3 altair optistruct
DESCRIPTION
optistructTRANSCRIPT
-
Copyright 2010 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
PEP, 30th June 2011
Emilien GOETZ
OPTIMISATION FOR PLASTIC PARTS
-
Copyright 2010 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Agenda
Introduction
Optimisation for plastic parts
Concept Optimisation Fine tuning Optimisation
02
01
01
-
Copyright 2010 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Historique Altair 01
19 85
20 10
$175M
$100M
-
Copyright 2010 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
CONCEPT OPTMIZATION
FULL COMPOSITE OPTIMIZATION
OPTIMIZE RADIOSS BULK ANALYSIS
COMPATIBLE WITH NASTRAN
DESIGN OF EXPERIMENT
MULTIPLE OBJECTIF OPTIMIZATION
ROBUST OPTIMIZATION
LINK WITH ANY SOLVERS
Optimization with HyperWorks Introduction
01
HyperStudy Optistruct
-
Copyright 2010 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
DESIGN OF EXPERIMENTS
INPUT PARAMETERS
PROBABILITY DENSITY
ABAQUS
ADAMS
ANSYS
DADS
LS-DYNA
DIGIMAT
MARC
NASTRAN
PAM-CRASH
SIMPACK
RADIOSS
OptiStruct
MotionSolve
HyperForm
And More
COMPUTE
SIMULATION
RESPONSE SURFACE
OPTIMIZATION STOCHASTIC
ANALYZE
Optimization with HyperWorks ALTAIR HYPERSTUDY
01
-
Copyright 2010 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Optimization with HyperWorks 01
Peak Stress
212 MPa
123 MPa
Volume
64420mm3
67087mm3
Gauge9 & 10
Gauge1, 2 & 3
Gauge4
Gauge5
Gauge6
Gauge7Gauge11, 12 & 13
Gauge14 &15
-
Copyright 2010 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
HY
PE
RS
TU
DY
+ S
OLV
ER
Optimization with HyperWorks OptiStruct
01
LINEAR
NON-LINEAR (IMPLICIT)
NON-LINEAR (EXPLICIT)
MULTI-BODY
DYNAMICS
OP
TIS
TR
UC
T
Statics, Dynamics, Buckling, Thermal, Plasticity, Normal
Modes, NVH, Contact
Quasi-static, Dynamics, Post-buckling, Materials,
Contact
Impact, Thermal, Materials, Contact
(Rigid & Flexible Bodies)
Kinematics, Static and
Dynamic, Quasi-static
Multi-physics, multi-disciplines
-
Copyright 2010 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Agenda
Introduction
Optimisation for plastic parts
Concept Optimisation Fine tuning Optimisation
02
01
-
Copyright 2010 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Concept Design Virtual and
real tests
= Cost is a problem to solve
# Id
en
tifi
ed
pro
ble
ms
# Id
en
tifi
ed
pro
ble
ms
Altairs Vision 02
Manufacturing Prototype
DMU
Simulation
CAE
Design
CAD
Concept
Phase
-
Copyright 2010 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Optimization
The Traditional Design Process
The Traditional Design Process
Altairs Vision 02
Concept design + Design (CAD) Virtual Test
(CAE) Build Test
Concept Design
Optimization
Design (CAD)
Virtual Test (CAE)
Build Test
Redesign
Redesign
-
Copyright 2010 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Positioning Concept Design...
Classic: Simulation as a
virtual test
What? Conceptual design, material substitution, weight loss, stress reduction, increase in stiffness, natural frequencies, ...
Product Safety Design through early maturity!
Altairs Vision 02
Manufacturing Prototype
DMU
Simulation
CAE
Design
CAD
Concept
Phase
-
Copyright 2010 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Optimisation for plastic parts 02
Manufacturing Prototype
DMU
Simulation
CAE
Design
CAD
Concept
Phase
First the concept then the fine Tuning!
-
Copyright 2010 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Optimisation for plastic parts 02
Manufacturing Prototype
DMU
Simulation
CAE
Design
CAD
Concept
Phase
Methods and examples of concept development
-
Copyright 2010 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
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 Optimisation for plastic parts How to ensure the Plastic parts requirements?
