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OptiStruct Optimization
Concept Design and Structural Optimization Volume I
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Table of Contents
Concept Design and Structural Optimization Volume I
OptiStruct Optimization
Chapter 1: Introduction to OptiStruct ................................................................... 1 Chapter 2: Topology Optimization ...................................................................... 15 Chapter 3: Topography Optimization................................................................ 121
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II
III
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Chapter 1
Introduction to OptiStruct
What is OptiStruct?
Altair OptiStruct is a finite element and multi-body dynamics software which can be used to design and optimize structures and mechanical systems. OptiStruct uses the analysis capabilities of RADIOSS and MotionSolve to compute responses for optimization.
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OptiStruct Optimization 1
HyperMesh
HyperViewPlayer HyperWeb HyperGraph HyperStudy HyperView MotionView OptiStruct MotionSolve HyperForm Altair HyperWorks HyperMesh
HyperGraph HyperStudy
OptiStruct
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
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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.
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.
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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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OptiStruct Optimization 5
Design Variables
Values of variables for the improved design
Constraints
Did we violate any constraints?
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Altair OptiStruct
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OptiStruct Optimization 7
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OptiStruct Optimization 9
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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OptiStruct Optimization 11
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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Chapter 2
Topology Optimization
Setting up Topology Optimizations
Topology optimization generates an optimized material distribution for a set of loads and constraints within a given design space. The design space can be defined using shell or solid elements, or both. The classical topology optimization set up solving the minimum compliance problem, as well as the dual formulation with multiple constraints are available. Constraints on von Mises stress and buckling factor are available with limitations. Manufacturing constraints can be imposed using a minimum member size constraint, draw direction constraints, extrusion constraints, symmetry planes, pattern grouping, and pattern repetition. A conceptual design can be imported in a CAD system using an iso-surface generated with OSSmooth, which is part of the OptiStruct package. Free-size optimization is available for shell design spaces. The shell thickness or composite ply-thickness of each element is the design variable.
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OptiStruct Optimization 15
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
(/0)p
/
0
Density Method
Very robust
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Penalty Factor
More discrete design proposals
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0 90
z
- 45
y X
45 PCOMP
0 Optimized PCOMP
min(Vol ) d1 d ub d 2 d lb
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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
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
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OptiStruct Optimization 23
Stiffening
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Original layout
Max. Deflection: 100%
Optimized design
Max. Deflection: 85%
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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)
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
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OptiStruct Optimization 25
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
Stress < 50
Stress < 30
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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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d= 60
d= 90
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OptiStruct Optimization 31
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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OptiStruct Optimization 33
Optimization Results
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Extrusion Constraint
Manufacturing control for constant cross sections
Package space
Member Member Size Size Draw Draw Direction Direction Pattern Pattern Repetition Repetition Pattern Pattern Grouping Grouping Extrusion Extrusion Constraint Constraint
Draw Direction
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Design space defines areas where ribs shall be introduced Manufacturing constraints crucial
Draw direction Minimum & maximum member size
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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OptiStruct Optimization 37
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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10. Click return 11. Right click inside the Model Browser, Create >> Property 12. For Name: enter prop_shell. 13. Pick PSHELL as Card image. 14. Select Steel as the Material. 15. Click on Create/Edit. 16. The PSHELL card image pops up. 17. Activate the thickness field for the shell component by clicking [T]. This allows you to edit this field. 1.0 is shown and is the default. Leave it at this value. 18. Click return to exit the panel. 19. From pull down menu, Collectors >> Edit >> Components. 20. Click on comps, check the box comp_shell and click select 21. Toggle no property to property = 22. Double click on property = and select prop_shell 23. Click on update 24. Click return.
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OptiStruct Optimization 43
2. Go to Analysis page and click on constraints panel. 3. Select nodes and corresponding dofs and click on create to create constraints as shown below.
4. Click Return.
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6. From pull down menu click on File >> Exit quit HyperView. 7. Click No on save popup window. 8. Click return to exit from the Radioss panel.
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OptiStruct Optimization 47
Optimization Setup
The preliminary finite element model, consisting of shell elements, element properties, material properties, and loads and boundary conditions has been defined. Now a topology optimization will be performed with the goal of minimizing the amount of material to be used. When reducing material in an existing mesh with the same loads and boundary conditions, it follows for the model to be less stiff and more prone to deform. Therefore, the optimization process needs to be constrained with a displacement so that a balance between material and overall stiffness is achieved. The forces in the structure are applied on the outer nodes of the opening of the clip, making those two nodes critical locations in the mesh. We applied a displacement constraint on the nodes so that they would not displace more than 0.07 in the y-axis.
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To create a displacement as a response, you will need to supply a meaningful name for the response, set the response type to displacement, select the node for the response, and select the type of displacement (dof). 1. While already on the response panel, click response= and type upperdis 2. Change the response type: to static displacement 3. Click the node labeled A (upper opening of c-clip) as shown in the figure to select it.
4. Choose dof2 for the node. 5. Click create. 6. Click response= and type lowerdis 7. The response type: should still be static displacement. 8. Click the node labeled B (lower opening of the c-clip) as shown in the figure. 9. Select dof2 and create the response
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1. Click on dconstraints panel 2. Click constraint= and enter c_upper. 3. Check the box for upper bound only. 4. Click upper bound= and enter 0.07. 5. Select response= and set it to upperdis. 6. Click loadsteps. 7. Check the box next to opposing forces. 8. Click select. 9. Click create. 10. Click constraint= and enter c_lower. 11. Uncheck the box for upper bound. 12. Check the box for lower bound only. 13. Click lower bound= and enter -0.07. 14. Select response= and set it to lowerdis. 15. Click create. 16. Click return to exit the panel.
