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Finite element mesh containing designable (blue) and non-designable (yellow) material.
A finite element model representing the designable and non-designable material (shown in figure) is imported into HyperMesh. Appropriate properties, boundary conditions, loads, and optimization parameters are defined and the OptiStruct software is used to determine the optimal material distribution. The results (the material layout) are viewed as contours of a normalized density value ranging from 0.0 to 1.0 in the design space. Isosurfaces are also used to view the density results. Areas that need reinforcement will tend towards a density of 1.0. The optimization problem for this tutorial is stated as: Objective: Constraints: Minimize volume. SUBCASE 1 The resultant displacement of the point where loading is applied must be less than 0.05mm. The resultant displacement of the point where loading is applied must be less than 0.02mm. The resultant displacement of the point where loading is applied must be less than 0.04mm.
SUBCASE 2 -
SUBCASE 3 -
Design variables:
The following exercises are included: Setting up the FE model in HyperMesh Setting up the optimization in HyperMesh Post-processing the results in HyperView
Exercise
Setting Up the FE Model in HyperMesh Step 1: Launch HyperMesh, Set the User Profile and Retrieve the File
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1. Launch HyperMesh 2. Choose the OptiStruct User Profile and click OK. This loads the user profile. It includes the appropriate template, macro menu, and import reader, paring down the functionality of HyperMesh to what is relevant for generating models in Bulk Data Format for RADIOSS and OptiStruct. The User Profiles GUI can also be accessed from the Preferences pull-down menu on the toolbar. 3. From the File pull-down menu on the toolbar, select Open .
4. Select the carm.hm file, located in the HyperWorks installation directory under <install_directory>/tutorials/hwsolvers/optistruct/. 5. Click Open.
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7. Select the node at the other end of the bushing (see the following figure) by clicking on it in the graphics window. 8. Constrain dof2 and dof3; make sure dofs 2 and 3 are checked. 9. Click create. A constraint is created. A constraint symbol (triangle) appears in the graphics window at the selected node. The number 23 is written beside the constraint symbol, indicating that dof2 and dof3 are constrained.
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10. Click nodes and select by id from the extended entity selection window. 11. Type the value 3239 and press Enter key. 12. This selects node ID 3239 (see the next figure). 13. Constrain only dof3. 14. Click create. A constraint is created. A constraint symbol (triangle) appears in the graphics window at the selected node. The number 3 is written beside the constraint symbol, indicating that dof3 is constrained.
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7. Click create. An arrow, pointing the x direction, should appear at the node on the screen. 8. For better visualization of the arrows, select uniform size=, type 100, and press Enter. 9. From the Model Browser, under the expanded LoadCollectors, right click on Corner, and click on Make Current. 10. Click nodes and select by id from the extended entity selection menu. 11. Type the node number 2699 and press Enter. 12. Click magnitude=, enter 1000.0, and press Enter. 13. Set the switch below to y-axis. 14. Click create. An arrow pointing in the Y direction should appear at the node on the screen. 15. From the Model Browser, under the expanded LoadCollectors, right click on Pothole, and click Make Current. 16. Click nodes and select by id from the extended entity selection menu. 17. Type the node number 2699 and press Enter. 18. Click magnitude=, enter 1000.0, and press Enter. 19. Set the switch below to z-axis. 20. Click create. An arrow, pointing in the Z direction, should appear at the node on the screen. 21. Click return to go back to the Analysis page.
Three separate forces in load collectors: brake, corner, and pothole with the component "design" turned off using the display panel.
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5. Click on the entry field and select SPC from the list of load collectors. 6. Check the box preceding Load and select Brake from the list of load collectors. 7. Click Create. 8. Similarly create the load cases Corner [by selecting the load collectors Corner and SPC] and Pothole [by selecting the load collectors Pothole and SPC]. 9. Click return to go back to the Analysis page.
Setting Up the Optimization in HyperMesh Step 7: Define the Topology Design Variables
1. From the Analysis page enter the optimization panel. 2. Enter the topology panel. 3. Make sure the create subpanel is selected using the radio buttons on the left-hand side of the panel. 4. Click DESVAR=, type design_prop, and press Enter. 5. Click props 6. Choose type: PSOLID. 7. Click Create. A topology design space definition, design_prop, has been created. All elements organized in this design property collector are now included in the design space. 8. Click return to go back to the optimization panel. , choose design_prop from the list of props, and click on select.
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3. Select the directory where you would like to write the OptiStruct model file and enter the name for the model, carm_check.fem, in the File name: field. The .fem extension is for OptiStruct input decks.
