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  • Model Calibration usingAltair HyperStudy

    Innovation Intelligence Fatma Koer

    Altair Engineering

    May, 2012

  • Copyright 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

    HyperStudy is:

    Solver Neutral Design of Experiment, Multi-Disciplinary Optimization and Stochastic Simulation Engine.

    Automates processes for parametric study, optimization and robustnessstudy, optimization and robustnessassessment

    Integrated with HyperWorks thru HyperMesh, MotionView and direct solver interfaces

  • Copyright 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

    HyperStudy: Business Benefits

    Design high-performance products

    Reduce cost and development cycle

    Increase the return on CAE investments

    Cost effective and innovative licensing model

  • Copyright 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

    HyperStudy: User Benefits

    Streamlined design exploration, study and optimization process Solver-neutral, multi-disciplinary Advanced data-mining capabilities State-of-the-art optimization engine HyperWorks integration: Morphing, Direct parametrization, Results Readers

  • Copyright 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

    Unilever Corp. (UK)Optimal Comfort Softener Bottle Design

    Challenge: Increase collapse load and stiffness of a softener bottle while minimizing the mass

    Solution: DOE to screen design variables:

    Fractional Factorial Method 7 design variables are selected

    DOE to create Approximate Model: Box Behnken Method

    Optimization using the Approximate Model: ARSM

    Results: Buckling capacity increased over 20% Mass reduced over 5%

    HyperStudy provides potential for reducing design cycle times, through facilitating definition of strong design concepts early in the design process, which require fewer down-stream modifications.

    Richard McNabb, Design Analysis and Technology Manager, Lever Faberg, Unilever Corporation

  • Copyright 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

    Capabilities Overview

    Capabilities Overview

    Next Generation

    User InterfaceModel Calilbration

  • Copyright 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

    HyperStudy: Architecture Schema

    StudyEngine:

    Model

    VariantVariantVariantVariant

    Variant

    SimulationSimulation

    Creation

    JobManagementEngine:

    DOEFitOptimization Stochastics

    ResultsResultsResultsResults

    Results

    SimulationSimulationSimulationSimulationSimulation

    Study ResultsOptimal parameters

    SensitivitiesModel Robustness

    Management

    Extraction

  • Copyright 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

    Parameters Screening

    HyperStudy: Study Types

    DOE Approximation Optimization Stochastic

    Parameters ScreeningSystem Performance StudyResponse Surface EvaluationOptimum DesignVariation AnalysisRobust DesignReliability Design

  • Copyright 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

    HyperStudy: Key Differentiators

    Technology

    State-of-the-art exploration,

    approximation and optimization methods

    Direct Results Access

    Direct result access to most Solvers: Abaqus, Ansys, Madymo, etc.

    DataMining

    Correlations, SnakeView, PCA, RDA,

    etc.

    Direct Parameterization

    Automatic transfer of modal parameters from

    HyperMesh, MotionView, HyperForm

    Shape Optimization

    Seamless integration with HyperMorph

  • Copyright 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

    Next Generation HyperStudy

    Capabilities Overview

    Next Generation

    User InterfaceModel Calilbration

  • Copyright 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

    Next Generation HyperStudy

    Differentiators of HyperStudy are kept tree-based process navigation in the study pages

    Changes in user interface data in tables extended edition features dedicated wizards

    Enhanced Task Management orchestration live monitoring and control

    Improved Post-Processing multiple plots richer charting

    Reporting messaging study report

  • Copyright 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

    Model Calibration using HyperStudy

    Capabilities Overview

    Next Generation

    User InterfaceModel Calibration

  • Copyright 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

    Background

    We need to model 6063 T7 Aluminum material in Radioss for the first time. 6063 T7 Aluminum has an isotropic elastic-plastic behavior which can be reproduced by a Johnson-

    Cook model without damage as:

    In Radioss Johnson-Cook model can be defined using the Law2 material card as:

  • Copyright 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

    Background

    In this card, we do not know the values for five material properties: Youngs modulus, yield stress (a), hardening modulus (b), hardening exponent (n) , and maximum stress.

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

    Our objective is to find the five material property values of Radioss Law2 card such that Radioss simulation of the tensile test gives the same curve as the test. Then we can be confident in our material model for further simulations.

  • Copyright 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

    Background

    We can model the tensile testing in Radioss as a quarter of a standard tensile test and using symmetry conditions. A traction is applied to the specimen via an imposed velocity at the left-end.

