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Student Project Summaries CAE and Design Optimization - Basics

Contents

Introduction.............................................................................................2
Installation Instructions: .......................................................................2
Redesign of Aluminum Housing.................................................................3
Description of the Problem ....................................................................3
Design Objectives .................................................................................4
The Analysis Model ...............................................................................5
The Optimization Model.........................................................................6
Results.................................................................................................6
Further Work ........................................................................................6
Summary .............................................................................................8
Frequency Optimization of Vehicle Floor ....................................................9
Description of the Problem ....................................................................9
Design Objectives ............................................................................... 10
The Analysis Model ............................................................................. 10
The Optimization Model....................................................................... 11
Results............................................................................................... 12
Further Work ...................................................................................... 12
Summary ........................................................................................... 13
Shape Optimization of Engine Block ........................................................ 14
Description of the Problem .................................................................. 14
Design Objectives ............................................................................... 14
The Analysis Model ............................................................................. 15
The Optimization Model....................................................................... 16
Results............................................................................................... 17
Further Work ...................................................................................... 17
Summary ........................................................................................... 17
Battery Tray Design ............................................................................... 19
Description of the Problem .................................................................. 19
Design Objectives ............................................................................... 19
The Analysis Model ............................................................................. 20
The Optimization Model....................................................................... 22
Results............................................................................................... 22
Further Work ...................................................................................... 22
Summary ........................................................................................... 22

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Student Project Summaries CAE and Design Optimization - Basics

Introduction
This material is best used after reading the book CAE And Design
Optimization – Basics.

Access to HyperWorks software is not essential for you, the instructor. Of


course, if you choose to solve the problem yourself before working with your
students, you will need HyperMesh and OptiStruct.

This book describes 4 assignment problems that highlight different


applications of HyperWorks. Each problem is independent, and is complete
in itself. Students may choose to do more than one, depending on their
interest.

To make best use of this material you will need a computer with a sound-
card and speakers. Your computer should have a media-player programme
(such as Windows Media Player) and an Internet Browser that supports
JavaScript. The material can be copied to a server and accessed by clients.

You can customize the HTML files to suit your


requirements. After opening the file, double-
click on any text to edit it. Use the save changes
link on the left of your Browser window when
you are finished.

Installation Instructions:
1. Copy the folders to your computer or to your server. If you are
working on a server, it is a good idea to set the folders to “read
only” to prevent inadvertent modifications.
2. The videos are best played in full-screen at a resolution of 1024 x
768. You may need to install the CamStudio Codec to view video on
your computer. To do this, right-click on the file camcodec.inf and
choose Install from the popup menu. You may need administrator
privileges to do this.
3. Ensure that JavaScript is enabled on your browser.
4. Each folder contains one HTML file. Double-click on it to open the
instructions.
5. Data files are provided as relevant – IGES files, HM files, etc.
6. In case you need support, contact your distributor or email
edu.support@altair.india.com

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Student Project Summaries CAE and Design Optimization - Basics

Redesign of Aluminum Housing


Areas covered:
• Geometry Abstraction for FE modeling
• Automatic Mesh Generation
• Constrained optimization with Stress constraints
• Design interpretations of FE results
• Transfer of an FE model to a CAD modeler for post-
optimization detailed-design
Software used:
• HyperMesh
• OptiStruct
• HyperView

Description of the Problem


A military tank carries projectiles in tubes. To protect
the projectiles, a flap closes the exit of the tube.
When ready to fire the flap opens, leaving the exit
clear for the projectile. Each flap is controlled by an
actuator, which is an electromechanical device
consisting of a motor, a cam, a gear train, and a few
other components.

All components are mounted inside a housing, which


is then sealed. The housing itself is bolted to the
tank body. In the current design the housing is
machined from an Aluminum casting.

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Student Project Summaries CAE and Design Optimization - Basics

The housing-manufacturer has been informed that


the units have developed cracks near the mounts. No
data on conditions causing the failure, pattern of
failure, etc are available. No changes can be made to
the mounting points on the tank. The internal
components (i.e. the actuator) also cannot be
modified or relocated.

The design problem is: How would you redesign


the housing?

The supplier wants to change the housing material


from Aluminum to Steel. One option is to maintain
the same dimensions and switch the material to
Steel. The student should be asked to consider that
since the forces that cause stresses are due to the
deadweight, increasing the stiffness will not help if
the mass also increases. Steel is stiffer than
Aluminum, but is also heavier.