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cclip_complete.out can be opened in a text editor to find details regarding any errors. This file is written to the same directory as the .fem file. 5. Close the DOS window. The default files that get written to your run directory include: cclip_complete.res cclip_complete.h3d cclip_complete.HM.comp. cmf HyperMesh binary results file. HyperView binary results file. HyperMesh command file used to organize elements into components based on their density result values. This file is only used with OptiStruct topology optimization runs. 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. Shape file for the final iteration. It contains the material density, void size parameters and void orientation angle for each element in the analysis. This file may be used to restart a run. HyperGraph file containing data for the objective function, percent constraint violations, and constraint for each 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. Contains the iteration history of the objective, constraints, and the design variables. It can be used to plot curves in HyperGraph, HyperView, and MotionView. Contains information about the CPU time used for the complete run and also the break up of the CPU time for reading the input deck, assembly, analysis, convergence, etc.
cclip_complete.out
cclip_complete.sh
cclip_complete.hgdata
cclip_complete.oss
cclip_complete_hist.mvw
cclip_complete.stat
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Select Design under the Load Case section and the last iteration listed under Simulation and click OK.
4. From pull down menu click on Graphics >> Iso Value. 5. Choose Element Densities as the Result type 6. Set the Current Value: to 0.3 7. Click Apply.
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8. 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.
Step 17: Compare a static contour between the Original and Optimized material layout
1. In HyperView, click on the Next Page arrow toolbar button to go to page 2.
2. This will bring up the cclip_complete_s1.h3d file, which contains the static subcase results for the first and last iteration steps 3. In the bottom portion of the GUI, click in the area circled below to activate the Load Case and Simulation Selection dialog.
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OptiStruct Optimization 53
5. From pull down menu click on Graphics >> Contour, 6. Choose Element Stresses (2D & 3D) as Result type: and select vonMises. 7. From pull down menu click on Graphics >> Iso Value. 8. Choose Result type: as Element Densities. 9. Choose Averaging Method: as Simple. 10. Click Apply. 11. From the pull-down menu, File >> Exit to quit HyperView. 12. Click No on save popup window. 13. Close HyperMesh widow too, click quit on the popup window.
The regions with high element densities indicate where material is needed and regions with low element densities are areas with scope for mass reduction.
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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 SUBCASE 2 SUBCASE 3 Design variables: 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.
The following exercises are included: Setting up the FE model in HyperMesh Setting up the optimization in HyperMesh Submitting the job Viewing the results in HyperView
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OptiStruct Optimization 55
Step 2: Create materials and properties and assigning them to the proper components
1. Click Model on the Tab menu 2. Right click inside the Model Browser Create >> Material. 3. For Name: enter, Steel. 4. Select MAT1 as Card image:. 5. Click on Create/Edit. 6. The MAT1 card image pops up. 7. For E, enter the value 2.1E5. 8. For Nu, enter the value 0.3. 9. Click return 10. Right click inside the Model Browser window again Create >> Property. 11. In the Name: field type design_prop. 12. Scroll down to select PSOLID as Card image:. 13. Select Steel as the Material. 14. Click on Create.
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15. Create another similar PSOLID property called nondesign_prop and assign it the Steel material. 16. From pull down menu, Collectors >> Assign >> Components Property 17. Click on comps, check the box nondesign then click select 18. Click on property = and select nondesign_prop 19. Click on assign 20. Repeat steps 17 20 to assign design_prop to the design component. 21. Click return.
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OptiStruct Optimization 57
5. Constrain dof1, dof2, and dof3. 6. Make sure dofs 1, 2, and 3 are checked and dofs 4, 5, and 6 are unchecked. Dofs with a check will be constrained while dofs without a check will be free. Dofs 1, 2, and 3 are x, y, and z translation degrees of freedom. Dofs 4, 5, and 6 are x, y, and z rotational degrees of freedom. 7. Click create. A constraint is created. A constraint symbol (triangle) appears in the graphics window at the selected node. The number 123 is written beside the constraint symbol, indicating that dof1, dof2 and dof3 are constrained.
8. Select the node at the other end of the bushing (see the following figure) by clicking on it in the graphics window. 9. Constrain dof2 and dof3. 10. Make sure dofs 2 and 3 are checked. 11. 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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12. Click nodes >> by id. 13. Enter the value 3239 and press Enter. This selects node ID 3239 (see the next figure). 14. Constrain only dof3. 15. 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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11. Enter 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. On Model Browser tab under expand LoadCollectors, right click on Pothole, and click on Make Current 16. Click nodes >> by id. 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 exit the panel.
Three separate forces in load collectors: Brake, Corner, and Pothole with the component "design" turned off using the display panel.
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3. Check the box for upper bound only 4. Click upper bound= and enter 0.05 5. Select response= and set it to disp1 6. Click loadsteps 7. Check the box next to Brake 8. Click select 9. Click create 10. Click constraint= and enter Constr_Corner 11. Check the box for upper bound only 12. Click upper bound= and enter 0.02 13. With the disp1 response selected, click loadsteps 14. Check the box next to Corner 15. Click select 16. Click create 17. Click constraint= and enter Constr_Pothole 18. Check the box for upper bound only 19. Click upper bound= and enter 0.04 20. With the disp1 response still selected , click loadsteps 21. Check the box next to Pothole 22. Click select 23. Click create 24. Click return twice to exit the panel.
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A Save file browser window pops up. 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 filename extension is the suggested extension for OptiStruct input decks. 4. Click Save. Note the name and location of the carm_check.fem file displays in the input file: field. 5. Set the export options: toggle to all. 6. Click the run options: switch and select check. 7. Set the memory options: toggle to memory default. 8. 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.
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can be opened in a text editor to find details regarding any errors. This file is written to the same directory as the .fem file. 5. Close the DOS window or shell and click return. The default files written to the directory are: carm_complete.hgdata HyperGraph file containing data for the objective function, percent constraint violations, and constraint for each iteration. OptiStruct history file containing iteration number, objective function values and percent of constraint violation for each iteration.
carm_complete.his_data
carm_complete.HM.comp.c HyperMesh command file used to organize elements mf into components based on their density result values. This file is only used with OptiStruct topology optimization runs. carm_complete.HM.ent.cm HyperMesh command file used to organize elements f into entity sets based on their density result values. This file is only used with OptiStruct topology optimization runs. 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
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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.
