Altair HyperWorks: A Platform for Innovation - mtevs.orgmtevs.org/images/MTEVS/Projects/CAE/2016-03 - Forum/Altair... · Altair HyperWorks: A Platform for Innovation Vladimir Obukhov

Altair HyperWorks: A Platform for Innovation

Vladimir Obukhov

Technical Consultant

Altair Engineering GmbH

Copyright © 2014 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

HyperWorks Desktop Integration – Typical FEA Process

POST-PROCESSING

Results Visualization

SOLVING

ALTAIR SOLVER EXTERNAL SOLVER

PRE-PROCESSING

1) GEOMETRY2) FINITE

ELEMENT MODEL3) ANALYSIS

IMPORT FROM CAD or CAE World

CAD CAE


Integration Matters: Flexibility

CAD

ACIS

CATIA V4 / V5

IGES (in)

IGES (out)

JT Precise

Parasolid (in)

Parasolid (out)

Pro/E

SolidWorks

STEP

Tribon

UG/NX

CAE

Adams

Abaqus

Actran

AcuSolve

Ansys

CFD++

Femfat

Fluent

Ls-Dyna

Madymo

Marc

Matlab

Moldflow

Moldex3D

MotionSolve

Nastran

nCode

Permas

Pam-Crash

RADIOSS

OptiStruct

Samcef

Simpack

StarCD

Custom User-defined

InterfacesScripting

Results

Math

Open, adaptable to your environment…


Modeling and Visualization: Pre-Processing

Pre-Processing

HyperMesh

FEA/CFD Modeling,

Customizable to capture

best practices,

Native CAD Support for

better model quality

MotionView

Multi-body modeling,

Parametric modeling,

Solver-neutral data

model,

Highly customizable

Simlab

CAE Pre-Post Processing

Tools to automate and

reduce the simulation time

without compromising

quality


Meshing Time Reduction HyperMesh, SimLab

• Superior mesh quality

• Hexaherals

• Tetrahedra

• Shells

• Complete solution

• Geometry cleanup & Meshing

• Loads & boundary conditions

• Morphing

• Broadest set of direct CAD and CAE interfaces

• Abaqus

• Ansys

• Dyna

• Nastran

• Radioss

• …

• Extensive geometry repair functionality


Modeling and Visualization: Altair SimLab

Simplified Modeling Processes for Complex Problems

Feature based

finite-element

modeling

Create high quality

mesh easily and

rapidly

Knowledge capture

and sharing via

templates

Extremely well-suited

for powertrain

modeling


Example: Turbine Blade Meshing Strategy at SiemensPresentation European HTC 2011


Cutting CAE Modeling Time by up to 50% at Dunlop Aerospace

Challenge• Need for complex solid mesh models for

simulation of aircraft braking systems

• Creation of HEXAEDER meshes took

sometimes weeks

Solution• HyperMesh’s HEX mesh capabilities

• “Solid Map” functionality: “intelligent”

extrusion of shell meshes into volumes

• Direct geometry input to eliminate time to

repair surfaces

• Morphing to quickly realize mesh based

design changes

Benefits• Up to 50% reduction in meshing time

• Extremely stable environment

• Easy to learn & use


Analysis: HyperWorks Solver Technology

Multiphysics Analysis and Optimization

Structural

Analysis

Manufacturing

Simulation

Systems

SimulationFluid

Dynamics

Thermal

Analysis

Crash, Safety,

Impact &

Blast

Electro-

Magnetics


HyperWorks Solvers

Thermal

and CFD

Highly Non-Linear

Crash

Safety

Forming

Statics

NVH

Thermal

Non-Linear

Multi-body

Dynamics

OptiStruct RADIOSS MotionSolve AcuSolve

Optimization

Smart Multiphysics

FEKO

Electro-

Magnetics


OptiStruct: Optimization-driven Structural Analysis

Smart Multiphysics

Optimization

Thermal

AnalysisNoise and

Vibrations

Stiffness,

Strength,

Stability

Powertrain

DurabilityKinematics &

Dynamics


Torque Plate – Design Objectives

Design Problem

• Secure contract for Airbus A380 wheel and

brake systems

• Respond to Airbus demands for lower mass,

reduced package space and lower costs

• Mass under 10kg (from 10.9kg)

Optimization Statement

• Minimize Mass

• Constraints on Displacements and Stress

Methodology

• Topology Optimization followed by Shape

Optimization of the torque plate walls Courtesy of Dunlop Aviation Braking Systems


