Nottingham University Guest Lecture - Welcome to …...Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Model » 2D shell model of the

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

Nottingham University Guest Lecture

Jacquelyn Quirk

May 1, 2013

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

25+

Years of Innovation

40+

Offices in 16 Countries

1500+ Employees Worldwide

Altair Engineering


Altair Engineering, UK

Altair Engineering, Ltd.

Imperial House

Holly Walk

Royal Leamington Spa

Warwickshire

CV32 4JG

Phone: 01926 468 600

Email: [email protected]

Website: http://www.altairhyperworks.co.uk

• Headquarters in Leamington Spa

• Offices in Bristol & Manchester

• Sales Area

UK, Ireland

• Employees

about 50 in UK

about 1.500 worldwide

3

Leamington Spa

Bristol

Manchester

mailto:[email protected]


Altair’s Brands and Companies

Engineering

Simulation Platform

Product Innovation

Consulting


Thousands of Customers Worldwide

Automotive Aerospace Government & Defense

Heavy Equipment Consumer Goods Other


HyperWorks at UK Universities


What is HyperWorks for Academia?

Altair’s HyperWorks is a finite element based

computer aided engineering (CAE) simulation

software platform that allows universities to do cutting

edge research and to prepare students for careers in

industry leading companies like Airbus, Rolls Royce,

and Jaguar Land Rover.


HyperWorks 12.0

Functionality

Usability

Performance


HyperWorks Solvers & Smart Multiphysics

Apply the right technology and the right type of

coupling to solve real world problems

Scalable – High Quality – Robust


Traditional Design Process

Design Build Verify


INNOVATION INTELLIGENCE

Innovate Simulate/

Optimize Inspire


CAE Driven Design

CAD

CAD

CAD

Design

Performance/Maturity/Details

Time

CAE

De-featuring

CAE

Results Modeling

Too late!

Traditional

CAD

CAD

CAD

CAE

CAE

CAE

CAE

Previous

Design

CAE Driven


HyperWorks Desktop Integration: Typical FEA Process

13

HyperMesh

Solver

HyperView

HyperGraph POST-PROCESSING

Results Visualization

SOLVING

ALTAIR SOLVER EXTERNAL SOLVER

PRE-PROCESSING

1) GEOMETRY 2) FEM 3) ANALYSIS

IMPORT FROM CAD or CAE World

CAD CAE

HyperMesh


HyperWorks Solver Technology

Multiphysics Analysis and Optimization

Structural

Analysis

Crash, Safety,

Impact & Blast

Thermal

Analysis

Fluid

Dynamics

Systems

Simulation

Manufacturing

Simulation


Altair RADIOSS

A Complete, Robust and Accurate Finite Element Solution

Linear

Linear Statics,

Dynamics, Buckling,

Thermal, Plasticity,

Quasi-static, Contact

Non-linear explicit

Non-Linear Explicit

Quasi-static,

Dynamics,

Post-buckling,

Materials, Contact

Non-linear implicit

Non-linear Implicit

Impact, Thermal,

Materials, Contact

Multi-domain

FSI, Multi-body

(MotionSolve) and CFD

(AcuSolve) direct

coupling. Optimization-

Ready


OPTIMISATION DISCIPLINES


TOPOLOGY & TOPOGRAPHY OPTIMISATION

Topology optimization

Method to find the optimum material

distribution in a given design space

Topography

optimization

Method to evaluate the optimum

stiffening pattern on a thin part


SHAPE & SIZE OPTIMISATION

Size optimization

Method to obtain optimum dimensions of

structural parts

Shape optimization

Find optimum shape of given part


Topology Optimized Chair in INSPIRE

Topology Optimisation in Industrial Design

Specify available design

space & mesh. Apply

loads & restraints.

Run the analysis

and interpret the

results.

Extract the result

geometry back into

CAD.


Rendering with EVOLVE


CASE STUDY 4: Rotor Head Bell Crank


Optimisation using Manufacturing Constraints

Design Problem

» 6 Load Cases

» Machined from one direction

» Maintain pad-ups around attach points to interface

with existing structure

» Reduce mass 10% while keeping stress limit on

previously optimized design

Optimisation Statement

» Minimise Mass

» Constraint on Stress (~100 MPa)

Methodology

» Topology optimisation with Draw Direction

manufacturing constraints

» Shape optimization to determine wall thickness



Optimisation using Manufacturing Constraints

Solid model meshed with Hex elements.

» Design region specified (green)

» Non-Design region (blue) separated



Design Optimisation Process

1

3

2

4



Final Design

» 25% reduction of component weight

» Principal stress below limit of 100 MPa

Optimisation Results Optimized Design Baseline Design



OptiStruct was invaluable in turning

around designs. We saw the effects

of our changes, and the software

guided us in terms of adding or

subtracting more material. Without

OptiStruct, we would not have had a

clue to the shape we were looking

for. Using OptiStruct we are going

to get a strong, light car. We could

not have done it any other way; we

are not asking traditional

[engineering] questions, we are very

unique in what we are asking.

OptiStruct makes us think about our

problems differently.

Mark Chapman, Chief Engineer,

Bloodhound SSC

CASE STUDY 5: Bloodhound SSC Chassis

http://www.bloodhoundssc.com/


» Original chassis configuration optimised with Optistruct.

» CFRP chassis proposed but not stiff enough, and also wouldn’t be able to contain a fire in the engines.

» Steel chassis proposed – OptiStruct used to optimise the stringer and truss placement.

» CFRP monocoque safety cell around cockpit, aso optimised using OptiStruct.

» Spaceframe global stiffness design priority, as it constitutes more than 50% of the primary vehicle structure.