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 1000 for value:. This means that the maximum displacement will be 1000 Model units and all other displacements will be proportional.
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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 .
A deformed animation for the first subcase (brake) should be displayed. Notice that the icon changes to 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 name Static Analysis or Iteration 0, Selection dialog. , to activate the Load Case and Simulation
16. Select the 19th iteration by double-clicking on Iteration 19. 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.
18. Click on the Next Page icon to move to the third page. The third page which has results loaded from carm_complete_s2.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 2 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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1. Click the Previous Page icon until the name of the page is displayed as Design History, indicating that the results correspond to optimization iterations. 2. Click the Contour toolbar button. 3. Note the Result type: is Element Densities [s] this should be the only results type in the file_name_des.h3d file. 4. The second pull-down menu shows Density. 5. In the Averaging method: filed select Simple. 6. 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. 7. At the bottom of the GUI, click on the name Design or Iteration 0 to activate the Load Case and Simulation Selection dialog. 8. 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).
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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. Set the Current Value: to 0.15 3. Click Apply
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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Finite element mesh containing designable (red) and non-designable (blue) material.
The optimization problem for this exercise is stated as: Objective: Constraint: Design variables: Maximize frequency of mode number 1. Upper bound constraint of 30% for the designable volume. Density of each element in the design space.
The following exercises are included: Setting up the normal modes analysis in HyperMesh Submitting the initial job Viewing the initial results in HyperView Setting up the optimization in HyperMesh Submitting the optimization job Viewing the results of the optimization in HyperView Setting up the final normal modes analysis in HyperMesh Submitting the job Viewing the final results in HyperView Comparing with initial results The following file is needed to perform this tutorial: sshield_opti.fem Original ASCII OptiStruct input deck.
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An OptiStruct file browser will pop up. 7. Pick the sshield_opti.fem file. 8. Click Open. 9. Click Import. The sshield_opti.fem OptiStruct input file is loaded into the current HyperMesh session. 10. Click Close to exit the Import tab menu.
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9. From the Card image: choose EIGRL. 10. Click create/edit. The EIGRL card image pops up. 11. For V2, enter the value 3000.000. 12. For ND, enter the value 2. If a quantity in brackets does not have a value below it, it is off. To change this, click on the quantity in brackets and an entry field will appear below it. Click on the entry field, and a value can be entered. 13. Click return to save changes and exit the panel. A real eigenvalue extraction card has been created. The first two roots between 0 and 3000Hz are to be extracted.
. 2. Go to Analysis page click on constraints panel. 3. Make sure the create subpanel is selected using the radio buttons on the left-hand side of the panel. 4. Click the entity selection switch and select nodes from the pop-up menu. 5. Click nodes >> by id. 6. Enter the value 1075 (beside id=) and press Enter. 7. Enter the value 1076 and press Enter. 8. Constrain all dofs.
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Dofs with a check will be constrained while dofs without a check will be free. Dofs 1, 2, and 3 are x, y, and z translation degrees of freedom. Dofs 4, 5, and 6 are x, y, and z rotational degrees of freedom. 9. Click create. Two constraints are created. Constraint symbols (triangles) appear in the graphics window at the selected nodes. The number 123456 is written beside the constraint symbol, indicating that all dofs are constrained. 10. Click return to exit the panel.
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3. Click Save. Note that the name and location of the sshield_analysis.fem file is now displayed in the input file: field. 4. Set the export options: toggle to all. 5. Click the run options: switch and select analysis. 6. Set the memory options: toggle to memory default. 7. Click Radioss. 8. Close the DOS window after you see the message: Process completed successfully. This launches the Radioss job. If the job is successful, new results files can be seen in the directory where the Radioss model file was written. The sshield_analysis.out file is a good place to look for error messages that will help to debug the input deck if any errors are present. The default files written to your directory are: sshield_analysis.html HTML report of the analysis, giving a summary of the problem formulation and the analysis results. Radioss output file containing specific information on the file set up, the set up 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. HyperMesh binary results file. Summary of analysis process, providing CPU information for each step during analysis process. HyperView results file.
sshield_analysis.out
sshield_analysis.res sshield_analysis.stat
sshield_analysis.h3d
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A Message Log pop-up will inform about the result files loaded into HyperView. 2. Click Close to exit the Message Log window. 3. Change the animation type from Transient to Modal .
4. From the pull-down menu, click Graphics >> Select Load Case. A Load Case Simulation and Selection window will appear showing the first two natural frequencies between 0 and 3000Hz. 5. Click Ok to close this window. 6. Enter the Deformed toolbar button .
7. Make or verify the following settings in the Deformed panel. Result Type: Scale: Type: Value: 8. Click Apply. 9. Enter the Animation Controls panel by clicking the directors chair . Eigen mode (v) Model Units Uniform 10
10. Move the Max Frame Rate: slider between 60 and 1 to increase or decrease the animation speed. You can also change the default values for Increment by: to refine your animation. 11. Click the Modal icon to start animation.
An animation of the mode shape should be seen for the first frequency. 12. Click the Modal icon again to stop the animation. 13. From the pull-down menu, click File >> Exit to quit HyperView. 14. Click No to save popup window..
