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Altair OptiStruct
Concept Design with Topology and Topography Optimization
Altair Engineering
HyperMesh
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HyperGraph HyperStudy
OptiStruct
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What is OptiStruct
An Optimizer with a Finite Element and Multi-body dynamics solver integrated Used for the design, analysis and optimization of structures and mechanical systems OptiStruct Structural Optimization solutions:
Topology Topography Shape and Size Free Size and Free Shape
Optimization Definitions:
Topology: is a mathematical technique that optimized the material distribution for a
structure within a given package space
Free Shape: is an automated way to modify the structure shape based on set of
nodes that can move totally free on the boundary to find the optimal shape.
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Optimization Terminology:
Design Variables: System parameters that are varied to optimize system performance. Design Space: selected parts which are designable during optimization process. For example, material in the design space of a topology optimization Response: Measurement of system performance. Objective Function: Any response function of the system to be optimized. The response is a function of the design variables. Ex. Mass, Stress, Displacement, Moment of Inertia, Frequency, Center of Gravity, Buckling factor, and etc. Constraint Functions: Bounds on response functions of the system that need to be satisfied for the design to be acceptable. Feasible Design: One that satisfies all the constraints. Infeasible Design: One that violates one or more constraint functions. Optimum Design: Set of design variables along with the minimized (or maximized) objective function that satisfy all the constraints.
Altair Proprietary and Confidential Information Copyright 2008 Altair Engineering, Inc. All rights reserved.
Note: The functions f(x), gi(x), can be linear, non-linear, implicit or explicit, and are continuous Example: Explicit y(x) = x2 2x Implicit y3 y2x + yx - x = 0
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Design Variables
Width: Height: bL < b < bU, hL < h < hU, 20 < b < 40 30 < h < 90
Design Region:
Design Constraints:
(b,h) max, with max = 160 MPa (b,h) max, with max = 60 MPa
h 2*b
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Design Variables
Values of variables for the improved design
Constraints
Did we violate any constraints?
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Need: effective concept design tools to minimize downstream redesign costs and time-tomarket
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Altair OptiStruct
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Response Definition
DRESP1 Simple response definition Mass, mass fraction, volume, volume fraction, compliance, frequency, displacement, stress, strain, force, composite responses, weighted compliance, weighted frequency, and compliance index, frequency response analysis responses
DRESP2 Response definition using a user defined function Defines responses as function of design variables, grid location, table entries, responses, and generic properties Example: Average displacement of two nodes:
F ( x1, x 2) =
DRESP3
x1 + x 2 2
Response definition using a user defined external function External function may be written in C (C++) or Fortran
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Optimization Tools:
DEQATN Defines an equation Linked to DVPREL2, DRESP2 for user defined property or response. DTABLE Defines constants used in DEQATN Linked to DVPREL2, DRESP2 DSCREEN Constraint screening definition DOPTPRM Optimization parameter definitions Max number of iterations, minimum member size control, moving limits, tolerances
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Optimization Setup module in HyperMesh Definition of Design Variables Definition of Responses, Constraints and Objective Definition of Equations Optimization Control, Constraint Screening
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Altair OptiStruct
Topology and Topography Optimization training
Optimization Disciplines
Topology optimization Method to find the optimum material distribution in a given design space
Topology Topography
Topography optimization Method to evaluate the optimum stiffening pattern on a thin part
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old design
design proposal
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Density = 0
E/E0 1 (/0)p
/
0
Density Method
Very robust
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Penalty Factor
More discrete design proposals
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0 90 - 45
y X
45 PCOMP
0 Optimized PCOMP
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min(Vol ) d1 d ub d 2 d lb
OSSmooth: Geometry Extraction of Optimization Results A Geometry creation tool for Topology/Topography/Shap e Optimized models Supports different output formats (IGES, STL, H3D etc.) Advanced geometry smoothing options for smoother surfaces Surface reduction option to reduce the size of IGES and STL files Integrated into HyperMesh and is easy to use
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IGES
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Final Design
Preliminary Design
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Original Design
Optimized Design
Max. Displ.
Mass
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Task: Stiffening of a bulk head using ribs 2 load cases Hydrostatic load (fuel) Take-off Pressure load on blue part Clamped perimeter
Design space
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2 man holes
Copyright 2008 Altair Engineering, Inc. All rights reserved.