Torque Plate – Conventional Design and Analysis Results

• Mass 10% over target of 10 Kg

• Stress 55% over target of 680 MPa

• Project in jeopardy

13 Kg 10.9 Kg

5 weeks

5 weeks of

conventional analysis

work without reaching

mass targets before

optimization Courtesy of Dunlop Aviation Braking Systems

1050 MPa


• Mass 5% under target

• Stress on target at 680 MPa

10.9Kg 9.5Kg

Courtesy of Dunlop Aviation Braking Systems

680 MPa1050 MPa



• Final design mass: 9.5 kg

• Final Peak Stress: 680 Mpa

• Financial penalties avoided

• Improved forging performance

• Out-of-plane bending avoided

Courtesy of Dunlop Aviation Braking Systems

Peak Stress

1050 MPa

680 MPa

Mass

13.0 kg

9.5 kg



Design Exploration: Altair HyperStudy

Multi Disciplinary design exploration, study and optimization software

Perform what-if studies

Calibrate simulation models

to match with test results

Design better performing

products

Increase the reliability of the

designs

Find robust designs that are

less sensitive to variations

Increase the return on CAE

investments

+17% in reliabilityBefore After


Optimization and Reliability Analysis of a Mars Lander

•ESA Aurora Exploration Program Launch in 2011 or 2013

•New Lander Design Concept Vented airbag, coming to rest on 2nd bounce Traditional concepts come to rest after 10 to 20 bounces

•Failure modes Roll-over (payload overturns), Dive-through (payload impacts rock) Rupture (fabric tears)

• Full scale terrestrial testing expensive / difficult: virtual design approach


Reliability Study: Range of Conditions

Controlled/Uncontrolled conditions

Wind speed (Weibull)

Rock Height (Exponential)

Lander pitch attitude (+/- 20 deg)

Lander pitch rate (+/- 30 deg/s) Probability Density Function f(H)

0.0000

1.0000

2.0000

3.0000

4.0000

5.0000

6.0000

7.0000

0.000 0.200 0.400 0.600 0.800 1.000 1.200 1.400 1.600 1.800

Rock Height H (m)

Pro

ba

bil

ity

De

ns

ity

(m

^-1

)

k = 10%

k = 20%

k = 30%


RADIOSS – The Standard behind Structure Safety


Crash SafetyDrop &

Impact

Blast &

Hydrodynamic

Impact

Terminal

Ballistic

Fluid

Structure

Interaction

Forming &

Composite

Mapping


Automotive Crash Simulation


Improving Helicopter Survivability

• Challenge

• Improve survivability

• Reduce costs and risk of qualification tests

• Solution

• Employ Radioss for impact and crash simulations

• Landing phase analysis

• Impact studies

• Seat behavior analysis

• Results

• Improved survivability

• Reduced number of qualification tests

MotionView

“We appreciate the responsiveness of the development team

to Eurocopter’s specific requirements“

Pierre Prudhomme Lacroix, Manager Structural Analysis


Structure

Domain 1

FLUID

Domain 2

9,000 shells

dt = 1.4 ms

130,000 bricks (~15x)

dt = 14 ms

Elapsed times ( 8 cores )

Monodomain : 65h50mn

Multi-Domain: 12h18mn

Fluid-structure interaction – Normal Force

AIRBUS-ONERA benchmark airplane ditching

Multi-Domain Approach / ALE v. Lagrange modeling in FSI


Example 3: Aero Simulation

Helicopter Survivability

Model: Helicopter floor structure

Objective: Improve survivability of cabin

crew under crash landing

Loading: Crash landing Vi= 3-10 m/s


Example 3: Aero Simulation

Helicopter Sinus Beam


Impact Simulations

Animation from t=0ms to t=150ms

Front Side

Back Side

Cracks Pattern: opening and closure


AcuSolve – Better Technology, Better Solution


Fluid-

Structure

Interaction

Thermal

ManagementComputational

Aero-acoustics

Non-

Newtonian

Flow

Simulation

Electronic

CoolingAerodynamics


Wind turbine

• Motivation

• Rotor diameter of 10m

• FSI between rotating blades and tower

• Numerical model

• Transient analysis

• DES turbulence model

• 20 structural modes (from Radioss)

• Sliding mesh approach for rotating blades

• Deforming mesh around the blades (boundary layer

mesh deforms with the structure)