Model

» 2D shell model of the vehicle creating using a

finer mesh for the design region.

» Suspension modeled using rigid elements and

spherical joints.

» EJ2000 engine, rocket, MCT V12 engine, jet

fuel tank and HTP tank modelled with 1D mass at

CofG.

Loadcases

» Bending - supports at hub centrelines and the

load 64000 N applied to the car.

» Torsion - support on the rear wheel centrelines

only with two opposing vertical forces applied to

the front wheels centrelines.

Constraints

» Minimise deflection of wheel centrelines, jet &

rocket mountings, fuel tank mountings are set as

design constraints

» Max and min size for the truss beams imposed

as manufacturing constraints.

Analysis

» OS run converged in 100 iterations.

» Optimisation results exported back into CAD

and used to create new design.

» New design optimised using shape and size to

specify trusses.




Change in the motor configuration.

» Rocket increased in size and

moved to lower position with

EJ2000 engine on top.

» Chassis design needed to be re-

optimised.




CASE STUDY 6: Roll Hoop ESLM optimisation


» Safety standards within formula 1 are constantly evolving.

» Principal roll over bars introduced in 1961 - must comply with stringent

FIA design limits & strength tests to protect driver in event of roll over.

FIA FORMULA 1 TECHNICAL regs. 15.2 & 17


>70mm

Fx = 60kN

Fz = -90kN

Fy = 50kN



Stage 1 STATIC

• Linear Static Topology Optimisation

• Uses aerodynamic shape for design volume

• Mass, compliance & stress main design considerations

• Topology Results Verification Analysis

Stage 2 ESLM

• Non-Linear Analysis

• Simulate dynamic impact

• Calculate Equivalent Static Loads

• Linear Free-Shape Optimisation

• Non-Linear > ESL > Linear Free-Shape process looped and iterated until converged.



FIRST STAGE - Linear Static Topology Optimisation

» OBJECTIVE: Minimise mass

» Manufacturing & symmetry constraints

» Linear stress limit in design domain

~75% Mass Removed

Initial Design Domain Element Density CAD Realisation Of Topology

Result



FIRST STAGE VERIFICATION

» Linear ‘check’ analysis performed

» Unacceptable stress levels in some areas

» Load-case 2 clearly dominant case (reversed x component)

Max. Von.Mises Stress

Combined Load-case Critical Load-case

VALUES <1, <sy



SECOND STAGE: Geometric Non-Linear Analysis

» OBJECTIVE: Minimise mass

» Symmetry constraints

» Non-linear stress limit in design domain

» Boundary mesh defined by aerodynamic surface

» 5x Non-linear loops

» Each linear optimisation

converged in <8 iterations

» Total time ~4hours

MASS REDUCED 16%

FREE SHAPE OPTIMISATION RESULT



Non-Linear Check Analysis

FREE SHAPE OPTIMISATION RESULT

LINEAR ANALYSIS:

DISP. UNDERESTIMATED ~3.4%

STRESS OVER PREDICTED 7-15%

NON-LINEAR ANALYSIS

The final design met all criteria and illustrated a significant mass reduction over the previous design The non-linearity of the problem was better exploited, and showed areas where significant savings were possible


CASE STUDY 7: Packaging Optimisation


CASE STUDY 7: Packaging Optimisation

» Goal: improve the packaging to reduce possible transit damage

» Simulation work required material testing (e.g. polystyrene foams, laminate paper)

» Correlation between physical drop tests and FE simulation, 9 load cases identified

» Topology optimisation with simplified FE model, design space around the product

» Objective: absorb maximum amount of energy

» Results: max acceleration levels reduced by 29 %

max product strain decreased by 28 %


CASE STUDY 8: Product Innovation Through CAE


CASE STUDY 8: Product Innovation Through CAE

» Faster and cost-effective development process

» “We look at sound as much as performance.”

» Many design variables: materials, size, shape, weight placement, internal structure

CFD analysis

Modal analysis

Impact analysis


CASE STUDY 9: Bird Strike Analysis

photo Brendan Modermid/Reuters in The New York Times

US Airways Flight 1549

» 15 Jan 2009

» Bird strike leads to the

loss of thrust in both

engines

» No fatalities



» Kinetic energy of the "bird" is imparted to the

structure while allowing the bird to break apart

and disperse

» Most important features: connection

characteristics (rivets) and material behaviour

» Studying rivet failure, material rupture, possibility

of separated debris

» 92 % at or below 3,000 ft above ground level

» From expensive airframe damage to catastrophic failure

» Established method: Smooth Particle Hydrodynamics (SPH)



» Airplane ditching

» Smooth Particle Hydrodynamics (SPH)

» Arbitrary Lagrangian-Eulerian (ALE) mesh

Lagrangian mesh

Eulerian mesh

ALE method SPH method


Visit Altair’s Lightweight Technology Blog

www.altairenlighten.com

http://www.altairenlighten.com/


Online Learning and Teaching Resources

• Academic Website www.altairuniversity.com

• Download the Free Student Edition of HyperWorks

• Regional news, support forum, videos, and case studies

• Academic Training Center – collection of tutorials and videos for

university students

http://www.altairuniversity.com/

http://www.training.altairuniversity.com/


HyperWorks 11.0 Free Student Edition

• Use as an introduction to Finite Element Analysis

• Learn to use analyse and optimize structures in OptiStruct

• Student Edition 12.0 coming this summer with more capabilities!


Free E-Book Student Guide

''Really impressive and user

friendly document, which

highlights very well good FEA

practise, together with linking to

the functionality of HyperMesh.'‘

–Kevin Hughes, PhD. Cranfield University

Documents

Nottingham University Guest Lecture - Welcome to …...Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Model » 2D shell model of the