Design Objectives
Since we have no information on the variation of the
actual loads with time, we will use an equivalent
static analysis. In this approach, we use a factor of
safety to allow the static design to mimic the
dynamic conditions. Interested students can look up
the MIL-Standard for shock loads to be rigorous.

Since the unit has worked for a substantial amount


of time before failing, failure is likely to be either
because of a special-case overload, or due to
fatigue. The latter is probable, since Aluminum does
not have an infinite fatigue life. Steel is a better
choice from this point of view.

Our approach, for optimization, will be to reduce the


stresses, regardless of the permissible stress. This is
a fair approach to take since we do not know the
original factors of safety. To achieve this, we first
perform a baseline analysis - an FEA of the initial
design to establish stresses for the given load. Since
we are performing linear analysis, the actual value of
the load does not matter.

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Student Project Summaries CAE and Design Optimization - Basics

We then run the optimization with the goal of reducing the stress to less
than that in the baseline analysis, under the same
loads, using steel.

To sum up, build an Analysis Model, calculate the


stress in the component, and build an Optimization
Model using the existing design as the design space.
We constrain the stress to be 0.75*baseline stress,
and our objective is to minimize the mass.

The Analysis Model


Since OptiStruct uses an Optimization Model, the
Analysis Model need not be perfect. It should, of
course, be adequate. Your students should perform
the baseline analyses with at least two different
element-sizes to confirm that the solution is fine
enough.

The housing poses a couple of challenges from the


point of view of meshing. The first, of course, is
which elements to use. The second is in the details
to keep.

We will choose to use solid elements since we


believe shear dominates (the walls are thin, but the
length:thickness ratio is fairly small). We will neglect
the lip that's grooved into the top face. We will also
omit the fastening holes. Hex elements are better
than tetrahedral elements but are harder to create.
It's a trade-off between spending more time meshing
and more time solving. For a student working on
optimization, tetrahedra are adequate, provided the
student has verified that the results are adequately
captured.

Solid elements have only 3 degrees-of-freedom per


node (the x, y and z components of deformation).
Since we will define the density of the material, the
FE solver will calculate the mass of each element.
We will also define special elements called mass
elements to represent the masses of the internal
components - since they are not being designed, we
will not model the components themselves.

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Student Project Summaries CAE and Design Optimization - Basics

Once these properties are assigned, we will define


the acceleration due to gravity (direction and
magnitude) so that the inertial forces can be
calculated.

After the analysis, we will review the von Mises


stress and record this for use as the design
constraint for the optimization model.

The Optimization Model


Stress as a response requires special attention. Since
sharp corners can cause stress to be singular,
OptiStruct uses an average measure of the stress.
This is why stress as a constraint, unlike
displacement, is specified for the complete model
rather than at specific points.

Results
Topology optimization decides an equivalent element
density for each element in the design space. A
density of 1 means material must fill the element,
while a density of 0 means the element needs no
material. For most elements, this value will vary
between 1 and 0. As a designer, you will need to
exercise your judgment. For example, you may decide that you will omit
material from all elements whose density is less than 0.3 (or 30%). Having
made this decision, you will need to take the geometry back to your CAD
modeler, smooth it out (that is, use geometrically regular edges or surfaces,
etc.) and re-evaluate the design for a satisfactory stress.

Further Work
The assignment brings home the advantages of the Optimization-as-an-
integral-part-of-CAE, as well as the advantages of using HyperWorks:

• designs are more likely to pass subsequent verification


• designs are not unnecessarily over-designed
• easy setup of the FE model
• easy creation of the Optimization model
• convenient reporting options with easy viewing

Depending on their proficiency, students may want to

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Student Project Summaries CAE and Design Optimization - Basics

• estimate the change in center-of-gravity, since this affects the forces at the
mounting screws. The center-of-gravity can be a constraint for optimization
• investigate the effect of mesh size on the optimization results
• use shape optimization to choose a fillet radius for the various fillets

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Student Project Summaries CAE and Design Optimization - Basics

Summary
By the end of this assignment, the student will know how to
• import IGES files into HyperMesh
• use the Model Browser
• zoom, pan and rotate
• change colors of entities
• control visibility of geometry
• create collectors for material data, elements, forces and
restraints (SPCs)
• measure distances and the diameter of circles
• find the centers of circles
• use consistent units
• check for different types of element-edges - free, shared, etc.
• fill and stitch surfaces
• create fixed points
• use temp nodes
• create mass elements
• create a load case
• ask for reactions to be output by the solver
• plot stress contours
• view deformed shapes
• use unaveraged stresses to check if the model is adequate
• organize elements in collectors to define the design space
• specify responses that the optimizer needs
• specify stress constraints and deflection constraints
• set the objective
• control the optimizer
• check for convergence and violation of constraints using the text
output files
• check for convergence and violation of constraints using
HyperView
• view density plots in HyperView
• run OS-Smooth to export data back to a CAD modeler

