 3 0 0
# ESPT1 EPSM1 EPST2 EPSM2 Dmax
0 0 0 0 .9999
# Wpmax Wpref Ioff
0 0 5
# C EPS ALPHA Icc
0 0 0 0
# sig_trac_1 B_1T N_1T SIGMA_1MAXT C_1T
1e+30 0 0 0 0
# EPS_1T1 EPS_2T1 SIGMA_RST1 Wpmax_trac_1
0 0 0 0
# sig_trac_2 B_2T N_2T SIGMA_2MAXT C_2T
1e+30 0 0 0 0
# EPS_1T2 EPS_2T2 SIGMA_RST2 Wpmax_trac_2
0 0 0 0
# sig_comp_1 B_1C N_1C SIGMA_1MAXC C_1C
1e+30 0 0 0 0
# EPS_1C1 EPS_2C1 SIGMA_RSC1 Wpmax_comp_1
0 0 0 0
# sig_comp_2 B_2C N_2C SIGMA_2MAXC C_2C
1e+30 0 0 0 0
# EPS_1C2 EPS_2C2 SIGMA_RSC2 Wpmax_comp_2
0 0 0 0
# sig_12 B_12T N_12T SIGMA_12MAXT C_12T
.0040 67.0 .29 0 0
# EPS_1T12 EPS_2T12 SIGMA_RST12 Wpmax_trac_12
0.00 0.00 0.00 0
# GAMMA_INI GAMMA_MAX Dmax
1E31 1E31 .9999
# Fsmooth Fcut
0 0
#---1----|----2----|----3----|----4----|----5----|----6----|----7----|----8----|----9----|---10----|
Composite Material Model: Damage and Failure
Damage & Failure
plastic work
Wp
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Failure models can be coupled with compatible material laws
Composite Material Model: Advanced Failure Models
24/03/2015
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Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Puck failure criteria
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Ergebnisse Paul Schischkin
24/03/2015
17
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Ergebnisse Paul Schischkin
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Ergebnisse Paul Schischkin
24/03/2015
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Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
CAE Process Chain
Phase 1:Free-Size
Optimisation
Phase 2:Sizing
Optimisation
Phase 3:Shuffle
Optimisation
Manufacturing and Design
ManufacturingSimulation
What is known ?
• Manufacturing process• Design idea• Available material (fabric, UD-layers, fiber/matrix)• Possible fiber orientations
In addition, we can answer:
• Is it possible to manufacture my design at all?• What is the influence of the manufacturing on the fiber orientation?• Do I have local thickenning or thinning?
What is not known ?
• Distribution of material and fiber orientation • Final lay-up of the laminate
Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
HyperMesh: Drape Estimator for Composite Fibers
• Calculate draping angles and thickness variation
• Geometry based, very fast (seconds)
• Good estimation for deviation of the fiber oriention,
but feedback on manufacturability only indirect
material/fiberdirection
24/03/2015
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Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Radioss: Draping Simulation
Sandwich method
1 Component1 Material1 Property
Sandwich material law
• All plies defined in the same property
Independant layers method
1 Component for each Ply1 Material for each Ply1 Property for each Ply
Fabric material law
• All layers definedindependently
• Contact interface betweenthe layers
Setup in HyperFormuser process
Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Sliding
• Sliding effect between layers can be modeled by contact interface
• Each layer is free to slide over other layers
• In this example, fiber orientaions are 0, +45, 90 and -45°regarding X axis
• The behavior during stamping is different for each layer
Radioss: Independent Layers Simulation
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Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
• Fiber orientation
• The rotation of fibers for each layer can be displayed in HV
Sandwich Method
Composite Forming
Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Radioss: Independent Layers with Resin
Independant layers + resin method
Connect material is used to model resin :
• A plasticity domain is reached after a small yield stress value• Strain rate dependancy available for user defined curves
Independent FiberLayers
Shell elements
Warm ResinSolid elements
Fibers + ResinShell + solid withcoincident nodes
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Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Altair Partner Alliance: Composites Offering
The composite offering from the Altair Partner Alliance reaches across many applications.
