3 Altair Optistruct

Copyright 2010 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
OPTIMISATION FOR PLASTIC PARTS
PEP, 30th June 2011

Emilien GOETZ
01
Agenda
01
02
Introduction
Optimisation for plastic parts

Concept Optimisation
Fine tuning Optimisation
01
Historique Altair
$175M
$100M
19
85
20
10
01
Optimization with HyperWorks

Introduction
Optistruct
HyperStudy
CONCEPT OPTMIZATION
DESIGN OF EXPERIMENT
FULL COMPOSITE OPTIMIZATION
MULTIPLE OBJECTIF OPTIMIZATION
OPTIMIZE RADIOSS BULK ANALYSIS
ROBUST OPTIMIZATION
COMPATIBLE WITH NASTRAN
LINK WITH ANY SOLVERS
01

ALTAIR HYPERSTUDY
DESIGN OF EXPERIMENTS
ANALYZE
INPUT PARAMETERS
SIMULATION
COMPUTE
OPTIMIZATION
PROBABILITY DENSITY
ABAQUS
ADAMS
ANSYS
DADS
LS-DYNA
DIGIMAT
MARC
NASTRAN
PAM-CRASH
SIMPACK
RADIOSS
OptiStruct
MotionSolve
HyperForm
And More
RESPONSE SURFACE
STOCHASTIC
01
Gauge9 & 10
Gauge1, 2 & 3
Gauge5
Gauge11, 12 & 13
212 MPa
Gauge6
Gauge7
Gauge4
67087mm3
Gauge14 &15
64420mm3
123 MPa
Peak Stress
Volume
01

OptiStruct
NON-LINEAR
(EXPLICIT)
MULTI-BODY
DYNAMICS
Quasi-static, Dynamics,
Post-buckling, Materials,
Contact
Impact, Thermal,
Materials, Contact
(Rigid & Flexible Bodies)

Kinematics, Static and
Dynamic, Quasi-static
Multi-physics, multi-disciplines
HYPERSTUDY
+ SOLVER
Statics, Dynamics, Buckling,

Thermal, Plasticity, Normal
Modes, NVH, Contact
NON-LINEAR
(IMPLICIT)
OPTISTRUCT
LINEAR
Agenda
01
02
Introduction

Concept Optimisation
Fine tuning Optimisation
02
Altairs Vision
= Cost is a problem to solve
# Identified problems
Concept Design
Concept
Phase
Design
CAD
Virtual and
real tests
Simulation
CAE
Prototype
DMU
Manufacturing
02
Altairs Vision
The Traditional Design Process

Virtual Test
(CAE)
Concept design + Design (CAD)
Build
Test
Redesign
Redesign
The Traditional Design Process

Concept
Design
Optimization
Design
(CAD)
Virtual Test
(CAE)
Optimization
Build
Test
02
Altairs Vision
Classic: Simulation as a
virtual test
Concept
Phase
Design
CAD
Simulation
CAE
Prototype
DMU
Manufacturing
Positioning Concept Design...
What? Conceptual design, material substitution, weight loss, stress

reduction, increase in stiffness, natural frequencies, ...
Product Safety Design through early maturity!
02
Concept
Phase
Design
CAD
Simulation
CAE
First the concept then the fine Tuning!
Prototype
DMU
Manufacturing
02
Concept
Phase
Design
CAD
Simulation
CAE
Prototype
DMU
Methods and examples of concept development
Manufacturing
02

How to ensure the Plastic parts requirements?
A preliminary design tool to generate optimal

design concepts
An optimization tool for weight reduction

and performance tuning of concept and
existing designs
A robust and accurate finite element solver

for linear structural analysis
02

Topology
METHOD TO FIND THE OPTIMUM MATERIAL DISTRIBUTION IN A GIVEN DESIGN SPACE
3D ELEMENTS
2D ELEMENTS
1D ELEMENTS
Manufacturing Constrains
Min/Max Member Size
Without Maximum Member Size
5Without
Repetitions
Draw Direction
Design Space
Without Pattern
HollowRepetition
section
No symmetry
Extrusion
Symmetry
No Symmetry
Draw Direction
Pattern Repetition
Cyclic Repetition
Symmetry
02
20 Repetitions
With Pattern Repetition

XZ, YZ symmetry
Without Extrusion
Material
Concentration
With Pattern Repetition
Without
Pattern Repetition
Eliminated
YZ symmetry
XZ symmetry
With Draw Direction
WITH Maximum Member Size
Ribs
With Extrusion
02

Geometry Recovery through OSSmooth
Iso-surface extraction and remeshing

NASTRAN, IGES, STL and H3D output formats
02
TOPOLOGY 3D
Time consuming because fine mesh

needed to respect the rib thickness
TOPOLOGY 2D
Fast simulation
Approximate approach
good method for panel
usefull for big design space
1 or 2 Step of 3D topology
Draw Z
Draw Z - No hole
MATERIAL DOWNSCALING
More conceptual : give path

loads
02

CASE STUDIES: 3D TOPOLOGY
MODEL
OPTIMIZATION
Draw Direction Constraints
FINAL DESIGN
02