Stiffening
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Original layout
Max. Deflection: 100%
Optimized design
Max. Deflection: 85%
Define three different load cases Define responses for volume and nodal displacements Set design constraints on nodal displacements for each load case Define the objective function: min(vol)
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Setup the normal modes analysis in HyperMesh Run the analysis and postprocess in HyperView Define the optimization problem Run the optimization and post-process Setup the final modes analysis in HyperMesh Run the analysis and postprocess in HyperView
Set up the FE model in HyperMesh Define the symmetry and draw direction control parameters for optimization Submit the check job to OptiStruct Post-process the results
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Stress < 50
Stress < 30
Topology Optimization with stress Constraints Common problem formulation when stress constraints are included
Minimize (total / regional) volume/ mass with stress constraints (displacement or frequency constraints can be combined)
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Create design variable for topology optimization Create von mises stress constraints on DTPL card Create response Create the objective function: min(vol) Post-process the results
4 loading cases
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Manufacturing constraints for topology optimization helps generate practical design concepts Minimum member size control specifies the smallest dimension to be retained in topology design. Controls checker board effect and discreteness. Maximum member size control specifies the largest dimension allowed in the topology design. It prevents large formation of large members and large material concentrations are forced to more discrete forms. Pattern grouping / repetition can be applied to enforce a repeating pattern or symmetrical design even if the loads applied on the structure are unsymmetrical or non-repeating. Draw direction / extrusion constraints can be applied to obtain design suitable for casting or machining operations by preventing undercut or die-lock cavities.
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d= 60
d= 90
Definition of maximum allowable structural member size Eliminates material concentrations Mesh considerations Shell and solid elements Tetrahedral and hexhedral Min member > 3 X mesh size Max member > 2 X min size
Without Maximum Member size
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Symmetry definitions Cyclic repetition of design features within a single domain User enters # of wedges Application: Cyclic structures with non symmetrical loadcases
Pattern Repetition
Application example: Airplane Wing Ribs
Goal: same topology on every rib Scaling factor to account for different sizes of design space
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Pattern Repetition
Application example: Airplane Wing Ribs
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Optimization Results
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Extrusion Constraint
Manufacturing control for constant cross sections
Package space
Member Size Draw Direction Pattern Repetition Pattern Grouping Extrusion Constraint
Draw Direction
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The use of HyperMesh to setup extrusion constraints The set up the design optimization problem responses, objective and constraints An examination of the results
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If too many constrained responses are screened, it may take considerably longer to reach a converged solution or, in the worst case, it may not be able to converge on a solution if the number of retained responses is less than the number of active constraints for the given problem.
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Free-Size Optimization
Free-Size Optimization
Topology optimization
Design space = Total Base Thickness Design variable Density Poor bending representation of semi-dense elements Truss-like design concepts, no Total Base shear panels thickness thickness
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Design variables - Thickness of each element Accurate bending representation Expandable to composites Shear panels possible if they Thickness represent the best concept
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Free-Size Optimization
Topology
Optimum mass
5,50 5,00 4,50 4,00 3,50 3,00 2,50 2,00 1,50 1,00 1 1,5 2 2,5 3 3,5 4 4,5 5
Maximum dispacement
Free-Size
Concept by topology and Free-Size Followed by sizing with buckling and stress constraints in sizing
Free-Size Optimization
The solution will be discrete when it needs to be so as the optimum design
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Create design variable for FreeSize optimization Define optimization responses, objective and constraints Run the same model with topology optimization Compare the results
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Topography Optimization
Search for optimal distribution of beads (swages) in shell structures Conceptual design method
Plate under torsion
Final Design
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Final contour
Copyright 2008 Altair Engineering, Inc. All rights reserved.
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CONTOUR
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FINAL RESULT
Copyright 2008 Altair Engineering, Inc. All rights reserved.
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Topography Optimization
Torsion Plate Example
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normal
global
Draw angle
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Create design variable for topography optimization Define optimization responses, objective and constraints Run the optimization Post-Process the results
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Altair OptiStruct
Size and Shape Optimization training
Optimization Disciplines
Size Shape
Size optimization Method to obtain optimum dimensions of structural parts
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Size Optimization
Properties are easily sizable
Shell Thickness, Beam Sections Masses, Spring Stiffness
Element (Shells and Beams) properties are a function of design variables Gauge Optimization
Simplified size optimization Shell thickness t = DV
p = C0 + C j DV j or
j
p = f (DV j ,C j )
Gauge panel in HyperMesh easy setup of thickness optimization for many components p - Element property C j - Constant
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Size Optimization
DESVAR
Design variable
DVPREL1
Simple Design Variable to Property RELationship Element property is linear combination of design variables
DVPREL2
User-defined function Design Variable to Property RELationship Defines properties as function of design variables, and table entries
bh 3 I (b, h) = 12
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Size Optimization
Example : Define Shell Thickness of Component ID 5 as a Size Variable. Initial Thickness: 1.0mm Thickness Range: 1.0 - 2.5
PID MID1 T MID2 12I/T3 MID3 TS/T NSM
PSHELL 5
204
ID
1.0
LABEL XINIT XLB XUB DELXV
DESVAR
1
ID
DV001 1.0
TYPE COEF1 PID DVID2
1.0
FID
2.5
C0
DVPREL1
88
DVID1
PSHELL 5 1
4
COEF2 Etc
0.0
1
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Size Optimization
Definition of Design Variables
Definition of initial value, lower bound, upper bound PROD (area) PBAR,PBEAM (Area, Moment of Inertia, etc.) PBARL,PBEAML (height, width, etc.) PELAS (stiffness) CONM (mass) PSHELL (thickness, etc.)