Working in tandem with OptiStruct and RADIOSS, material modeling, failure modeling,
optimization with failure constraints, composite panel analysis and composite panel detail
stress analysis can all be performed effectively.
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
9:00 Registrierung und Kaffee
9:30 Begrüßung
Überblick: Aufgabenstellungen in der Strukturmechanik
Kaffeepause
Thermisch-mechanische Analyse am Beispiel eines Motorblocks
Materialmodellierung für unterschiedliche Werkstoffe
Strukturberechnung mit MKS-Lastbestimmung
13:00 Mittagessen
Composites: Modellaufbau, Berechnung und Auswertung
Workflow für Schwingungs- und Akustikanalysen
Möglichkeiten zur Strukturoptimierung
Diskussion
Agenda
24/03/2015
22
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Workflow für Schwingungs-und Akustikanalysen
HyperWorks Solver Technology
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Noise and Vibration - workflow
Thermal and CFD
Highly Nonlinear
CrashSafety
Forming
Multi-bodyDynamics
OptiStruct RADIOSS MotionSolve AcuSolve
Optimization
Smart Multiphysics
FEKO
Electro-Magnetics
Statics
NVH
Thermal
Nonlinear
24/03/2015
23
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Model Build
Analysis Root Cause Analysis
SensitivityFocused
Optimisation
MDO
ValidationDelivery
- Modular Construction
- Flexible Assembly
- Parametric
- Reporting- Targets / Metrics- Model reduction- Rating /
Appraisal
- TPA- Participation- Force vs TFs- Test forcing
- What if- Sensitivity- Robustness- DOE
- Correlation- Performance- Issue Resolution- Mass / Cost
- Size- Gauge- Shape- Topography- ERP
- Common Model Parameters
- Design Constraints
Noise and Vibration - workflow
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Efficiency gains through integration
61
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Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Improve simulation efficiency
CMS super element method
� Reduction of degrees of freedom
� Structural/Fluid or Combined Fluid-Structural SE
� Both Craig-Chang and Craig-Bampton methods
� General Method (combined free and fixed
attachment points)
� Participation factors (PFCMS)
FRF based super element
� Compliments CMS based approach
� Faster residual run solution in the medium
frequency range (up to 500 Hz)
� component dynamic stiffness (CDS) - OptiStruct
AMSES (Automatic Multilevel Substructuring
Eigen Solver) - OptiStruct
Noise and Vibration - workflow
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
• CDS superelement technology in OptiStruct
• Reduces runtimes for variants to seconds
NVH parametric study (e.g. bushings)
overnight
Noise and Vibration - workflow
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Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Model Build
Analysis Root Cause Analysis
SensitivityFocused
Optimisation
MDO
ValidationDelivery
- Modular Construction
- Flexible Assembly
- Parametric
- Reporting- Targets / Metrics- Model reduction- Rating /
Appraisal
- TPA- Participation- Force vs TFs- Test forcing
- What if- Sensitivity- Robustness- DOE
- Correlation- Performance- Issue Resolution- Mass / Cost
- Size- Gauge- Shape- Topography- ERP
- Common Model Parameters
- Design Constraints
Noise and Vibration - workflow
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Problem Response
What’s Moving?
What If…?
Which Mode?
Which Panel?
Which Paths?
What Power Flow?
What DSA?What
Energy?