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2. Go to Analysis page, click on optimization panel. 3. Click on topology to access panel. 4. Go to create subpanel using the radio buttons on the left-hand side of the panel. 5. Click desvar = and enter shield. 6. Click props. 7. Check the box next to design and click select. 8. Set type toggle to PSHELL. 9. Click on base thickness = and change the value to 0.300. 10. Click create. A topology design space definition, shield, has been created. All elements organized into the design property collector are now included in the design space. The thickness of these shells can vary between 0.3 (base thickness defined above) and the maximum thickness defined by the T (thickness) field on the PSHELL card. The object of this exercise is to determine where to locate ribs in the designable region. Therefore, a non-zero base thickness is defined, which is the original thickness of the shells. The maximum thickness, which is defined by the T field on the PSHELL card, should be the allowable depth of the rib. Currently the T field on the PSHELL card is still set to 0.3 (the original shell thickness), this needs to be changed. 11. Click return to exit the panel. 12. Click the Card Editor button on collector toolbar.
13. Set the entity selection to props using the down arrow next to the listed entity 14. Click the yellow props button and check the box next to design. 15. Click select. 16. Select the card image= and select PSHELL from the pop-up menu. 17. Click edit. The PSHELL card image for the design component collector pops up. 18. Replace 0.300 in the T field with 1.000. 19. Click return twice to exit the panel.
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A Save file browser window pops up. 3. Select the directory where you would like to write the OptiStruct model file and enter the name for the model, sshield_optimization.fem, in the File name: field. The .fem extension is used for OptiStruct input decks. 4. Click Save. Note that the name and location of the sshield_optimization.fem file is now displayed in the input file: field. 5. Set the export options: toggle to all. 6. Click the run options: switch and select optimization. 7. Set the memory options: toggle to memory default. 8. Click OptiStruct. This launches the OptiStruct job. If the job is successful, new results files can be seen in the directory where the OptiStruct model file was written. The sshield_optimization.out file is a good place to look for error messages that will help to debug the input deck if any errors are present. 9. Close the DOS windows when you see the message: Process completed successfully. The default files written to the directory are: Sshield_optimization.hgdata HyperGraph file containing data for the objective function, percent constraint violations and constraint for each iteration. OptiStruct history file containing iteration number, objective function values, and percent of constraint violation for each iteration. HyperMesh command file used to organize elements into components based on their density result values. This file is only used with OptiStruct topology optimization runs. HyperMesh command file used to organize elements into entity sets based on their density result values. This file is only used with OptiStruct topology optimization runs.
Sshield_optimization.hist
Sshield_optimization.HM.comp.cmf
Sshield_optimization.HM.ent.cmf
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Sshield_optimization.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 your 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. HyperView 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, to run OSSmooth files for topology optimization. Summary of analysis process, providing CPU information for each step during analysis process.
Sshield_optimization.oss
Sshield_optimization.out
Sshield_optimization.H3D Sshield_optimization.sh
Sshield_optimization.stat
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2. Click Close to exit the Message Log window. 3. Click on Entity Attributes and turn off the component named non-design.
4. Check the box before Auto apply mode to activate this mode. 5. Click the Mesh Lines icon 6. Click All 7. Enter the contour panel by clicking the Contour icon 8. Set the Result type: to Element Densities(s). 9. Click Apply. 10. From the pull-down menu, click Graphics >> Select Load Case to bring up the Load Case and Simulation Selection pop up GUI. 11. Choose the last Iteration # in the list. 12. Click Ok. 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. 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 (set in the opti control panel on the optimization panel). If adjusting the DISCRETE parameter, incorporating a checkerboard control, 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), you may want to review the set up of the optimization problem. Some of the defined constraints may not be attainable for the given objective function (or visa-versa). Where would you place your ribs? on the toolbar. to active this for the Auto apply mode.
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Contour plot of element densities at iteration 12 with all components except the designable component turned off. (top view)
13. From the pull-down menu, click File >> Exit to quit HyperView.
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5. An OptiStruct file browser will pop up. 6. Select the sshield_newdesign.fem file. 7. Click Apply. The sshield_newdesign.fem OptiStruct input file is loaded into the current HyperMesh session. The ribs which were added are in the ribs component collector 8. Click Close to exit the Files panel.
4. Click Save. 5. Note that the name and location of the sshield_newdesign.fem file is now displayed in the input file: field. 6. Set the export options: toggle to all. 7. Click on the run options: switch and select analysis. 8. Set the memory options: toggle to memory default. 9. Click Radioss.
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7. Click Apply. 8. Click the Animation Modal Icon to Start/Stop the animation of the mode. An animation of the mode shape should be seen for the first frequency. 9. Click the Animation Controls icon on the toolbar. 10. Move the MAX Frame Rate: slider bar from 60 to 1 to control the speed of the animation. 11. You can also change the Angular Increment: to refine your animation. 12. Click Modal again to stop the animation.
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. The optimization problem for this exercise is stated as: Objective: Constraints: Minimize volume. SUBCASE 1 SUBCASE 2 SUBCASE 3 Design variables: 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.
In this exercise, you will: Set up the FE model in HyperMesh Define the symmetry and draw direction control parameters for optimization Submit the job to OptiStruct Post-process the results
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A Select RADIOSS (Bulk Data Format), OptiStruct file browser will pop up. 7. Select the carm_draw_symm.fem file, located in the HyperWorks installation directory under <install_directory>/tutorials/hwsolvers/optistruct/. 8. Click Open. 9. Click Import.
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required, as OptiStruct will create variables that are nearly identical across the plane(s) of symmetry. The plane of symmetry is defined by specifying the anchor and the first nodes. The plane of symmetry will then be perpendicular to the vector from the anchor node to the first node, and passes through the anchor node. 5. Click anchor node, input the node id= 3241, and press ENTER. This selects the node with the ID of 3241. 6. Click first node, input the node id= 3877 and press ENTER. This selects the node with the ID of 3877. 7. Click the update button to update the design variables. This completes the definition of the symmetry constraint. 8. Go to draw subpanel. 9. Toggle the draw type: to single. The draw option single assumes that a single die will be used to cast the component and it slides in the defined draw direction. The draw direction is defined by specifying the anchor and the first nodes, with the draw direction being along the vector from the anchor node to the first node. 10. Click anchor node, input the node id= 3165, and press ENTER. This selects the node with the ID 3165. 11. Click first node, input the node id= 3753, and press ENTER. The anchor node, in conjunction with the first node, sets the draw direction or the direction of the movement of the die during casting. 12. Click the update button to update the design variables. 13. Click return twice to exit the panel.