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Student Project Summaries CAE and Design Optimization - Basics

Frequency Optimization of Vehicle Floor


Areas covered:
• Geometry Abstraction for FE modeling
• Automatic Mesh Generation
• Constrained optimization with frequency constraints
• Use of manufacturing-constraints
• Design interpretations of FE results
• Transfer of an FE model to a CAD modeler for post-
optimization detailed-design
Software used:
• HyperMesh
• OptiStruct
• HyperView

Description of the Problem


Typically made of sheet metal, the floor separates the seating / cargo area
from the underbody. As with most other components
in a vehicle, avoidance of resonance is important.
Vehicle designers provide ranges of frequencies to
component designers, who must ensure that these
are complied with.

Plane sheet panels exhibit poor stiffness and NVH


performance due to their flexibility. A common and
cost-effective approach in the automotive industry to
improve the stiffness and NVH performance of sheet
panels is the addition of beads.

The design challenge is to make changes to the


proposed shape, without altering mounting points or
other assembly aspects, to ensure that the base
frequency is above 40 Hz.

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Student Project Summaries CAE and Design Optimization - Basics

Design Objectives
The design problem involves the specifications, the
methods of addressing these, and the potential for
success. The last point is the most important: in
design, a negative result is also extremely useful. It
is very possible that the floor, with the given
thickness, will not be able to attain the required
characteristics.

Beads (also referred to as swages) are subject to


manufacturing constraints. Design requirements of
punch-and-die sets often conflict with requirements
of product-design. Within the floor itself, a bead
may interfere with another component, so we will
want to keep the bead-depth down to a reasonable
level.

In an application like this, topology optimization is a


definite possibility. However, since this is a floor, we
do not want to use cutouts. Size optimization can
also help us suggest a better thickness than the
given 3.25 mm.

We will use topography optimization since beads


are an accepted stiffening-approach, and are most
likely to be accepted by both designers and
manufacturing-engineers.

Our design approach is fairly simple: build an


Analysis Model, then build the Optimization Model
with the base frequency and bead characteristics as
constraints. The Objective is to maximize a
weighted sum of the first 5 frequencies.

The Analysis Model


In these instructions, only one mesh will be
created. Your students should perform the analyses
with at least two different element-sizes to confirm
that the solution is fine enough.

Shell elements lend themselves readily to the


problem.

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Student Project Summaries CAE and Design Optimization - Basics

How do we decide the element size? Numerical


models sometimes introduce spurious modes of
vibration, and it is hard to filter these out without
access to test data. In this problem, we will use
values that keep the solution-time within limits.
Since shell elements have 6 degrees-of-freedom per
node, a 20,000 node model has 1,20,000 dofs. This
can be quite time consuming!

Your student should review the basics of modal


analysis: the Rayleigh-Ritz method is essential
reading, while a quick review of Simultaneous
Vector Iteration (SVI) and Lanczos is recommended.

We will ask the software to calculate the first few


mode shapes. Since changes in the geometry can
change mode shapes, we will ask OptiStruct to track
the modes. This is a very useful feature, whereby
OptiStruct uses the eigenvalues to ensure that it is
indeed constraining the correct modes.

We will also use two of HyperMesh's strongest


features: autocleanup and QI Meshing. We specify
the range of element properties we want to accept
and allow the software to determine which features
to retain. Used with care, it can substantially speed
up the model-building process.

The Optimization Model


Why did we identify that the base frequency as a
constraint and not as the objective? Because at this
stage we will be satisfied if we can exceed the given
value: there is no need to take it even higher.

Your student should realize that there are other


ways to alter resonant frequencies. For instance,
adding a point of support can make a substantial
difference.

We study how to organize elements in collectors to


define the design space, and how to specify
manufacturing constraints for topography
optimization.

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Student Project Summaries CAE and Design Optimization - Basics

We also use the Mode-tracking option since changes


in geometry can result in a change in eigenvalues:
for instance, what was the 3rd mode may become
the 4th, after the change.