Size Optimization
Build relationship between design variables and properties
PROD (area) PBAR,PBEAM (Area, Moment of Inertia, etc.) PBARL,PBEAML (height, width, etc.) PELAS (stiffness) CONM2 (mass) PSHELL (thickness, etc.)
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Size Optimization
Build relationship between design variables and properties using functions
Setting up the optimization problem in HyperMesh Submitting the job Post processing results in HyperView
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Exercise 1.2: 3-D Composite Optimization using OptiStruct Retrieving the HyperMesh database file Setting up the problem in HyperMesh Submitting the job Viewing the results
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Shape Optimization
Modify geometry to achieve objective
Fillet Radii Rib Height Channel Depth / Width Solid Cross Sections
Shape Optimization
Initial design
Final design
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Shape Optimization
Single nodal movement due to single shape variable
x
x=x(0)+x x(0)
Original location:
= {1 , 2 ,3 ,L,n }
X = X ( 0 ) + j X j
j =1
Shape Optimization
DESVAR
Design variable Card Image
ID LABEL XINIT XLB XUB DELXV
DESVAR 1
DV001
0.0
-1.0
1.0
DVGRID
Unit mesh perturbations Total perturbation due to a single design variable is DESVAR * DVGRID Card Image
DVID GID CID COEFF X Y Z
DVGRID 1
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1.0
1.0
0.0
0.0
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Shape Optimization
Defining Shapes in HyperMesh
Define shapes
Mesh topology must be maintained Shapes are then assigned to design variables Perturbations are exported with the OptiStruct input deck
Assign DESVAR
Auto-generate DVGRID
Introduction to HyperMorph
What is HyperMorph
Mesh morphing module in HyperMesh. Allows you to morph an FE model in useful, logical, and intuitive ways which result in minimal element distortion.
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HyperMorph Tools
Morph constraints: Create/update/release constraints to morph a CAE model. Systems: Create, edit and update system Symmetry: Create, edit and update symmetry. Update domains/handles to symmetry Shapes: Create/apply/autoshape/convert shape into loads/save shape/apply the saved shape to another model. Morph Volume: Create/edit & update/save & export-import/convert HEXA into morph volume Domains: Create/edit/update domains and setup parameters Handles: Create/edit/update handles and dependency or save-to load-from a file Morph: morph the model and create shape entities. Map to geom: map domains and handles to geometric data. Freehand: Easy way of morphing. Good for quick change and bead creation.
Freehand morphing
Enables direct morphing of the mesh without any morphing entities. Provides the ability to insert beads by mesh sculpting via tools with regular or arbitrary cross-sections.
Section morphing:
Enables rapid shape changes by mapping to profile lines corresponding to new design cross-sections.
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HyperMorph Applications
Rapidly change shape of existing model Fit old model to new design data Map an existing mesh onto lines, surfaces, map to section etc Generate NURB surfaces using FE -> Surf feature in HyperMesh Generate and edit shape variables for optimization
Morphing example: Dart to a X-29 supersonic jet Before After
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Before
After
Before
After
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Before
After
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With
Copyright 2008 Altair Engineering, Inc. All rights reserved.
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Use any of the four morphing methods Morph the model to the desired shape. Save the shape Undo the shape Save the HyperMesh session file. Create a desvar (design variable) Run Optimization.
Morph
Save shape
Undo morph
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Load the model Generate the Morph entities Edit Domains Modify the model using Morph.
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Exercise 2.3 : Mapping a mesh to a new geometry Practice the morphing process:
Using HyperMorph to modify an existing model based on a new geometry
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Smooth edge Vary the radio of surface fillet Modify channel depth Modify channel width
Radius to optimize
Shock Absorber
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Stabilizer Bracket
Courtesy
Copyright 2008 Altair Engineering, Inc. All rights reserved.
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Problem Statement
Objective: Min (Max Stress) Design variables: Grid points of domains
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Final
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Free Shape optimization uses a proprietary optimization technique developed by Altair, wherein the outer boundary of a structure is altered to meet with pre-defined objectives and constraints Can be combined with any type of optimization e.g. w/ morphing based shape optimization
Optimum ?
DSHAPE
ID PERT DTYPE MVFACTOR NSMOOTH GRID GID1 GID8 GID2 GID9 GID3 . GID4 GID5 GID6 . GID7
CTYPE1 CTYPE2 ..
CID1 CID2
X1 X2
Y1 Y2
Z1 Z2
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BOTH (default)
Undeformed Deformed
GROW
SHRINK
(b) NSMOOTH = 1
NSMOOTH can be larger than the number of available layers. e.g., NSMOOTH = 100 will work fine in the above example.
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Objective :
Minimize compliance
Subject to:
Volume < 4000.00
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DSHAPE 2
DSHAPE 1
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Move only on X-Z plane fix the height of the beam section
ITER 0 :
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ITER 26 :
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Create design variables for Free-Shape (DSHAPE) Define responses and objective, constraints Solve and post-process w/o GRIDCON Create GRIDCON Solve and post-process
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