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2. Click save as, enter carm_complete.fem as the file name, and click Save. 3. Click the run options: switch to optimization. 4. Make sure the memory options: toggle is set to memory default. 5. Click OptiStruct to run the optimization. The message Processing complete appears in the window at the completion of the job. OptiStruct also reports error messages if any exist. The file carm_complete.out can be opened in a text editor to find details regarding any errors. This file is written to the same directory as the .fem file. 6. Close the DOS window or shell and click return.
carm_complete.hgdata
HyperGraph file containing data for the objective function, percent constraint violations, and constraint for each iteration. OptiStruct history file containing iteration number, objective function values, and percent of constraint violation for each iteration.
carm_complete.his_data
carm_complete.HM.comp.cmf HyperMesh command file used to organize elements into components based on their density result values. This file is only used with OptiStruct topology optimization runs. carm_complete.HM.ent.cmf HyperMesh command file used to organize elements into entity sets based on their density result values. This file is only used with OptiStruct topology optimization runs.
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 set up 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.
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carm_complete.oss
carm_complete.out
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Review this file for warnings and errors that are flagged from processing the cclip_complete.fem file. carm_complete.res carm_complete.sh 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.
cclip_complete.stat
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6. 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. 7. At the bottom of the GUI, click on the name Design or Iteration 0 to activate the Load Case and Simulation Selection dialog. 8. 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 6: 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 the pull down menu, Graphics >> Iso Value and pick Element Densities as the Result type. 2. Set the Current Value: enter, 0.3. 3. Click Apply.
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An iso value plot is displayed in the graphics window. The parts of the model with densities greater than the specified value of 0.3 are shown in color, and the rest are transparent (shown in the figure below).
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. 5. From the File pull-down menu, select Exit to quit HyperView.
Review
Has the volume been minimized for the given constraints? Have the displacement constraints been met?
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The structural model is loaded into HyperMesh. The constraints, loads, subcases and material properties are already defined in the model. The topology design variables and the optimization problem set up will be defined using HyperMesh, and OptiStruct will be used to determine the optimal material layout. The results will then be reviewed in HyperView. The optimization problem is stated as: Objective function: Constraints: Design Variables: Minimize volume. Von Mises stress < 1.6 e 04. The density of each element in the design space.
The following exercises are included in this tutorial: Setting up the optimization problem in HyperMesh Submitting the job to OptiStruct Post-processing the results in HyperView
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An Import tab is added to your tab menu. 2. Make sure the Import type: is set to FE Model. 3. Make sure the File type: is set to Optistruct. 4. Click the Select files button , File: browser for hook.fem
A Select OptiStruct file browser will pop up. Browse for your file and select it. 5. Click Open 6. Click Import.
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4. Ensure that the total/by entity toggle is set to total (this is the default).
5. Click create. A response, volume, is defined for the Total Design Volume of the model. 6. Click return to exit the panel.
2. Select the directory where you would like to save the database and enter the name for the database, hook_opt.hm, in the File name: field. 3. Click save.
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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, hook_opt.fem. The .fem filename extension is the suggested extension for OptiStruct input decks. 4. Click Save. Note the name and location of the hook_opt.fem file displays in the input file: field. 5. Make sure the memory options: toggle to memory default. 6. Click the run options: switch to optimization. 7. Make sure the export options: toggle to all. 8. Click OptiStruct. This launches the OptiStruct job. If the job was successful, new results files can be seen in the directory where the OptiStruct model file was written. The hook_opt.out file is a good place to look for error messages that will help to debug the input deck if any errors are present. 9. Close the DOS windows after you see the message: Process completed successfully
4. Select the Result type: Element densities (s). 5. At the bottom of the GUI, click in the portion circled below to activate the Load Case and Simulation Selection dialog.
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7. Click OK.. 8. Make sure that Show is set to above. 9. Click Apply. 10. Move the below Current value: slider to look at the element densities. 11. You can also enter a value of 0.3 in the Current value: field.
The isosurface post-processing feature is an excellent tool to use for viewing the density results from OptiStruct.
12. Click and move the slider bar (currently pointing to a value representing 0.3) for your density to change the isosurface. You will see the isosurface in the graphics window interactively update when you change it to a new value. Use this tool to get a better look at the material layout and the load paths from OptiStruct. 13. Click Clear Iso.
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The second page, which has results loaded from the hook_opt_s19.h3d is displayed; this contains the linear static results for the 1st subcase. 2. Click the Contour toolbar button .
3. Select the first pull-down menu below the Result type: and select Element stresses. 4. Select the second pull down menu and select vonMises. 5. At the bottom of the GUI, click in the portion circled below to select the last Iteration.
6. Click Apply.
Notice that there are some local regions where the stresses are still high; this is because topology stress constraints should be interpreted as global stress control or global stress target. The functionality has some ways to filter out the artificial or local stresses caused by point loading or boundary conditions, but those artificial stresses will not be completely removed unless the geometry is changed by shape optimization.
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Step 11: Querying the results of the elements with stresses higher than 1.6e4:
1. Click on the Query toolbar button .
2. Under Elements, uncheck any of the options which you do not want to see in the table and then click on Elements and choose By Contour. 3. Below value, enter >16000 and click Add. 4. Click Apply. This would give a list of elements with the stress value above 16000; use the mask option to graphically find the elements above the stress value.
Mask panel
5. Click the Next Page toolbar button to move to the third page. 6. Notice that the file Hook_opt_s32.h3d is already loaded with the results of the 2nd subcase. 7. Click on the Contour panel to observe the Stress results; they are within the permissible range.