Results
Since the solution time for the floor can be quite
substantial, the instructions for this section use a
sample geometry. We study how to check for
convergence and violation of constraints using the
text output files, how to check for convergence and
violation of constraints using HyperView. We also
view bead plots in HyperView and use OsSmooth to
export data back to a CAD modeler

Further Work
The assignment underscores the advantages of
treating Optimization-as-an-integral-part-of-CAE, and
the advantages of using HyperWorks:

• designs that are more likely to pass subsequent


verification
• designs that are not unnecessarily over-designed
• easy setup of the FE model
• easy creation of the Optimization model
• convenient reporting options with easy viewing

You may choose to assign further investigations to


your students based on their level of proficiency on
CAD, the time available, etc.

Some of the areas that could include

• the use of size optimization to suggest a better


sheet thickness
• the inclusion of a Static load case to include load-
bearing capacity in the design requirements

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Student Project Summaries CAE and Design Optimization - Basics

Summary
By the end of this assignment, the student will know how to
• import IGES files into HyperMesh
• use the Model Browser
• zoom, pan and rotate
• change colors of entities
• control visibility of geometry
• create material collectors
• create component collectors
• create load collectors
• create loadcases
• measure distances
• use consistent units
• work with different types of edges - free, shared, etc.
• fill and stitch surfaces
• measure the diameter of circles
• find the centers of circles
• use temp nodes
• use autocleanup to do all of the above
• create restraints or SPCs
• specify options for the eigenvalue-solver
• organize elements in collectors to define the design space
• specify responses for the optimizer
• specify topography constraints - i.e., the bead parameters
• use manufacturing constraints
• set the objective
• control the optimizer
• check for convergence and violation of constraints using the text
output files
• check for convergence and violation of constraints using
HyperView
• view bead plots in HyperView
• export data back to a CAD modeler

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Student Project Summaries CAE and Design Optimization - Basics

Shape Optimization of Engine Block


Areas covered:
• Geometry Abstraction for FE modeling
• Automatic Mesh Generation
• Free-shape optimization with Stress constraints
• Design interpretations of FE results
• Transfer of an FE model to a CAD modeler for post-
optimization detailed-design
Software used:
• HyperMesh
• OptiStruct
• HyperView

Description of the Problem


An assembly model for the engine of a model
aircraft has been proposed. Any design changes
must only be incremental - structural changes are
ruled out by the project-deadlines. Instead, the
designers have asked that attention be paid to the
outer profile of the engine block.

The radii chosen at the CAD stage were not based


on any calculations. The goal now is to start with the
given shape and check if changes to the shape can
reduce stresses.

Design Objectives
Engine design is multi-disciplinary, since heat
transfer and fluid flow (for combustion) are at least
as important as structural design. There are also
forces that the engine experiences because of the
movement of the piston.

It may seem that a topology optimization on the


engine block to suggest material layout is a good
idea, but there are thermal considerations that are
important, and these have not been provided to us.
Remember that thermal heat capacity of the engine,
its heat-dissipation characteristics, etc. are more
important than weight-reduction.

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Student Project Summaries CAE and Design Optimization - Basics

There is no functional basis for the outer-profile of


the engine block. We can only work with the
exterior, and with areas away from the mounting
and assembly points.

Ideally we should carry out an analysis of the entire


assembly. Unfortunately that is not within the scope
of the design. In actual usage, a range of allowable
values for subsystems (stresses, natural frequencies,
etc.) should be provided to the component designer
by the system-integrator. In the absence of these,
we will concentrate on the behavior under static
loading.

Since we do not have any data on the loading


conditions, we will use a compare-with-original
approach. Even here, we are not given any idea of
the loading. Therefore we will assume unit
acceleration along each of 3 orthogonal directions.

We will want to monitor the stress in several


elements, so we will ask the optimizer to minimize
the maximum of these stresses - this is called a
minmax optimization.

Our design approach is build an Analysis Model,


build the Optimization Model with stress as the
response. The Objective is to minimize the maximum
stress in the area of interest.

The Analysis Model


Since OptiStruct uses an Optimization Model, the
Analysis Model need not be perfect. It should, of
course, be adequate. Your students should perform
the analyses with at least two different element-
sizes to confirm that the solution is fine enough.

Deciding which elements to use is not easy. Since


the engine block is a complicated shape, solid
elements are the only option, but should we use
tetrahedra or hexahedra? The latter are superior in
performance but the effort of creating a mesh is
quite high. Since our focus is on design, we will choose to work with

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Student Project Summaries CAE and Design Optimization - Basics

tetrahedra - this allows us to focus on the design


aspects without getting tied down in meshing
complications.