• 14Mio cells 48 cores 4h per blade revolution


MotionSolve - Optimize System Performance


Kinematics &

DynamicsStatics &

Quasi-staticsLinear and

Vibration

Loads

ExtractionEffort

Estimation

Packaging

Synthesis


Altair’s MBS Solution at DaimlerChrysler Consult Graz GmbH

• Challenge

• Generate Load Histories for Durability

Analyses

• Solution

• Modular simulation model to serve multiple

configurations

• Frame and body structure modelled as

flexible bodies

• Results

• Validated vehicle model

• Virtual prototype to assess different

methods for virtual durability testing

"MotionSolve delivers accurate component

loading histories for durability analysis"

Nenad Bozic

Senior Engineering Manager


Case Study

Virtual Testing at Daimler Chrysler

• Challenge

• Assess and optimize durability performance of body parts

• Static load cases do not correlate with physical tests

• Solution

• Replicate physical test procedure within MotionView

• Combine multibody simulation with fatigue life predictions

• Results

• Simulated critical fatigue locations match physical tests

• Optimized durability performance

baseline optimized


FEKO – Leader in High-frequency Electro-Magnetics


Antenna

Analysis &

Placement

EMC

AnalysisBio-EM

Cable

CouplingRadar Cross

Section

Wave

Guides


Process Simulation and Design Optimization

Metal

ExtrusionPolymer

ExtrusionForming

Friction Stir

WeldingMetal

Rolling

Altair Manufacturing Solutions


HyperForm


HyperXtrude / HyperStudyOptimization of a Profile Flow

• Velocities of material flow are influenced to a great amount by the friction

length of the tool (called „bearing length)

• Changing the bearing lengths leads to different velocity results,

short bearing = high velocity, longer bearing = slower velocity


Ideation and Conceptual Design: SolidThinking EVOLVE

• 3D industrial design and conceptual modeling tool

• Сreate surface and solid geometry easily, rapidly and cost-effectively

• Create photo-realistic renderings of models

• Geometry

• H3D results


Construct Build Test

Traditional Development-Process


InnovationSimulation Inspiration

Simulation Driven Design


Air Spring Carrier

Original Design:

Inspire Design Proposal

Final Design: - 55% mass!

*Source:. Hoepke, S. Breuer

(Hrsg.),Nutzfahrzeugtechnik, Vieweg+Teubner,

Wiesbaden 2013

*


Modeling and Visualization: Post-Processing

Post-Processing and Data Analysis

HyperView

Result Visualization,

High performance

architecture,

Advanced reporting

functionality,

Solver independent

HyperGraph

Data analysis with automatic

plot generation

Mathematical library for

advanced analyses

3D Result plotting

HyperMath

General purpose

numerical computing

Allows to easily develop

and perform custom

mathematical operations


Automated Reporting – Overview

Create / exchange / present simulation result reports frequently

• Applicable when simulations need to be analyzed part / component / group based

• Embedded in HyperView solution loops over all defined groups and load case

and creates a single report page each

Independent of industry, product type, simulation type or simulation

result type

• Analysis is based on given results and load cases, e.g. frequency responses

analysis or eigenforms (NVH)

• Analysts performing Stress analysis, frequency response analysis, durability

calculation, model optimization

Reduce the time to assess the simulation results for 10 components

and 10 loadcases from 6 h to 45 min


PBS Works

• PBS Professional is an open workload management solution that

maximizes the efficiency and utilization of high-performance

computing (HPC) resources and improves job turnaround in a number

of industries.

Policy for

resource

allocation

PBS Pro

Projects

Input

Files

Applica-

tionsCPUs

Memory

Disks

Custom

Codes License

Servers


Value-based Business Model: HyperWorks Licensing

Innovative licensing system to reduce software costs and increase

utilization … translates into immediate cost saving and increased flexibility


HyperWorks Unit Chart

Product 1

Product 2 Product 3Nu

mb

er

of

HW

U u

se

d

Leveling


Altair Partner Alliance (APA)

Material Library

ManufacturingThermal

Analysis

Durability & Fatigue

NVH

CFD Impact

Additive

Manufacturing

Complexity

Management

Stress

Mathematics

& Analytics

Project Management

Engine

Simulation

EMS

1D

Systems

MBD Rendering

Composites


HyperWorks: Performance Enhancing Software Suite

Documents

Altair HyperWorks: A Platform for Innovation - mtevs.orgmtevs.org/images/MTEVS/Projects/CAE/2016-03 - Forum/Altair... · Altair HyperWorks: A Platform for Innovation Vladimir Obukhov