Optimization of a Family

of Supporting Frames

Under Multiple Analysis

Constraints Using

HyperStudy

Yimin Zhan, Ph.D.

Malisha Djokic, M.Sc.Tech., P.Eng.

Van-Rob Kirchhoff Automotive

Aurora, Ontario,

Canada L4G 0A2

Contents

• Preface

• Objectives and Description

• Modeling in HyperMesh

• Baseline Analysis using HyperWorks Solvers

• Optimization using HyperStudy

• Validation using HyperWorks Solvers

• Conclusions

Preface

• Van-Rob Kirchhoff, based in Aurora Ontario Canada, is a tier-one full

service global supplier of automotive OEMs

• 29 production plants in 12 countries serving both domestic and

overseas customers

• Use of Altair HyperWorks Suite since year 2002 to optimize designs

and improve performance

• Meshing and modeling, linear (static and dynamic) and non-linear

Objectives and Description

Short Version

Long Version

Modeling in HyperMesh

Short Version Long Version

Baseline Analysis

using HyperWorks Solvers

Short Version Long Version

Analysis Type #1:

Push-test stiffness under boundary condition #1

X Y

Z

X Y

Z

X Y

Z

X Y

Z

X Y

Z X Y

Z

X Y

Z

X Y

Z

X Y

Z

X Y

Z

Baseline Analysis

using HyperWorks Solvers

Analysis Type #2:

Push-test stiffness under boundary condition #2

Short Version Long Version

Baseline Analysis

using HyperWorks Solvers

Analysis Type #3:

Modal analysis

Short Version Long Version

Baseline Analysis

using HyperWorks Solvers

Analysis Type #4:

Non-linear impact analysis

Short Version Long Version

Optimization using HyperStudy

Short Version Long Version

g3

g4

g1

g5

g2

g6S

g6L

Optimization using HyperStudy

Morphing variables:

S1S for short version

S1L for long version

Morphing variables:

S2S for short version

S2L for long version

Optimization using HyperStudy

Morphing variable:

S4

Morphing variable:

S3

Optimization using HyperStudy

Create study

Optimization using HyperStudy

Create models

Optimization using HyperStudy

Create design variables

Optimization using HyperStudy

Do nominal run

Optimization using HyperStudy

Create responses

Optimization using HyperStudy

Link design variables

Optimization using HyperStudy

Create optimization study

Optimization using HyperStudy

Define design variables

Optimization using HyperStudy

Apply constraints

Optimization using HyperStudy

Create objective

Optimization using HyperStudy

Post processing

Optimization using HyperStudy

Post processing

Optimization using HyperStudy

Post processing – Visualize…

Optimization using HyperStudy

Post processing – Visualize…

Optimization using HyperStudy

Optimization

Baseline

Optimization

Baseline

Optimization using HyperStudy

Optimization

Baseline

Validation

using HyperWorks Solvers

Validation

using HyperWorks Solvers

Analysis Type #1: Push-test stiffness under boundary condition #1

X

Y

Z

Short version Long version

Location 1 Location 1

1 mm 1 mm

0.1 mm 0.1 mm

0.2 mm 0.2 mm

Validation

using HyperWorks Solvers

Analysis Type #2: Push-test stiffness under boundary condition #2

Y

Short version Long version

2 mm 2 mm

Validation

using HyperWorks Solvers

Analysis Type #3: Norm mode

Short version Long version

30 Hz 30 Hz

Validation

using HyperWorks Solvers

Analysis Type #4: Non-linear impact

Short version Long version

Target: < 0.5 mm Target: < 0.5 mm

Conclusions

• HyperStudy is capable to perform simultaneous analysis on multiple FEA

models with multiple types of FEA analysis, design variables and constraints;

• Some components can be shared in different models. This means significant

reduction of processing cost and time;

• All design constraints are achieved and violation level is under 2%;

• Objective is met with mass penalty 0.5 Kg;

• HyperStudy is a quite powerful package for conducting structural optimization;

• Time saving: months versus days or even hours;

Conclusions

Wish list:

(a) Topology optimization variables, e.g.

element densities under extrusion

constraints, should be convertible to

become design variables acceptable to

HyperStudy;

(b) Hope to have an “Uncheck” option for the

post-processing panel, so that quick

uncheck of all items and then re-pick of

items needed to display are enabled.

Optionally, a multiple selection of items,

using SHIFT button and left mouse button,

is needed.

Thank you