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8. Repeat the above steps to observe the results of the next 2 subcases which are a duplicate of the first 2. Notes: The advantages of using stress based optimization over the classical minimize (compliance) subject to volume fraction constraint is that it eliminates the guessing of the right volume fraction. Additionally, it eliminates the need for compliance weighting bias for multiple subcases. There might still be high local stress regions which can be improved more effectively with local shape and size optimization.
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The DTPL (Design Variable for Topology Optimization) card is used for this optimization. The finite element mesh of the curved beam is shown in the following.
Finite element mesh of the curved beam showing loads and boundary conditions
The three-part process to complete an OptiStruct topology optimization with extrusion constraints includes: 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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6. Choose type: PSOLID 7. Click Create. A topology design space definition, design_solid, has been created. All elements organized in this design property collector are now included in the design space. 8. Click return twice to go back to the main menu.
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Isosurface plot of a curved beam rail layout of the topology optimization with extrusion constraints
As expected, the result with manufacturing extrusion constraints permits a constant cross section for the entire length of the model.
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As expected, the result with manufacturing extrusion constraints shows constant cross section through the length of the model. 7. Click Delete in the section cuts panel to get back to the original model.
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There are four shell components in the model: the mounting flange, the web, the top and bottom flanges, and the lug. The web is connected to the lug by gap elements. Appropriate properties, loads, boundary conditions, and nonlinear subcases have already been defined in the model. The design region is the web and the rest of the components are non-design. Since a large portion of aerospace components are shell structures which are manufactured by machining or milling operations, free-sizing optimization is very suitable for those components. To understand the limitations of topology optimization for such applications, a nonlinear gap topology optimization will also be done on the wing rib model. The optimization problem for this exercise is stated as:Objective: Constraints: Design variables for free sizing optimization: Minimize weighted compliance WCOMP. Volume fraction on the web < 0.3. Thickness of each shell element in the design space.
Design variables for topology optimization: Element density of each element in the design domain.
HyperWorks 9.0
This exercise will use the following steps to set up free-sizing optimization and topology optimization: Create design variable for free-sizing optimization Define manufacturing constraint for free size Define optimization responses, objective and constraints Run the free-sizing nonlinear gap optimization Post-process the thickness distribution in the design domain Create topology design variables Define manufacturing constraint for topology Run the nonlinear gap topology optimization Post-process results using HyperView Review and compare results from free-size optimization and topology optimization
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Step 1: Launch HM, set the RADIOSS OptiStruct User Profile and retrieve the file rib_complete.hm
1. Launch HyperMesh 2. Choose OptiStruct in the User Profile dialog and click OK. 3. From the pull-down menu on the toolbar, File >> Open. An Open file browser window pops up. 4. Browse for the rib_complete.hm file. 5. Click Open
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3. Click the switch for response type and go to the next page of available types by using >>, and click on weighted comp. 4. Click loadsteps and select both the Coup_Vert and Pressure loadcases. The weighting factor should be 1.0 for both. 5. Click return. 6. Click create. 7. For response =, input the name volfrac to create the volume fraction response. 8. For response type, go to the previous page using <<, and click on volume frac. 9. Leave the type as total. 10. Click create. 11. Click return. 12. Click on the dconstraints panel to define the volume fraction constraint. 13. For constraint =, input the name vol. 14. Click response =, and select the volfrac response. 15. For upper bound =, input a value of 0.3. 16. Click create. 17. Click return. 18. Click on the objective panel to define the objective. 19. Toggle to min if not already done. 20. For response =, select the wcomp response. 21. Click create. 22. Click return twice. The optimization parameters have now been defined.
3. Select the directory where you would like to write the optimization file and enter the name rib_freesize.fem in the File name: field. 4. Click Save.
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Note the name and location of the rib_freesize.fem file shows in the input file: field. 5. Set the export options: toggle to all. 6. Click the run options: switch and select optimization. 7. Set the memory options: toggle to memory default. 8. Click OptiStruct. This launches the OptiStruct job. If the job was successful, new results files can be seen in the directory where the OptiStruct model file was written. The rib_freesize.out file is a good place to look for error messages that will help to debug the input deck if any errors are present. The default files written to the directory are: rib_freesize.hgdata HyperGraph file containing data for the objective function, percent constraint violations, and constraint for each iteration. This file is a HypeView session file and may be opened from the File pull-down menu in HyperView or HyperGraph. The file automatically creates individual plots for each of the results (objectives, constraints) contained in the .hist file. Each plot occupies its own page within HyperView (HyperGraph).
rib_freesize_hist.mvw
rib_freesize.HM.comp.c This is a HyperMesh command file. When executed in mf HyperMesh, the .HM.comp.cmf file organizes all elements in the model into ten new components based on their element thicknesses at the final iteration. The components for this run are named 0.0-0.01, 0.01-0.02, 0.02-0.03, and so on, up to 0.09-0.1, considering the plate thickness of the Web is 0.1mm. rib_freesize.html HTML report of the optimization, giving a summary of the problem formulation and the results from the final iteration. The file contains default settings for running OSSmooth after a successful optimization. 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
rib_freesize.oss
rib_freesize.out
HyperWorks 9.0
processing the rib_freesize.fem file. rib_freesize.res rib_freesize.sh HyperMesh binary results file. Shape file for the final iteration. The .sh file may be used to restart a run. Summary of analysis process, providing CPU information for each step during analysis process. HyperView binary results file for element thickness information. HyperView binary results file for displacement and stress results for subcase 1. HyperView binary results file for displacement and stress results for subcase 2.
rib_freesize.stat
rib_freesize_des.h3d
rib_freesize_s1.h3d
rib_freesize_s2.h3d
5. Click on the Web component to get a shaded mesh. 6. Go to the Contour panel and set the Result type: to Element Thicknesses.
7. Choose Select Load Case from the Graphics pull-down menu to open the Load Case and Simulation Selection dialog. 8. Select the last iteration listed in the Simulation list and click OK. 9. Click Top in the view controls section (in bottom right of HyperView panel) to get a top view of the Web.