Noise and Vibration - workflow
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Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Diagnostic tools
Vib
ratio
nN
oise
Low Frequency Mid Frequency
Transfer Path AnalysisGrid participation
Energy consideration
Power Flow
Design Sensitivity Analysis
Modal participation
N&
VNoise and Vibration - workflow
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Noise and Vibration - workflow
Sensitivity filtering
� Optimization on all possible parameters in full vehicle model is to large
� Detection of sensitive components or parameters (use normalized variables)
� Size variables; gauge, stiffness, damping, materials
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Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Model Build
Analysis Root Cause Analysis
SensitivityFocused
Optimisation
MDO
ValidationDelivery
- Modular Construction
- Flexible Assembly
- Parametric
- Reporting- Targets / Metrics- Model reduction- Rating /
Appraisal
- TPA- Participation- Force vs TFs- Test forcing
- What if- Sensitivity- Robustness- DOE
- Correlation- Performance- Issue Resolution- Mass / Cost
- Size- Gauge- Shape- Topography- ERP
- Common Model Parameters
- Design Constraints
Noise and Vibration - workflow
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
• Frequencies
• FRF
• Forces, Stress, von-Mises Stress
• Functions: max, average, sum, …
• Normal displacement, velocity, acceleration,
• Frequency sub-ranges
• Mode shape
• PSD and RMS of displacement, velocity, acceleration, pressure, stress, strain
• Acoustic pressure
• ERP (Equivalent Radiated Power)
• Equations
• External routines (DRESP3 -> Fortran, C, HyperMath)
Noise and Vibration - workflow
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Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
� Min(max)
� Min (max) with frequency sub ranges
� System identification
mjg
T
Txfwwith
or
mjg
T
Txfw
j
i
iii
j
n
i i
iii
,,10)(: Subject to
)( : Minimize
,,10)(: Subject to
)(: Minimize
1
2
K
K
=≤
≤−
=≤
−∑
=
x
x
ββ
[ ]mjg
ffixd
j
ni
,,10)(: Subject to
,...,)(max: Minimize 0
K=≤
=
x
[ ]mjg
ffixd
j
subsubi
,,10)(: Subject to
,...,)(max: Minimize 21
K=≤
=
x
Curve Fitting
Noise and Vibration - workflow
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
� Trimmed body optimisation using screening techniques
TPA Result (Vehicle Model)
+
Full FE Tbdy Model
Panel Participation Plot at peak frequencyModal Participation
Identify peaks
Component Gauge + Topography optimisation
Panel Set as design Variables
Noise and Vibration - workflow
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Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
� Trimmed body optimisation using screening techniques
Response Curves
� Minimise Mass with constraint on Response (157Hz)
� 3dB improvement at peak of interest
� 40% reduction in mass of panel set
� Topography result to lead bead pattern design loop
� 35hr Run time for 30 iterations (12 cpus, AMSES)
Gauge Results
Topography Results
Noise and Vibration - workflow
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
• Use topology optimisation to design an efficient
engine cover
• Minimise radiated noise for a given volume of
material:
• Equivalent radiated power
• Σ area * normal velocity2 * constant
• Use CMS superelement of non-designable
structure
Designable Material
12400 nodes included in ERP response
Noise and Vibration - workflow
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Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
• Concept design for internal reinforcement
structure
• Optimised structure reduces ERP by 30%
• Run time 2.5hrs (laptop)
• Memory 8Gb
Noise and Vibration - workflow
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Fast and Accurate Analysis
Model Quality – Flexibility – Time Reduction
Root Cause Understanding
Problem Diagnostics – Transfer Path – Sensitivity
Robust Optimization Algorithms and Processes
Problem Definition – Method selection – Reduction Techniques –
Multi Disciplinary
Analysis Root Cause Analysis
SensitivityFocused
Optimisation
MDO
ValidationDeliveryModel
Build
OptiStructHyperStudy
Noise and Vibration - workflow
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Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
9:00 Registrierung und Kaffee
9:30 Begrüßung
Überblick: Aufgabenstellungen in der Strukturmechanik
Kaffeepause
Thermisch-mechanische Analyse am Beispiel eines Motorblocks
Materialmodellierung für unterschiedliche Werkstoffe
Strukturberechnung mit MKS-Lastbestimmung
13:00 Mittagessen
Composites: Modellaufbau, Berechnung und Auswertung
Workflow für Schwingungs- und Akustikanalysen
Möglichkeiten zur Strukturoptimierung
Diskussion
Agenda
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Möglichkeiten zur Strukturoptimierung
HyperWorks Solver Technology
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32
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Cost
Weight
Performance