CASE STUDIES
Is it permissible for an isotropic material model with linear and static load
cases, an interpretation of possibly dynamically loaded plastic components
to make?
Not only allowed on, but

useful!
Optimization of Plastic Products BPODevelopment; Oscar Brocades Zaalberg
Optimization of Plastic Products BPODevelopment; Oscar Brocades Zaalberg
02

CASE STUDIES
Linearization of crash loading case :
Maximum 3 point harness forces

Dummy contact forces
Design Space
02

02

MODEL
OPTIMIZATION
FINAL DESIGN
TOTAL VOLUME
CU.UNITS
COMPLIANCE
EXISTING DESIGN
2.99 E-01
1.563
NEW OPTIMIZED DESIGN
2.99 E-01
1.384
02
Concept
Phase
Design
CAD
Simulation
CAE
Prototype
DMU
Manufacturing
02

Size
AUTOMATED WAY TO MODIFY THE STRUCTURE PARAMETERS (THICKNESS, 1D

PROPERTIES, MATERIAL PROPERTIES, ETC) TO FIND THE OPTIMAL SOLUTION
02

Shape
AUTOMATED WAY TO MODIFY THE STRUCTURE SHAPE BASED

ON A PREDEFINED SHAPE VARIABLES TO FIND THE OPTIMAL
SHAPE
Morphing Concept as Tool

Motivation: Reduce CAD Loops
Idea: FE-based Modification
Related changes make where the problem area has been identified!
Related changes directly on the simulation model
Concept development based on the predecessors FE-model!
02

CASE STUDIES : Fine tuning optimisation
DESIGN PROBLEM
Improve the stiffness
Collapse load on top of the model
Mass reduction
METHODS USED
DOE for identified most important parameters!
Shape and size optimization
02

Parameterized
model
Update design
variables: geometry,
temperature,
pressure, ...
Simulation
Results
Optimum?
Yes
No
02

Design sensitivities
Improved collapse mechanism

Increased Buckling +20%
Mass reduction: 5%
02

Freeze contact and morphing in HW 11
Combining the freeze contact between 2 shells elements and Morphing

allow you quick update and optimization with HyperStudy
+
FREEZE CONTACT
02

Airbus Wing Rib
Challenge
Develop the design concept to meet the mass target within a three week process
development period
A further four weeks was then allocated to optimizing the thirteen rib package
02

Airbus Wing Rib
Topology Optimization
Package Space Definition
ICAD
Solid Geometry Extraction
Material Layout
Geometry Extraction
Size and Shape Optimization
Buckling and Stress
02
Airbus Wing Rib
Results
Mass Savings of 44% (500kg)

Deadline met: Ribs developed in 13 weeks
02

PLATFORM FOR THE VIRTUAL DEVELOPMENT PROCESS
Filling
Crash / Drop Test
+
Fiber orientation
Fatigue,
Concept
Phase
Design
CAD
Simulation
CAE
Prototype
DMU
Manufacturing
MERCI
Altair Engineering, Inc.

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3 Altair Optistruct

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Copyright 2010 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

OPTIMISATION FOR PLASTIC PARTS

PEP, 30th June 2011

Optimisation for plastic parts

Optimization with HyperWorks

FULL COMPOSITE OPTIMIZATION

MULTIPLE OBJECTIF OPTIMIZATION

OPTIMIZE RADIOSS BULK ANALYSIS

COMPATIBLE WITH NASTRAN

LINK WITH ANY SOLVERS

Optimization with HyperWorks

Optimization with HyperWorks

Optimization with HyperWorks

(Rigid & Flexible Bodies)

Statics, Dynamics, Buckling,

Optimisation for plastic parts

The Traditional Design Process

Concept design + Design (CAD)

The Traditional Design Process

Positioning Concept Design...

What? Conceptual design, material substitution, weight loss, stress

Optimisation for plastic parts

First the concept then the fine Tuning!

Optimisation for plastic parts

Methods and examples of concept development

Optimisation for plastic parts

A preliminary design tool to generate optimal

An optimization tool for weight reduction

A robust and accurate finite element solver

Optimisation for plastic parts

METHOD TO FIND THE OPTIMUM MATERIAL DISTRIBUTION IN A GIVEN DESIGN SPACE

Without Maximum Member Size

Optimisation for plastic parts

With Pattern Repetition

Optimisation for plastic parts

Iso-surface extraction and remeshing

Optimisation for plastic parts

Time consuming because fine mesh

good method for panel

usefull for big design space

More conceptual : give path

Optimisation for plastic parts

Draw Direction Constraints

Optimisation for plastic parts

Not only allowed on, but

Optimization of Plastic Products BPODevelopment; Oscar Brocades Zaalberg

Optimization of Plastic Products BPODevelopment; Oscar Brocades Zaalberg

Optimisation for plastic parts

Linearization of crash loading case :

Maximum 3 point harness forces

Optimisation for plastic parts

Optimisation for plastic parts

NEW OPTIMIZED DESIGN

Optimisation for plastic parts

Optimisation for plastic parts

AUTOMATED WAY TO MODIFY THE STRUCTURE PARAMETERS (THICKNESS, 1D

Optimisation for plastic parts

AUTOMATED WAY TO MODIFY THE STRUCTURE SHAPE BASED

Morphing Concept as Tool

Optimisation for plastic parts

Optimisation for plastic parts

Optimisation for plastic parts

Improved collapse mechanism

Optimisation for plastic parts