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10. Click Apply. This will show the contour element thickness on the Web component.
Thickness contour from free-sizing nonlinear gap optimization, on the Web of plate thickness 0.1mm
As can be seen from the figure above, the result from free sizing optimization is a web with optimized thickness distribution that can be reduced subsequently into larger zones for simplification of the manufacturing process. Moreover, the design obtained from free sizing offers the freedom to create cavities, ribs and varying thickness simultaneously, which is not possible in topology optimization. 11. Click Files from the pull-down menu and select Exit to quit HyperView.
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6. Click designvars, select shells and click select. 7. Click delete entity. The message 1 entity was deleted should appear in the header bar. 8. Click return. 9. From the Analysis page, select the optimization panel. 10. Choose the topology panel. 11. Select the create subpanel. 12. For desvar = input the name shells. 13. Click props, choose the Web component, and click select. 14. Under type, choose PSHELL and leave the base thickness as 0.0. 15. Click create. The web component has now been defined as the design component for topology optimization.
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2. Make sure the rib_topology.fem file shows in the input file: field. 3. Set the export options: toggle to all. 4. Click the run options: switch and select optimization. 5. Set the memory options: toggle to memory default. 6. Click OptiStruct. This launches the OptiStruct job. If the job was successful, new results files can be seen in the directory where the OptiStruct model file was written. The rib_topology.out file is a good place to look for error messages that will help to debug the input deck if any errors are present. The default files written to the directory are:
rib_topology.hgdata HyperGraph file containing data for the objective function, percent constraint violations, and constraint for each iteration. HyperMesh command file used to organize elements into components based on their density result values. HyperMesh command file used to organize elements into entity sets based on their density result values. 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 rib_topology.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. Summary of analysis process, providing CPU information for each step during analysis process. HyperView binary results file for information on element density.
rib_topology.HM.comp.cmf
rib_topology.HM.ent.cmf
rib_topology.html
rib_topology.oss
rib_topology.out
rib_topology.res rib_topology.sh
rib_topology.stat
rib_topology_des.h3d
HyperWorks 9.0
rib_topology_s1.h3d
HyperView binary results file for displacement and stress results for subcase 1. HyperView binary results file for displacement and stress results for subcase 2.
rib_topology_s2.h3d
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Contour of element density on the Web component from topology nonlinear gap optimization
The results from topology optimization show very discrete results as expected.
Review and compare results from free-sizing optimization and topology optimization
Results from the topology optimization show a truss type design with extensive cavities and voids, while the results from free-sizing optimization tend to come up with shear panels. While solid/void density distribution is the only choice for solid elements; for shell structures, intermediate densities can be interpreted as different thicknesses and penalizing then could result in potentially inefficient shell structures. Moreover, since a large portion of aerospace structures are shell structures, a shear panel type design is often desirable for manufacturing purposes especially for machine milled shell structures. Free-sizing optimization can prove to be very beneficial in those situations.
HyperWorks 9.0
Chapter 3
Topography Optimization
Topography Optimization
Topography optimization generates an optimized distribution of shape based reinforcements such as stamped beads in shell structures. The problem set up is simply done by defining the design region, the maximum bead depth and the draw angle. OptiStruct automatically provides the design variable creation and optimization control. Manufacturing constraints can be imposed using symmetry planes, pattern grouping, and pattern repetition.
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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
HyperWorks 9.0
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
HyperWorks 9.0
Finite element model of the design space with loads and constraints.
A finite element model (shown in the above figure) is loaded into HyperMesh. The constraints, load, material properties, and subcase (loadstep) of the model are already defined. Topography design variables and optimization parameters are defined and the OptiStruct software is used to determine the optimal reinforcement patterns. The results are viewed as animations of the contours of shape changes of the design space. Finally, the use of the grouping patterns is shown; based on the shape changes suggested by OptiStruct, a possible pattern is chosen for ease of manufacturing. The optimization problem for this tutorial is stated as: Objective: Design variables: Minimize nodal displacement at grid point where loading is applied. Shape variables on the designable space.
The first exercise includes: Setting up the problem in HyperMesh Submitting the job Viewing the results In the second exercise, grouping pattern is defined to generate manufacturable patterns
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Step 1: Launch HM, load the OptiStruct user profile and retrieve the model
1. Launch HyperMesh. 2. Choose OptiStruct in the User Profile dialog and click OK. This loads the OptiStruct 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. User Profiles can also be accessed from the Preferences pull-down menu on the toolbar. 3. Open the Open file GUI by selecting the File icon 4. Browse for and select the torsion_plate.hm file. 5. Click Open. The torsion_plate.hm database is loaded into the current HyperMesh session, replacing any existing data. on the main menu.
A PSHELL card image panel should appear. OptiStruct stores information regarding shell thicknesses on the PSHELL card. 2. Ensure that the thickness, T, is set to the value 1.0. 3. Click return to go to the main menu.
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This tells OptiStruct to leave nodes at which loads or constraints are applied out of the design space. 16. Click update. A "bead" definition has been created for the design space 'topo'. Based on this information, OptiStruct will automatically generate bead variable definitions throughout the design variable domain as shown on the DTPG page of the Reference Guide. 17. Select the bounds subpanel using the radio buttons on the left-hand side of the panel. 18. Ensure topo is in the field next to desvar = . If it is not, click on desvar = and select topo from the list of topographical design spaces. 19. Click on upper bound and enter 1.0 (this is the default). Upper bound on variables controlling grid movement (Real > LB, default = 1.0). This sets the upper bound on grid movement equal to UB*HGT. 20. Click on lower bound and enter 0.0 (this is the default). 21. Click update. The upper bound sets the upper bound on grid movement equal to UB*HGT and the lower bound sets the lower bound on grid movement equal to LB*HGT. 22. Click return to go to the optimization panel.