Deciding what size of elements to use is not easy


either. We will start with a problem-size that is
relatively small so that we can first ensure that the
problem is well-posed. Since solid elements have 3
degrees-of-freedom per node, a 10,000 node model
has 30,000 dofs. This is reasonable for static
analyses.

Our model will have 1 material (Steel), 1 element


type (tetrahedra), 3 loads (accelerations along three
axes), 1 set of restraints, and only 1 type of solution
(static).

To take advantage of symmetry, we will build a solid


from the IGES surfaces and split it along the plane
of symmetry.

Our problem involves Body Loads, which act at all


points in the body. We will create a load case that is
a combination of other loads: after just one solve,
we will want to see the stresses separately for the x-
direction acceleration, for the y-direction
accelerations, for the z-direction acceleration and
for all three acting together.

The Optimization Model


It is a good idea to ensure that the students
understand the full power of free-shape
optimization. The software can actually suggest the
external shape - this is remarkable.

Encourage your students to experiment with setting


up different parts of the component as design
variables. But do not use a brute-force approach.
Choosing all external nodes and identifying them as
design variables can prove to be expensive, since
the optimizer will set up variables for each node!

Free size optimization hides some maths from the


user. Interested students may want to read the on-

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Student Project Summaries CAE and Design Optimization - Basics

line documentation on Shape Optimization for an in-


depth understanding.

Results
Our principal interest is in the shape-variables. We
will want to apply the recommended values to the
FE model. This causes the FE model to be modified
to match the recommendations of the optimizer. We
will then build surfaces from the FE mesh and export
IGES geometry for CAD usage.

Further Work
The advantages of the Optimization-as-an-integral-
part-of-CAE are clear, as are the advantages of
using HyperWorks:

• designs that are more likely to pass subsequent


verification
• designs that are not unnecessarily over-designed
• easy setup of the FE model
• easy creation of the Optimization model
• convenient reporting options with easy viewing

You may choose to assign further investigations to


your students based on their level of proficiency on
CAD, the time available, etc.

Some of the areas that could include

• application of free-shape to other areas in the


model - for instance, wall-thicknesses
• the inclusion of natural frequencies as a response
• a study of the effect of design changes on the
center-of-gravity of the engine block
• inclusion of a displacement constraint limiting the
maximum movement of the nodes

Summary
By the end of this assignment, the student will know
how to
• import IGES files of assemblies into HyperMesh
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Student Project Summaries CAE and Design Optimization - Basics

• use the Model Browser


• zoom, pan and rotate
• change colors of entities
• delete unwanted imported data
• control visibility of geometry
• create material collectors
• create component collectors
• edit a component collectors to ensure it is using the correct
material
• create load collectors
• create body loads
• create load combinations
• use multiple load cases
• create restraints or SPCs
• apply symmetry BCs
• create solid geometry
• cut a solid with a plane
• measure distances
• use consistent units
• perform an analysis and obtain baseline results
• choose nodes that constitute the design space for Free Shape
optimization
• specify a minmax objective
• control the optimizer
• check for convergence and violation of constraints using the text
output files
• to check for convergence and violation of constraints using
HyperView
• to view and apply shape changes
• to export data back to a CAD modeler

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Student Project Summaries CAE and Design Optimization - Basics

Battery Tray Design


Areas covered:
• Geometry Abstraction for FE modeling
• Automatic Mesh Generation
• Constrained optimization with FRF excitation
• Design interpretations of FE results
• Transfer of an FE model to a CAD modeler for post-
optimization detailed-design
Software used:
• HyperMesh
• OptiStruct
• HyperView

Description of the Problem


A design for the tray to hold the battery of an
automobile has been proposed. The basis for the
model is a study of earlier designs. The designer
wants to know how the tray will perform under the
range of excitations it is likely to experience when
mounted on the vehicle.

Also, the CAD designers have asked whether ribs


can be added to minimize the deformation.

The goal is to start with the given shape and check


if the FRF displacement can indeed be reduced, and
to suggest to the designer the likely increase in
weight.

The starting point of the problem is the IGES file of


the CAD assembly. A frequency-domain load is
applied to simulate a frequency-sweep: from 0 to
1000 Hz.

Design Objectives
The proposed design is made from 2 mm thick
sheet metal, and is designed to assemble with pre-
designed components. It has to carry 2 batteries
that together weight 15 kg.

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Student Project Summaries CAE and Design Optimization - Basics

Design for static loads is quite easy, but the problem


here is that when the engine is running, the tray is
expected to receive excitations at a wide range of
frequencies. How can we design it for these dynamic
loads?