Performance / Weight / Cost Balancing
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Optimization enhances the comprehensible Design Space
New Weight Target
PhysicalDesign Limit
Compreh.Design Limit
Current DesignPoint
Weight
Perf
orm
an
ce
Effort / Cost
Weight
Optimization
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Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Structural Optimization
Thermal and CFD
Highly Nonlinear
CrashSafety
Forming
Multi-bodyDynamics
OptiStruct RADIOSS MotionSolve AcuSolve
Optimization
Smart Multiphysics
FEKO
Electro-Magnetics
Statics
NVH
Thermal
Nonlinear
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Structural Optimization
OptiStruct
HyperStudy
Syst
em
Le
ve
l
C
om
po
ne
nt
Leve
l
Concept Design Detailed Design
INSPIRE
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Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
NVH Optimisation Methodology C
once
pt P
hase
Det
aile
d D
esig
n
System Level Subsystem/Component Level
TopologyHigh number of DV
Global stiffness responsesDesign Space
SizeMedium number of DV
NVH responsesConcept Model
Topology/TopographyHigh number of DV
NVH responsesReduced Model
Size/ShapeLow number of DV
NVH responsesReduced ModelSize/Shape
Medium number of DV NVH responsesDetailed Model
Body Gauge Reduce mass
Topography Panel Acoustic Response
Size/Shape Mount LocationsMode Tracking
Topology Concept Structure and
loadpath definition
FreeSizeHighlight reinforcement
patterns
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Optimization – State of the Art Technology Today
..... ..... .....
15% 20%.....
23%
Calculating weight saving Calculating weight savingCalculating weight saving
FE-Based optimization technology
topology, topography, sizing, shape,
staking, free-shape, multi-disciplinary...
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Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Moving in Direction of Strategic Optimization
What is strategic optimization?
1. Simultaneous consideration of all important functional
requirements
2. Application on subsystems, systems and global level
3. Deployment of optimization early in development
(Optimization drives Design)
4. Direct connection to development program
(and mass)
(management)
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Optimization of Assemblies – getting Strategic!
.....Calculating weight saving .....Calculating weight saving
20% 45%
FE-Based optimization technology
topology, topography, sizing, shape,
staking, free-shape, multi-disciplinary...
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86
Optimization of Assemblies
• Multi-model optimization (MMO) aims to simultaneously optimize
multiple parts or configurations with common design variables
• Simplify the iterative design process associated with optimizing multiple
parts, especially when conflicting requirements exist
• Models may be entirely different or share identical parts
• Models may be assigned individual objectives and constraints, while
global responses may also be defined
• Performance and scalability are taken into consideration
87
Optimization of Assemblies
• Similar models with different meshes
(e.g. coarse and fine)
• Similar models with subcase-dependent
configurations or characteristics (e.g.
damping)
• Different models sharing identical
designable parts
• Different models connected at
designable locations
• Different models with combined
objectives or constraints
• Any combination of the above
W1 W2
min (W1+W2)
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Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Single Model Optimization Multi-Model OptimizationOptimization Problem
OptiStruct: Multi-Model Optimization
Optimization of Assemblies
Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
95%
100%
105%
110%
115%
120%
125%
130%
135%
140%
93% 94% 95% 96% 97% 98% 99% 100% 101% 102%
Tors
ion
Mo
de
(H
z)
BIW Weight (Kg)
Modal Performance v BIW Weight
Target
Optimum Modal
Performance versus
Weight
Optimization of Assemblies
Require Major Architectural
Changes
Risk
• Modal Performance versus Weight Study
• Study creates visibility on relations between performance and weight
• Example is showing a design limit not known to customer
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Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Optimization - Fundamentals
Robust and Repeatable Analysis
Predict the Trend
Fast and Accurate Analysis
Performance and Scalability
Robust Optimization Algorithms and Processes
Convergence and Efficiency
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Altair Solver Technology
Multiphysics Analysis and Optimization
Structural Analysis
Manufacturing Simulation
Systems Simulation
Fluid Dynamics
ThermalAnalysis
Crash, Safety, Impact & Blast
Electro-Magnetics
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Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Altair HyperWorks: Performance Enhancing Software