HyperWorks 9.0
total disp is the resultant of the translational displacements in x, y, and z directions. total rotation is the resultant of the rotational displacements in x, y, and z directions. 7. Click create. A response, 'displace', is defined for the z-displacement of node 2500. 8. Click return to go to the optimization panel.
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6. Click the run options switch, located in the center of the panel, and select optimization. 7. Set the memory toggle, located at the left-hand side of the panel, to memory default. 8. Click OptiStruct. This launches the OptiStruct job. If the job was successful, new results files can be seen in the directory where the OptiStruct model file was written. The torsion_plate.out file is a good place to look for error messages that will help to debug the input deck if any errors are present. The default files written to the directory are: torsion_plate.grid An OptiStruct file where the perturbed grid data is written. HyperGraph file containing data for the objective function, constraint functions, design variables, and response functions for each iteration. An OptiStruct output file for xy plotting containing the iteration history of the objective function, maximum constraint violation, design variables, DRESP1 type responses, and DRESP2 type responses. 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. The OptiStruct output file containing specific information on the file set up, the set up of the optimization problem, estimate 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 torsion_plate.fem file. The HyperMesh binary results file. HyperView binary results file for information on shape changes. HyperView binary results file for displacement and stress results for subcase 1.
torsion_plate.hgdat a
torsion_plate.hist
torsion_plate.html
torsion_plate.oss
torsion_plate.out
HyperWorks 9.0
torsion_plate.sh
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.
torsion_plate.stat
5. Click in the bottom right portion of the GUI (as pictured) to activate the Load Case and Simulation Selection dialog.
6. Select the last iteration listed in the Simulation list and click OK. A deformed plate appears. 7. Click Apply. 8. Is the max= field showing 4.0e + 00? 9. In this case, it is. If it is not, your optimization has not progressed far enough. Decrease the OBJTOL parameter (set in the opti control panel on the optimization panel). This value, 4.0e+00, comes from the draw height defined earlier.
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Contour plot showing the reinforcement pattern at the last iteration (converged solution)
2. Click the traffic light icon to start the animation. 3. Click the directors chair icon to the Animation Controls panel. 4. With the animation running, use the slider bar below Max Frame Rate: on the left side of the panel to adjust the speed of the animation. 5. Click the traffic light icon again to stop the animation.
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This page has the subcase information from the torsion_plate_s1.h3d file. 2. Verify that the animate mode menu is set to Linear Static. For a better visual of what it happening with this model turn on mesh lines and contour the results as in the previous step. 3. Click the Deformed icon on the toolbar 4. Set Result type: to Displacement(v). 5. Click in the bottom right portion of the GUI as pictured below to activate the Load Case and Simulation Selection dialog. to enter the panel.
6. Select the first iteration Iteration 0. 7. Click the cantilever beam icon to start the animation.
8. Click the directors chair to go to the Animation Controls panel. 9. With the animation running, use the slider bar below Max Frame Rate: on the left side of the panel to adjust the speed of the animation. A deformation animation of the original model is shown in the graphics window. Does the deformed shape look correct for the boundary conditions you applied to the mesh? 10. Click the cantilever beam icon again to stop the animation. 11. Go to File on the pull-down menu and click Exit to quite HyperView.
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HyperWorks 9.0
Note the name and location of the torsion_pattern.fem file displays in the input file: field. 5. Set the export options toggle, underneath the run options switch, to all. 6. Click the run options switch, located in the center of the panel, and select optimization. 7. Set the memory toggle, located at the left-hand side of the panel, to memory default. 8. Click OptiStruct. This launches the OptiStruct job. If the job was successful, new results files can be seen in the directory where the OptiStruct model file was written. The torsion_pattern.out file is a good place to look for error messages that will help to debug the input deck if any errors are present. View the new results as before. Also check the objective value for the zero-th and last iteration in the .out file. How does the final value for the objective compare to the final value obtained using 'none' option for pattern grouping?
Contour plot showing the reinforcement pattern with pattern grouping constraint at the last iteration
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L bracket layout.
The following steps are included: Import the the completed fem file to Hypermesh Submit the job Post processing
HyperWorks 9.0
Step 1: Launch HM set the OptiStruct User Profile and Import the Fem file
1. Launch HyperMesh. 2. Choose OptiStruct in the User Profile dialog and click OK. User Profiles can also be accessed from the Preferences pull-down menu on the toolbar. 3. From the File pull-down menu on the toolbar, select Import. An Import tab is added to your tab menu 4. Select the import type: FE Model. 5. Choose the File type: Optistruct. 6. Select the Files icon button. 7. An OptiStruct file browser will pop up. 8. Select the Lbkttopog_bead.fem file. 9. Click Apply. The Lbkttopog_bead.fem OptiStruct input file is loaded into the current HyperMesh session. 10. Click Close to exit the Import tab.
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The default files written to the directory are: Lbkttopog_bead.grid An OptiStruct file where the perturbed grid data is written.
Lbkttopog_bead.hgdata HyperGraph file containing data for the objective function, percent constraint violations and constraint for each iteration. Lbkttopog_bead.hist OptiStruct iteration history file containing the iteration history of the objective function and of the most violated constraint. Can be used for an xy plot of the iteration history. Hypermesh Results File 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. It is highly recommended to review this file for warnings and errors that are flagged. Hyper 3D 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.
Lbkttopog_bead.res Lbkttopog_bead.oss
Lbkttopog_bead.out
Lbkttopog_bead.h3d Lbkttopog_bead.sh
Lbkttopog_bead.stat
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The final nodal positions are applied to the structure. Be careful with saving the model now, the HyperMesh database has changed. This model can be used for further analyses. Results can now be viewed on the final shape. 10. Click Reject to get back the original shape and return to go back to main menu.
The new geometry will be automatically loaded into the existing Hypermesh file, turn off the display of all the elements to view the new concept geometry.
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Topography results
Note:
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