On a test-rig, we would load the tray and excite it at


frequencies within the specified range. In testing-
terms, we would "sweep" through all frequencies.

FRF (short for Frequency Response Function)


excitation is the way to do this using a numerical
model. We will first evaluate the natural frequencies
of the proposed design. We will use these natural-
frequency-and-mode-shape pairs to perform a
"modal response" analysis for frequencies within the
specified range.

Next, we will ask OptiStruct to tell us how to stiffen


the material to minimize the displacement at a point
of interest. Rather than using topography
optimization, we will use topology optimization. We
will use the results of the optimization to decide
where to place ribs under the tray.

Topography optimization and size optimization could


also have been used in this case.

The Analysis Model


The model is quite simple, geometrically. The mesh
is likely to be quite small, so the challenge does not
lie in the FE mesh preparation. It lies in specifying
and interpreting data that simulates a frequency-
sweep.

The element choice is easy - shell elements. It does


not matter much whether we mesh the outer
surface, the inner surface or the mid-surface. A quick
fix on geometry errors and automeshing can give us
an adequate mesh. In this project, however, we will
see that it is sometimes easier to fix the mesh than
to fix the geometry.

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Student Project Summaries CAE and Design Optimization - Basics

Since the model is small, we will not need to


worry much about the element size, though the
student must, of course, ensure that the results
are adequately accurate.

We will need to be careful in our choice of units.


Analysis results and data are specified in cycles-
per-unit-time. If if we use SI units we can work
with Hz (cycles / second).

A baseline analysis establishes the mode shapes


of the proposed design. The specifications call
for an excitation between 0 and 1000 Hz. We
therefore use the Lanczos method to obtain
mode shapes upto 3000 Hz.

We will use the modal-analysis method, where


we approximate the transient behaviour as a
weighted sum of the mode shapes. To reduce
error, we use mode shapes upto 3000 Hz -
thrice the excitation range.

The restraints are easy to setup - clamps at the


specified locations are best represented by
SPCs.

The loads are a little more complicated.


Specifying FRF loading requires care.

We specify the frequency range through which


we want to sweep using the TABLED1 card. The
DAREA card specifies the amplitude of the
excitation, and the RLOAD2 card puts the
frequency and the amplitude together.

We then specify the frequencies at which we


want to evaluate the responses. We use the
FREQ1 option to choose intervals of evaluation.

Finally, we use the ~EIGRL option to specify


which modes are to be evaluated - all evaluated
modes are used in the modal-evaluation of the
FRF response.

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Student Project Summaries CAE and Design Optimization - Basics

The Optimization Model


The bottom of the tray is our design space. We
want to minimize the FRF response at a selected
node. Our constraint is the mass. We will be
liberal with the mass constraint for the first
setup. If the results look promising, we can
investigate the effect of tightening the mass
constraint. You should encourage your students
to experiment with the constraints.

Results
Our principal interest is in the element
thickness. We will see what OptiStruct has
recommended, and use these to suggest where
ribs should be used under the tray.

Further Work
The advantages of the Optimization-as-an-
integral-part-of-CAE are clear, as are the
advantages of using HyperWorks:

*designs that are more likely to pass subsequent


verification
*designs that are not unnecessarily over-designed
*easy setup of the FE model
*easy creation of the Optimization model
*convenient reporting options with easy viewing

You may choose to assign further investigations


to your students based on their level of
proficiency on CAD, the time available, etc.

Some of the areas that could include

*the use of topography optimization (remember that


mass should not be used as a response!)
*the use of minmax optimization to minimize the
frequency at more nodes than one
*a study of the effect of design changes on the
center-of-gravity of the battery tray

Summary
By the end of this assignment, the student will know how to

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Student Project Summaries CAE and Design Optimization - Basics

• import IGES files of assemblies into HyperMesh


• use the Model Browser
• zoom, pan and rotate
• change colors of entities
• control visibility of geometry
• create material collectors
• create component collectors
• create load collectors
• create FRF loads using the RLOAD2, DAREA and TABLED1 cards
• create FRF evaluation frequencies using the FREQ1 card
• use the Modal-method to evaluate FRF response
• create load combinations
• create restraints or SPCs
• measure distances
• use consistent units
• perform an analysis and obtain baseline results
• view and animate mode shapes
• control the optimizer
• check for convergence and violation of constraints using the text
output files
• to check for convergence and violation of constraints using
HyperView

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