-
Copyright 2010 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
METHOD TO FIND THE OPTIMUM MATERIAL DISTRIBUTION IN A GIVEN DESIGN SPACE
02 Optimisation for plastic parts Topology
2D ELEMENTS 3D ELEMENTS 1D ELEMENTS
-
Copyright 2010 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Min/Max Member Size
Draw Direction
Extrusion
Symmetry
Pattern Repetition
Cyclic Repetition
02 Optimisation for plastic parts Manufacturing Constrains Without Maximum Member Size
WITH Maximum Member Size
Material
Concentration
Eliminated
Hollow section
Ribs
Without Draw Direction
With Draw Direction
Without Extrusion
Design Space
With Extrusion
Without Pattern Repetition With Pattern Repetition
Without Pattern Repetition With Pattern Repetition
No symmetry XZ, YZ symmetry
YZ symmetry XZ symmetry S
ym
me
try
5 Repetitions
No
Sy
mm
etr
y
20 Repetitions
-
Copyright 2010 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Iso-surface extraction and remeshing
NASTRAN, IGES, STL and H3D output formats
02 Optimisation for plastic parts Geometry Recovery through OSSmooth
-
Copyright 2010 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
TOPOLOGY 2D MATERIAL DOWNSCALING
Time consuming because fine mesh needed to respect the rib thickness
1 or 2 Step of 3D topology
Fast simulation
good method for panel
More conceptual : give path loads
Draw Z - No hole
Approximate approach
usefull for big design space
Draw Z
TOPOLOGY 3D
Optimisation for plastic parts 02
-
Copyright 2010 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Draw Direction Constraints
MODEL OPTIMIZATION FINAL DESIGN
Optimisation for plastic parts CASE STUDIES: 3D TOPOLOGY
02
-
Copyright 2010 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Is it permissible for an isotropic material model with linear and static load
cases, an interpretation of possibly dynamically loaded plastic components
to make?
Optimization of Plastic Products BPODevelopment; Oscar Brocades Zaalberg
Optimization of Plastic Products BPODevelopment; Oscar Brocades Zaalberg
Not only allowed on, but useful!
Optimisation for plastic parts CASE STUDIES 02
-
Copyright 2010 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Linearization of crash loading case : Maximum 3 point harness forces Dummy contact forces
Design Space
Optimisation for plastic parts CASE STUDIES 02
-
Copyright 2010 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Optimisation for plastic parts CASE STUDIES: 3D TOPOLOGY
02
-
Copyright 2010 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
TOTAL VOLUME
CU.UNITS
COMPLIANCE
EXISTING DESIGN
2.99 E-01
1.563
NEW OPTIMIZED DESIGN
2.99 E-01
1.384
MODEL OPTIMIZATION FINAL DESIGN
Optimisation for plastic parts CASE STUDIES: 3D TOPOLOGY
02
-
Copyright 2010 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Optimisation for plastic parts 02
Manufacturing Prototype
DMU
Simulation
CAE
Design
CAD
Concept
Phase
-
Copyright 2010 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
AUTOMATED WAY TO MODIFY THE STRUCTURE PARAMETERS (THICKNESS, 1D PROPERTIES, MATERIAL PROPERTIES, ETC) TO FIND THE OPTIMAL SOLUTION
02 Optimisation for plastic parts Size
-
Copyright 2010 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
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 Optimisation for plastic parts Shape
-
Copyright 2010 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
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 Optimisation for plastic parts CASE STUDIES : Fine tuning optimisation
-
Copyright 2010 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Simulation
Parameterized
model
Results
Optimum? No
Yes
Update design
variables: geometry,
temperature,
pressure, ...
Optimisation for plastic parts CASE STUDIES : Fine tuning optimisation 02
-
Copyright 2010 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Improved collapse mechanism
Increased Buckling +20%
Mass reduction: 5%
Design sensitivities
Optimisation for plastic parts CASE STUDIES : Fine tuning optimisation 02
-
Copyright 2010 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Combining the freeze contact between 2 shells elements and Morphing
allow you quick update and optimization with HyperStudy
+ FREEZE CONTACT
Optimisation for plastic parts Freeze contact and morphing in HW 11
02
-
Copyright 2010 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
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 Optimisation for plastic parts Airbus Wing Rib
-
Copyright 2010 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Optimisation for plastic parts 02 Airbus Wing Rib
Topology Optimization
Geometry Extraction
ICAD
Solid Geometry Extraction Size and Shape Optimization
Topology Optimization
Package Space Definition
Topology Optimization
Material Layout
Buckling and Stress
-
Copyright 2010 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Results
Mass Savings of 44% (500kg)
Deadline met: Ribs developed in 13 weeks
02 Optimisation for plastic parts Airbus Wing Rib
-
Copyright 2010 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
02 Optimisation for plastic parts PLATFORM FOR THE VIRTUAL DEVELOPMENT PROCESS
Manufacturing Prototype
DMU
Simulation
CAE
Design
CAD
Concept
Phase
Crash / Drop Test
Filling
Fatigue,
Fiber orientation
+
-
Copyright 2010 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Altair Engineering, Inc.
Innovation Intelligence
MERCI