    Thickness = 2.0 mm

    We can then calculate the engineering strains are by dividing the node 1 displacement by the reference length (75 mm), and engineering stresses by dividing the section 1 force by its initial surface (12 mm2).

    Node 1

    (displacement) Section 1

    (force)

  • Copyright 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

    Results from the Initial Radioss Simulation

    Radioss simulation with initial guesses of Youngs modulus, yield stress (a), hardening modulus (b), hardening exponent (n) , and maximum stress values of 60400 MPa, 110 MPa, 120 MPa, 0.15, 280 MPa leads to significant differences between the test and simulation results as seen below

  • Copyright 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

    ObjectiveThe objective is to find the values for the five material properties so that the simulationresults match to tensile test results. We can achieve this if we minimized (ideally zero):1. difference between Radioss and experimental stress (141MPa) at Strain equal 0.022. difference between Radioss and experimental stress (148MPa) at Necking point3. difference between Radioss and experimental strain (0.08) at Necking point

  • Copyright 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

    Method

    We will use optimization to achieve this objective.

    We will use a special optimization problem formulation called System Identification.

    System identification minimizes the sum of normalized error-squared. Error is the difference between the target values and simulation results.

    2

    where fi(x) is the ith response obtained from analysis, Ti are the target value for the ith response.

    Note that, in HyperStudy we do not need to enter this equation manually. We can simply enter the target values for each response and use the System Identification objective.

    2

    mini

    ii

    TTf

  • Copyright 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

    Problem Formulation

    where

  • Copyright 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

    DemonstrationDemonstration

  • Copyright 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

    DOE Results

    32 Design Full Factorial

    Youngs Modulus and SigMax are not significant so we will continue our study with three design variables.

  • Copyright 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

    First Optimization Results

    Adaptive Response Surface Method (ARSM) is used for this case. In 5 iterations, we minimized the system identification objective function value from

    0.158 to 0.06. In the optimum design, the DV values are: 99, 132, 0.165 The response values are: 140, 146, 0.06 (note that the targets were 141, 148 and 0.08;

    initial design values were 147, 150, 0.05)

    We observe that all three design variables are at their lower or upper bounds. If we can relax those bounds; we may be able to get closer to the target values. We started a new optimization from the best result of the first optimization and with

    relaxed bounds.

  • Copyright 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

    Second Optimization Results

    ARSM is used for this case. In 10 iterations, we minimized the system identification objective function value from

    0.06 to 0.0. In the optimum design, the DV values are: 93, 157, 0.2. The response values are: 140, 149, 0.08 (note that the targets were 141, 148 and 0.08)

    First two objectives are off by 1.0 from the target and last one is on target

  • Copyright 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

    Results

    Initial Opt 1 Opt 2VariablesE 60400 60400 60400a 110 99

    (99-121)93

    (50-150)b 120 132 157

    (108-132) (100-200)n 0.15 0.165

    (0.135-0.165)0.19

    (0.1-0.3)Sigma 280 280 280ResponsesObj1 147 (Target 141) 140 140Obj2 150 (Target 148) 146 149Obj3 0.05 (Target 0.08) 0.06 0.08

  • Copyright 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

    Results

    Radioss results for the Initial Design vs. Test Results: There are significant differences between the two curves.

    Radioss results for the Optimum Design vs. Test Results: The two curves are almost identical.

  • Copyright 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

    Conclusions

    HyperStudy provides a user friendly GUI to easily set up design studiesincluding system identification.

    Design Study methods in HyperStudy are efficient and effective in meetingdesign targets.

    HyperStudy is solver independent and can also work with applicationsrunning other solvers such as LS-Dyna, Abaqus, Ansys, Adams, etc.

  • Copyright 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

    Altair HyperStudy

    Altair HyperStudy is a user-level, solver neutral, multi-disciplinary, exploration, study and optimization tool,

    helping engineers to

    HyperStudy enabled us to efficiently implement DOE and optimization methods. The new automatedprocess is able to cover different types of applications and can be used in various projects. Besides thetechnical advantages and the saved development time, Magna benefits from being an HyperWorks PartnerAlliance member and therefore can use the needed software at no additional costs.

    Werner Reinalter, Teamleader, MBS Simulation, Magna Steyr

    helping engineers to design high-performance products, reduce cost and development cycle, increase the return on CAE investments

    with advanced optimization and data mining capabilities.