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4. Click Save. 5. Note the name and location of the carm_check.fem file displays in the input file: field. 6. Set the export options: toggle to all. 7. Click the run options: switch and select check. 8. Set the memory options: toggle to memory default. 9. Click OptiStruct. This launches the OptiStruct check run. Once the processing is complete (indicated in the UNIX or MSDOS window which pops up), view the file carm_check.out. This is the OptiStruct output file containing specific information on the file setup, optimization problem setup, RAM and disk space requirement for the run. Review this file for possible warnings and errors. Is the optimization problem set up correctly? See Optimization Problem Parameters section of the carm_check.out file. The objective function? See Optimization Problem Parameters section of the carm_check.out file. The constraints? See Optimization Problem Parameters section of the carm_check.out file. What is the recommended amount of RAM for an In-Core solution? See Memory Estimation Information section of the carm_check.out file. Is there enough disk space to run the optimization? See Disk Space Estimation Information section of the carm_check.out file.
carm_complete.his_data
carm_complete.HM.comp.cmf
carm_complete.HM.ent.cmf
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carm_complete.html
HTML report of the optimization, giving a summary of the problem formulation and the results from the final iteration. OSSmooth file with a default density threshold of 0.3. The user may edit the parameters in the file to obtain the desired results. OptiStruct output file containing specific information on the file setup, the setup of the optimization problem, estimates for the amount of RAM and disk space required for the run, information for each optimization iteration, and compute time information. Review this file for warnings and errors that are flagged from processing the cclip_complete.fem file. HyperMesh binary results file. Shape file for the final iteration. It contains the material density, void size parameters and void orientation angle for each element in the analysis. The .sh file may be used to restart a run and, if necessary, run OSSmooth files for topology optimization. Summary of analysis process, providing CPU information for each step during analysis process.
carm_complete.oss
carm_complete.out
carm_complete.res carm_complete.sh
cclip_complete.stat
The second page has the results from the carm_complete_s1.h3d file. Note that the name of the page is displayed as Subcase 1 Brake to indicate that the results correspond to subcase 1.
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4. Select Linear Static as the animation mode 5. Click the Contour toolbar button .
6. Select the first pull-down menu below Result type: and select Displacement [v]. 7. Select the second pull-down menu and select Mag. 8. Click Apply to display the displacement contour. 9. Click the Deformed toolbar button .
10. Set Result type: to Displacement (v), Scale: to model units, and Type: to Uniform. 11. Enter 10 for value:. This means that the maximum displacement will be 10 Model units and all other displacements will be proportional. 12. Below the Undeformed shape: section, click on the pull-down menu next to Show and select Wireframe. 13. Click Apply. A deformed plot of your model with displacement contour should be visible, overlaid on the original undeformed mesh. 14. Click the linear static icon to animate the model . to
A deformed animation for the first subcase (brake) should be displayed. Notice that the icon changes indicate that the model is being animated. In what direction is the load applied for the first subcase? Which nodes have degrees of freedom constrained? Does the deformed shape look correct for the boundary conditions applied to the mesh? 15. At the bottom of the GUI, click on the names Static Analysis or Iteration 0,
, to activate the Load Case and Simulation Selection dialog. 16. Select the 18th iteration by double-clicking on Iteration 18. The contour now shows the displacement results for Subcase 1 (brake) and iteration 18 which corresponds to the end of the optimization iterations. 17. Click the linear static icon again to stop the animation. to move to the third page.
The third page which has results loaded from carm_complete_s12.h3d file, is displayed. Note that the name of the page is displayed as Subcase 2 corner to indicate that the results correspond to subcase 2. 19. Repeat steps 4 to 15 to display the displacement contours and deformed shape of the model for the second subcase. In what direction is the load applied for the second subcase? Which nodes have degrees of freedom constrained? Does the deformed shape look correct for the boundary conditions applied to the mesh? 20. Similarly, review the displacements and deformation for subcase 3 (pothole).
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Note the Result type: is Element Densities [s]; this should be the only results type in the file_name_des.h3d file. The second drop-down menu shows Density. 3. In the Averaging method: file, select Simple. 4. Click Apply to display the density contour. Note the contour is all blue this is because your results are on the first design step or Iteration 0. 5. At the bottom of the GUI, click on the name Design or Iteration 0 to activate the Load Case and Simulation Selection dialog. 6. Select the last iteration by double clicking on the last Iteration #. Each element of the model is assigned a legend color, indicating the density of each element for the selected iteration. Have most of your elements converged to a density close to 1 or 0? If there are many elements with intermediate densities, the DISCRETE parameter may need to be adjusted. The DISCRETE parameter (set in the opti control panel on the optimization panel) can be used to push elements with intermediate densities towards 1 or 0 so that a more discrete structure is given. In this model, refining the mesh should provide a more discrete solution; however, for the purposes of this tutorial, the current mesh and results are sufficient. Regions that need reinforcement tend towards a density of 1.0. Areas that do not need reinforcement tend towards a density of 0.0. Is the max= field showing 1.0e+00? In this case, it is. If it is not, the optimization has not progressed far enough. Allow more iterations and/or decrease the OBJTOL parameter (also set in the opti control panel). If adjusting the discrete parameter, refining the mesh, and/or decreasing the objective tolerance does not yield a more discrete solution (none of the elements progress to a density value of 1.0), review the set up of the optimization problem. Some of the defined constraints may not be attainable for the given objective function (or vice versa).
Step 15: View an Iso Value Plot on Top of the Element Densities Contour
This plot provides the information about the element density. Iso Value retains all of the elements at and above a certain density threshold. Pick the density threshold providing the structure that suits your needs. 1. From Graphics pull down menu, click on Iso Value, and choose Element Densities as the Result type. 2. Click Apply. 3. Set the Current Value: to 0.15.
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4. Move the slider below Current value: to change the density threshold. You will see the iso value in the graphics window update interactively when you scroll to a new value. Use this tool to get a better look at the material layout and the load paths from OptiStruct.
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